Featured Products
MOLDINO Co., Ltd. / Alpha High-Feed Radius Milling Machine “TR4F5063B-4”
➀Purpose
At a manufacturer producing large-scale molds,
machining time per part was lengthy, and production schedules were consistently tight.
Amid calls to “reduce machining time even slightly” and “lighten the workload on the shop floor,”
the sales representative hypothesized that there might be room for improvement in the tools used and the machining processes,
and conducted interviews to gather feedback.
②Key Points for Implementation
The customer had been using an early-model high-feed cutter (2-flute, 2-corner) manufactured by MOLDINO.
Although they had tried tools from other manufacturers, they were hesitant to switch due to issues such as short tool life, dissatisfaction with insert performance, and the hassle of modifying CAM programs.
We therefore proposed the latest indexable high-feed tool, the “TR4F5063B-4,” which excels in both the number of cutting edges and tool life.
We revised the process design to allow roughing and semi-roughing to be performed in a single operation,
and presented a plan that achieves both a shorter overall process time and stable machining.
③Examples
The newly introduced tool is compatible with 4-flute and 4-corner configurations, offers a long service life, and delivers high machining performance.
As a result, we can now efficiently perform roughing and semi-finishing operations in a single pass, rather than as separate steps as before.
Furthermore, while we were previously limited to a cutting depth of 1 mm due to concerns about warping caused by heat,
this new solution allows us to machine at depths of up to 2 mm without deformation.
This has enabled us to achieve both high quality and high speed.
④Results
The introduction of new tools yielded the following results:
・Processing time reduction: 80 minutes → 60 minutes (25% reduction)
・Processing cost per unit: ¥9,940 → ¥6,780 (32% reduction)
・Monthly processing cost (based on processing 4 units): ¥39,760 → ¥27,120
・Annual cost savings: Approximately ¥150,000 (calculated as ¥3,160 cost reduction per unit × 4 units per month × 12 months)
・Production capacity: Approximately 19% increase (able to produce 5 units instead of 4 in the same amount of time)
・Cutting depth: Increased from 1 mm to 2 mm (allowing for machining without warping)
This has enabled a more systematic production system
and reduced the workload for on-site staff.
We have received positive feedback from the customer, who remarked,
“We never expected that reviewing our tools would improve machining efficiency and reduce costs to this extent.”
This initiative is an example of our approach as a partner who “works closely with customers to identify and resolve their challenges,”
based on our company credo: “Revolutionizing the manufacturing floor.”
