Case Studies

Abstract

When an automaker switched to aluminum, only RobbJack met the machining requirements where over 20 other toolmakers failed.

The Problem

In pursuit of performance and fuel efficiency, automakers are increasingly switching from heavy steels to lighter aerospace aluminum for everything from body panels to door frames. An American light duty truck manufacturer recently made this switch. It needed consistent performance within demanding parameters: to cut the cycle times in half by more than doubling the feed rate.

Over 20 toolmakers tried—and failed—on multiple counts:

• Their tools vibrated and chattered against thin walls.
• Targeted cycle times and feed rates caused chip packing and tool breakage.
• Extreme burring required secondary operations.
• Tools slipped and pulled out of tool holders.

Then RobbJack took on the challenge.

Our Solution: The A1-303 series, designed specifically for aluminum

This powerful tool had all the features needed to deliver the goods, including:

• Patented geometry to eliminate chatter and vibration
• Superior chip removal
• H5 shank tolerance
• Better gripping force in the tool holder

The Result

This powerful tool had all the features needed to deliver the goods, including:

• The RobbJack A1-303 was the only tool series that could meet the design and performance benchmarks required.
• It allowed faster feed rates, increased performance and longer tool life.
• Not one has ever pulled out of a high quality tool holder.

CUTS CLEAN HOLES. SHREDS COMPETITION.

Abstract

When drilling carbon fiber reinforced polymer (CFRP) wing spars, an aircraft manufacturer struggled with poor quality cuts and expensive scrap until switching to RobbJack’s new Single Shot PCD diamond drill.

The Problem

Prized for its high rigidity and strength-to-weight ratio, CFRP is notoriously difficult to machine without delamination, uncut fibers and fiber pullout. One manufacturer was going through 25 carbide drills to make one ship set of wing spars, scrapping many very expensive parts along the way. The process was intolerably costly and unstable.

Then RobbJack took on the challenge.

OUR SOLUTION: THE SINGLE SHOT PCD-TIPPED 135°/ 20° 8 FACET TIP, DESIGNED SPECIFICALLY FOR CARBON FIBER COMPOSITES

This powerful, newly developed tool had all the features needed to do the job right, including:

• A polycrystalline diamond tip that outperforms diamond coating in materials with high plastic content, is a much sharper tool, and maintaining its edge longer
• A sharp outer edge that cleanly shears the material without delamination, uncut fibers or fiber pullout
• An innovative tip that drills and reams in one operation
• A tool life 25 times longer than traditional carbide drills in CFRP applications—and can be extended even further with re-sharpening

The Result

• The RobbJack PCD-tipped 135°/ 20° Single Shot Drill was the only tool that could meet the manufacture’s exacting design and performance standards, cutting over 4000 clean holes in tolerance; other tools struggled to get 160 holes.
• It completely stabilized and streamlined a previously difficult and wasteful process—secondary operations were no longer required
• Just one PCD-tipped drill was sufficient to make a complete ship set of wing spars—a process that previously had gone through 25 lesser drills

The RobbJack PCD-Tipped 135°/ 20° Single Shot Drill consistently achieved clean, precise cuts. Plus, freed from the hassle and time of replacing worn drills, the manufacturer achieved increased capacity & throughput.

ABSTRACT

The new carbide material and new coating combination in RobbJack’s DM/MDM Die/Mold Carbide End Mill lasts 450% longer than comparable carbides and coatings designed for hard metal applications—and reduces wear by 909%.

THE PROBLEM

Hard milling applications are becoming more complex with tighter tolerances. Poor tool life requires tool changes in the middle of a job, magnifies difficulty and leads to scrapped parts.

THE TEST

Tests were conducted in D2 58 HRc, pitting comparable carbides and coatings against our new DM/MDM Die/Mold Carbide End Mills. We compared tool life and tool wear.

THE RESULT

Typical tools designed for hard metal machining had a wear land or deep notches of .0275”. The new RobbJack DM/MDM series tool outperformed every test tool with a smooth wear land of only .0025”. That’s a whopping 909% less wear.

The RobbJack DM/MDM with revolutionary new carbide and coating lasted so much longer than any other tool we were able to cut molds in difficult material 450% longer—completely eliminating the need to switch tools midway through and hope for the best. The new tools generated less heat, held size, and cut the part within tolerance.

Additional Details

• Better finishes that eliminate or reduce the need for polishing
• Tighter tolerances and longer lasting in difficult areas like parting lines
• Great for materials up to 70 HRc
• Higher temperatures
• Reduced cycle times
• Excellent precision
• Dry cutting ability

Before: Typical hard metal carbide grade and coatings for molds.

After: New revolutionary carbide grade and coating. “The one to get it done.”

Abstract

When trimming carbon fiber reinforced polymer (CFRP) aerospace skins, an aircraft manufacturer struggled with poor cycle times, poor tool life, and expensive scrap until switching to RobbJack’s CPCD diamond trimming tools

The Problem

Prized for its high rigidity and strength-to-weight ratio, CFRP is notoriously difficult to machine without delamination, uncut fibers and fiber pullout. One manufacturer was going through one carbide burr per part. They had to rough the part in two passes and then change the tool to abrasive diamond grinding tool to finish the part. Requiring 3 passes to finish the part.
RobbJack took on the challenge!

Our Solution:

CPCD-203 series PCD Trimming tool, Designed specifically for Composites.

The CPCD-203 Series PCD tool roughs and finishes the part in a single pass reducing the cycle time from 20 minutes down to 5 minutes 400% cycle time reduction.

• PCD lasts much longer than carbide from 982 carbide burrs per year down to 42 tools per year.
• Built in drill point allows the tool to plunge into the material without causing delamination on the exit
• New and revolutionary technology in the manufacture of PCD tools. This new technology improves tool quality, PCD adhesion to the tool body, and increases heat resistance during cutting. All of these improvements allow tool performance that was once impossible.

The Result:

• RobbJack’s CPCD-203 Series PCD router solved their trimming pains and was also able to achieve a cost savings of more than $216,000 per year.
• It completely stabilized and streamlined a previously difficult and wasteful process—secondary operations were no longer required
• Just one CPCD router was able to cut 23 parts —a process that previously had gone through 23 tools plus a finishing tools.
• The tooling cost per part went from $48 to $18 per part.
• They were able to keep up with demand and take on other jobs because we able to finish the job 4X faster.

The RobbJack CPCD-203 Series router consistently achieved clean, precise cuts. Plus, freed from the hassle and time of replacing worn tools, the manufacturer achieved increased capacity & throughput.

Total yearly savings $216,000