Custom Corner Radius End Mill
Lower cost, same critical geometry
A high-use application depended on a purchased corner-radius end mill costing roughly $100 per tool. APG engineered and manufactured a replacement with the required geometry and performance characteristics.
Results
• Produced at roughly 20% of the prior purchase cost
• Delivered repeatable performance in a high-use application
• Created a geometry platform for similar follow-on applications
Custom Step
Drill
One tool, multiple features, better process control
A production application required tight concentricity between two hole diameters and a chamfer. The prior process created quality issues and inefficiency.APG designed a custom step drill to produce all three features in a single operation.
Results
• Improved concentricity and process consistency
• Reduced scrap
• Reduced machining time
• Increased parts per tool
Custom Carbide Reamer
Better size control in a difficult stainless application
A nitride-coated 15-5 stainless application was using a boring process that struggled with inconsistent hole size, high insert wear, and long cycle times.APG designed a custom reamer using 6% cobalt grade carbide to improve stability and hold size more consistently.
Results
• Improved dimensional consistency
• Increased parts per tool
• Reduced cycle time
• Lowered wear-related process disruption
Custom Carbide Broach
Major lead-time and cost reduction in titanium
A titanium broaching application relied on a high-speed steel full-form broach with a six-month lead time, high cost, and low tool life.APG developed a single-point, double-sided carbide broach to replace the incumbent tool.
Results
• Reduced tool cost from approximately $1,600 to about $62
• Improved performance from about 4 parts per tool to 170 parts on one side
• Maintained comparable cycle time• Generated estimated savings of roughly $68,738
• Eliminated a major lead-time bottleneck
High-Performance End Mill for Stellite
More than doubling tool life in a demanding material
A Stellite application using a conventional end mill was achieving only about 10 parts per tool.APG designed a 16 mm, 15-flute, non-end-cutting end mill and tested coated and uncoated options to optimize performance.
Results
• Increased tool life to about 25 parts per tool
• More than doubled tool performance versus the prior solution
• Identified the best-fit design through application-specific testing
Custom Thread
Mill
Better form control, longer life, fewer adjustments
A 15-5 stainless threading application relied on a hand-modified insert that created inconsistency in thread form and frequent operator compensation. APG designed a solid-carbide single-point thread mill with lateral coolant holes to improve form accuracy and process stability.
Results
• Increased tool life from an initial 73 parts uncoated
• Achieved coated production life of 180 parts and 400 parts, depending on version
• Reduced operator adjustment requirements
• Improved thread form consistency