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YG-1 Product Success Story – Higher Productivity with Single-Insert Solution

A machining customer faced frequent coolant contamination due to casting burrs, leading to coolant replacement every 2 months, high oil consumption, and long maintenance hours. After installing a Sump Cleaner, coolant tanks were cleaned without shutdown, extending coolant life to one year. The solution saved ~1,600 liters of cutting oil annually, reduced cleaning time from 4–5 hours to just 15–20 minutes, minimized downtime, and significantly improved productivity and maintenance efficiency.

Sumitomo Product Success Story – Proven Performance on SS 316

A machining trial on SS 316 auto components demonstrated significant productivity gains by replacing a standard TNMG insert with a high-performance Sumitomo AC6040M grade. Cutting time was reduced from 3.55 minutes to 1.25 minutes per component, while tool life increased from 8 to 14 components per insert. Despite a marginally higher insert cost, overall machining cost per component dropped substantially due to faster cycle times and improved tool life, delivering a reliable and cost-effective turning solution.

Sump Cleaner

Mixtron Dosing pump

A manufacturing unit in the Pipaliya–Rajkot industrial area reduced cutting oil consumption and improved process efficiency by installing a Mixtron Dosing Pump. Within 6 months, cutting oil usage dropped by ~10.7%, saving nearly ₹2.5 lakhs. The automated system eliminated manual coolant preparation, ensured consistent coolant concentration, and improved overall operational control.

Mixtron Dosing pump-2

Sump Cleaner products

Mixtron Dosing pump

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.

Sump Cleaner

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 year instead of every 2 months.

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

Sumitomo Product Success Story – Proven Performance on SS 316

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:

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.

YG-1 Product Success Story – Higher Productivity with Single-Insert Solution

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.

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