A successful machining trial was conducted at one of our customer’s facilities to improve productivity and simplify tool usage in a milling operation for a fabrication-related component made from MS-WCB material with a hardness of 35 HRC. The operation was performed on a Jyoti HMC 400 horizontal machining center.

Challenge

Earlier, the customer was using two different inserts—RPMT 12 for roughing and APMT 16 for finishing. While the insert cost was low, the process required multiple tool changes, higher cutting time, and resulted in limited tool life, affecting overall machining efficiency.

Solution

To overcome these challenges, we recommended the YG-1 PNMU 1206ZNN YG712 insert, which is capable of performing both roughing and finishing operations with a single insert.

Result

After implementing the YG-1 solution, the customer achieved notable improvements:

• Cutting time for full setup reduced from 1 hour 10 minutes to 1 hour
• Tool life increased from 80 components to 120 components
• Elimination of multiple inserts, as both roughing and finishing were completed using one insert
• Improved process stability and reduced tool change downtime

Although the insert cost was higher, the overall cost per component was reduced due to longer tool life, lower setup complexity, and improved productivity.

Customer Benefit

The YG-1 YG712 grade delivered excellent wear resistance, consistent performance, and operational simplicity. By using a single insert for multiple operations, the customer achieved higher output, better tool utilization, and improved machining economics.

This successful trial highlights how YG-1 cutting tools help manufacturers enhance productivity while reducing total machining cost.

A successful machining trial was conducted at one of our customer’s facilities to improve productivity and tool life in a turning application for an auto part component made from SS 316

material with a hardness of 65. The machining was carried out on an ACE Micromatics CNC machine.

Challenge

The customer was previously using a standard TNMG 120408 insert, which resulted in longer cutting time and limited tool life, impacting overall machining efficiency and cost per component.

Solution

To address this, we recommended Sumitomo TNMG 120408 GU AC6040M insert, designed for high performance and durability in difficult-to-machine materials.

Result

After switching to the Sumitomo insert, the customer achieved significant improvements:

• Cutting time reduced from 55 minutes to 1.25 minutes per component
• Tool life increased from 8 components to 14 components per insert
• Despite a slightly higher insert cost, the overall machining cost per component was substantially reduced due to faster cycle time and longer tool life

Customer Benefit

The Sumitomo AC6040M grade delivered excellent wear resistance, stable performance, and higher productivity, making it a cost-effective and reliable solution for SS 316 turning operations in auto part manufacturing.

This successful trial clearly demonstrates how the right cutting tool selection can significantly enhance productivity, tool life, and overall machining economics.

One of our customers engaged in machining of casting components was facing frequent coolant contamination due to small casting burrs and fines entering the coolant tank. This resulted in poor coolant quality and forced the customer to drain and reload fresh coolant every 2 months, leading to high cutting oil consumption and long maintenance hours.

After installing a Sump Cleaner, the customer started cleaning coolant tanks regularly without complete shutdown. This significantly improved coolant cleanliness and extended coolant life, allowing fresh coolant replacement only once in 1 years instead of every 2 months.

Key Benefits Achieved

• Cutting oil saving of approximately 1,600 liters per year
  Earlier, each machine required 10 liters of cutting oil every 2 months. With 32 machines, annual oil consumption was around 1,920 liters. After using the sump cleaner, annual fresh fill requirement reduced to 320 liters, resulting in massive oil savings.
• Drastic manpower time reduction
  Manual coolant tank cleaning earlier took 4–5 hours per machine. With the sump cleaner, cleaning time is reduced to just 15–20 minutes.
• Extended coolant life and reduced machine downtime

Lower maintenance cost and improved productivity

A key manufacturing unit located in the Pipaliya–Rajkot industrial area was facing high cutting oil consumption, manual effort in coolant preparation, and inconsistent coolant concentration. To overcome these challenges, a Mixtron Dosing Pump was installed to automate coolant mixing and top-up. Within just 6 months of operation, the customer achieved approximately 10.7% reduction in cutting oil consumption, resulting in savings of nearly ₹2.5 lakhs worth of cutting oil. Additionally, significant manpower time was saved by eliminating manual coolant preparation, while the system ensured consistent and accurate coolant concentration, leading to better process control and operational efficiency.