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OSG Corporation / “AE-TS-N” 3-flute end mill for aluminum
➀Purpose
When machining A5052 aluminum, we previously used two-flute carbide end mills, but faced the following challenges:
・Long machining times
・Frequent tool changes
・Unstable machining accuracy
To improve productivity and machining stability without significantly altering the machining conditions,
we considered switching to the “AE-TS-N” three-flute end mill for aluminum.
②Key Points for Implementation
③Examples
■ Tool Life Comparison
・2-flute: Replace the end mill after approximately 100 parts
・3-flute: Replace the end mill after approximately 150 parts
→ The replacement cycle has been extended, and tool life has improved by approximately 1.5 times.
By adopting the AE-TS-N (3-flute for aluminum), which can handle everything from roughing to finishing with a single tool, we have achieved process simplification and stabilization.
④Results
✔ 30% reduction in machining time
✔ 1.5x increase in tool life
For equipment operating 200 hours per month, a 30% reduction translates to approximately 60 hours of spare capacity, effectively increasing monthly production capacity by about 1.3 times.
This makes it possible to improve productivity without adding new equipment.
Furthermore,
・Reduced operating costs
・Lower defect rates
・Reduced tool waste
・Lower energy consumption
These benefits can be expected, making this an improvement measure that balances profitability with environmental considerations.
On an annual basis, the expected improvement effect is in the range of several hundred thousand yen.
