A 40-minute machining process reduced to just 6 minutes! What’s the other option for rough machining?

From MOLDINO Co., Ltd., “High-Efficiency End Mill for Side Milling ER5HS-PN,” December 2024, p. 2

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MOLDINO Co., Ltd. / “ER5HS-PN” High-Efficiency End Mill for Side Milling

➀Purpose

Rough machining of vertical walls was time-consuming, which often disrupted the flow of the entire production line.

Since the process was divided among different operators, a delay in any one step would ripple through the entire line, posing a major challenge.

Therefore, we proposed a tool designed to speed up the rough machining process and improve the smooth flow between process steps.

②Key Points for Implementation

Vertical wall machining places a heavy load on cutting tools, and the inability to increase feed rates with conventional tools had been a major challenge.
To address this, we proposed MOLDINO’s ER5HS series, which enables high-efficiency machining while minimizing cutting resistance.
By optimizing spindle speed and feed conditions to fully leverage the tool’s characteristics, we significantly reduced the load during rough machining, enabling high-speed machining and
streamlining the entire production process.

③Examples

Previously, we used a three-flute end mill from a certain manufacturer and machined under significantly restricted conditions—a cutting speed of 49 m/min and a feed rate of 350 mm/min—to prevent chatter.
As a result, rough machining took a long time, and in some cases, this caused delays in subsequent processes.
After proposing MOLDINO’s ER5HS12-PN, we were able to optimize the spindle speed and feed rate to maximize the tool’s performance.
We were able to increase the cutting conditions to the manufacturer’s recommended standards—such as a cutting speed of 150 m/min and a feed rate of 2,390 mm/min—
and achieved stable cutting while suppressing chatter even during rough machining of vertical walls.

④Results

The introduction of the ER5HS12-PN has significantly increased the feed rate from the previous 350 mm/min to 2,390 mm/min—a nearly sevenfold improvement.
This has reduced the rough machining time for vertical walls from nearly 40 minutes to approximately 6 minutes, resulting in a time savings of about 34 minutes.
With reduced chatter, the machined surface has become more stable, enabling a smoother handoff to subsequent processes and improving the overall flow of the production line.