It seems hard to believe, but it’s true. Earlier this year, Advanced Manufacturing published an online article reporting that Flexco, a manufacturer of belt conveyer components, saved approximately $200,000 on slotting operations since the company began retooling with a different set of end mills. Flexco is expecting to save another $200,000 on its mill-turn operations.

So, what’s the secret weapon?

After disappointing results from the current standard tips and testing out several others, Flexco found that Ingersoll’s Chip Surfer replaceable solid-carbide tip cutting tools made the biggest impact on the manufacturer’s production. The company replaced the existing 5/16” (8-mm) solid-carbide end mills with 3/8” (9.5-mm) Chip Surfer cutters and the results were extremely positive. The metal removal rate (MRR) jumped 60% and tool life increased to three times longer.

The work that previously took Flexco 8 hours to complete, now takes less than 4 hours and where 1 tool change was previously required to finish 1 bed, now one tool tip is able to last through making 2 entire hardened steel parts. Changing the tip is also simple. It can be done right in the spindle within seconds.

Flexco’s operation in question is a slotting operation in which the company makes what it refers to as a bed. This bed is made in many sizes and is basically a 4140 steel rectangle measuring 5-7’ long and 3.5” wide with 58-70 slots along the length.

The Chip Surfer

Ingersoll’s Chip Surfer is a 4, 5, and 6 Flute, 45° Helix, center-cut end mill tip. See Chip Surfer videos.

Various tips in this series can be bought right here on the BlackHawk site.

For any questions about Chip Surfer or any other products sold by BlackHawk, give us a call. We’re happy to help. Our mission is to provide innovative, value-added services and products that reduce our customer’s total cost. Feel free to contact us for more information.