CNC machining is one of the most demanding industries out there in the world. In this industry, cutting tool wear remains one of the biggest challenges that manufacturers face. Every single production manager has to go through this frustration. They invest in tools that promise to deliver exceptional performance. However, they last only for hours instead of days. As a result, they have to deal with frequent downtimes for tool changes.
Moreover, they have to deal with surface finishes that gradually deteriorate as the cutting edges dull.
For high-volume operations, these issues translate directly into lost productivity. It can also increase costs and make your facility miss delivery deadlines.
These struggles are not new to the aluminum machining industry. Aluminum has received excellent reputation as a “Soft” material. It has the tendency to adhere to different cutting surfaces, generate built-up edge, and cause rapid tool degradation. This is where traditional carbide end mills fail to deliver the best results with aluminum processing. It makes aluminum manufacturers go in search for better tools. A DLC-coated end mill can be the ideal solution available in such a situation.
Let’s go through a case study on how a Canadian automotive parts supplier could transform aluminum machining operations using Huana Tools DLC-Coated End mill Technology. In fact, they could achieve an outstanding 40% tool reduction wear while improving surface quality and reducing production costs.
Client Background – Northtech Precision Automotive Manufacturing in Ontario
Northtech Precision Automotive Manufacturing is a mid-sized automotive parts supplier based in Windsor, Ontario. The specialize in manufacturing high-precision aluminum components. These components are used for North American automotive OEMs.
As of now, Northtech Precision Automotive Manufacturing has 85 employees and 24 CNC machining centers that run three shifts. The company processes over 15,000 aluminum parts monthly. They range from transmission housings to engine brackets and many more.
The facility mainly machines 6061-T6 and 7075-T6 aluminum alloys. These materials are quite popular for their excellent strength to weight ratios. However, they are also notorious for challenging machining characteristics. While operating within the competitive automotive supply chain, Northtech Precision faces numerous constant pressure to reduce costs. Moreover, the company needs to maintain high quality standards and focus on strict delivery schedules.
Similar to many other manufacturers dealing with this situation, Northtech Precision has been going through different aluminum machining tools. Different suppliers offer different tools. However, reducing cutting tool wear and improving quality was a challenge that left unanswered.
The Problem – Frequent Tool Changes, Short Tool Life, and Poor Finish
By early 2024, Northtech Precision has been dealing with numerous challenges. These challenges were impacting the bottom line of the manufacturing facility. Moreover, they were creating a negative impact on customer relationships as well. Let’s deep dive and take a look at these challenges.
Excessive Tool Wear and Frequent Changes
The existing carbide end mills of Northtech Precision weren’t lasting tool long. They offered an average of only 180 parts before requiring replacement. When compared to the overall production volume, they had to do tool changes every 3-4 hours. This resulted in significant downtime as well as labor costs. The manufacturing team calculated that around 15% of their available machine time was consumed by these tool changes.
Deteriorating Surface Quality
When the tools wore down, part surface finish reduced significantly. It started as an acceptable Ra 0.8 μm surface finish. However, it would soon deteriorate to 2.5 μm or even worse at the end of tool life. This inconsistency forced Northtech Precision to implement additional quality control measures. Dealing with occasional part rejection was inevitable. It further increased their expenses.
Built-up Edge Formation
The traditional tools used by Northtech Precision consistently developed built-up edge or BUE. This is a common issue when machining aluminum. The biggest challenge was when dealing with the 7075 alloy. This situation didn’t just accelerate tool wear. It created significant dimensional inconsistencies that threatened overall part quality.
Increasing Operational Costs
Northtech Precision noticed that their tool costs increased by over 35% within the past 18 months. In the meantime, the production demands continued to grow as well. The combination of frequent tool changes increased scrap rates. Moreover, the manufacturing plant was spending a lot of money on overtime labor, just to meet delivery schedules. This was squeezing their overall profit margins.
According to the Production Manager at Northtech Precision, David Chen, “We were caught in a cycle where cheap tools were costing us more money. Every few hours, we had to shut down a machine and change tools. It resets everything. Hope the next batch would perform better and the current operations have become unsustainable”.
The Huana Solution – DLC Coated 2-Flute End Mills
As a reputed CNC machining supplier, we at Huana Tools had the perfect solution to the issue that Northtech Precision has been dealing with.
Northtech Precision contacted multiple suppliers and tested different solutions before contacting us. The manufacturer was not happy with the cutting tool wear of all previous suppliers. Hence, they wanted something better than traditional carbide end mills. This is where our DLC-coated 2-flute end mills offered the right solution.
The solution we offered with custom CNC tools could address all challenges that Northtech Precision has been struggling with. Let’s take a look at some of the aspects of our custom-engineered high-performance milling tools. Then you will figure out why Northtech Precision was happy with the solution we offered.
The Technical Benefits of DLC Coating
Diamond-Like Carbon (DLC) coating is one of the most significant advancements in cutting tool technology. It is much different from traditional coatings. That’s because DLC offers a unique combination of properties that make it well-suited for aluminum machining. Here are those properties:
- Ultra-low friction coefficient
DLC coatings offer a friction coefficient of just 0.1. This can dramatically reduce the tendency of aluminum to adhere to cutting surfaces. This characteristic can eliminate built-up edge formation. Moreover, it can reduce the cutting force by a significant amount as well.
- Exceptional hardness
The custom tools with DLC coating offer hardness values that are equivalent to natural diamond. As a result, DLC coatings offer excellent wear resistance. They also maintain the toughness required for interrupted cuts. This combination can extend overall toll life. It is much better than traditional coatings.
- Chemical Inertness
The chemical stability of DLC-coated end mill technology is impressive as well. It prevents reactions with aluminum workplace materials. As a result, it is capable of maintaining cutting edge integrity throughout extended machining cycle. This property is valuable when machining aluminum alloys with different alloying elements.
- Self-lubricating properties
You can also find inherent lubricity in Diamond-Like Coating. It can reduce heat that generates during the cutting process. As a result, it is possible to experience higher cutting speeds. Moreover, it can improve overall surface finishes as well. This characteristic will eventually enable more aggressive machining parameters. It would never compromise the tool life.
Customized Tool Design
Huana Tools is a leading manufacturer of custom CNC tools. Our engineering team could develop a specialized end mill for aluminum. It featured following results:
- 2-flue design that is optimized for aluminum chip evacuation.
- High helix angle of 45 degrees, which offer improved surface finish.
- Polished flute surfaces minimize aluminum adhesion.
- Sharp cutting edges that offer optimized rake angles.
- DLC coating applied using advanced PVD processes.
The tools were manufactured using premium micro grain carbide substrates. It offered the ideal foundation for the overall DLC Coating systems.
Results Achieved – 40% Longer Tool Life, 30% Fewer Tool Changes and Many More
We implemented a testing phase with Northtech Precision to measure the changes in overall performance of custom CNC tools. The pilot program was conducted in two of the three machining centers. The team was able to select their most challenging application for this test. IT was machining 7075-T6 aluminum transmission brackets with complex internal geometries. There was a tight surface finish requirement as well.
Baseline Performance Improvement
Before introducing the DLC-coated end mill technology, the team at Northtech Precision could establish baseline performance metrics. They were as follows:
- Average tool life: 180 parts per tool.
- Surface finish: Ra 0.8-2.5 μm (degrading over tool life).
- Cycle time: 8.5 minutes per part.
- Tool change frequency: Every 3.2 hours.
- Scrap rate: 2.1% due to surface finish issue.
Initial Testing Results
The Huana Custom CNC tools were able to demonstrate improvements across all measured parameters. The initial test could also show promising results.
Comprehensive Results – Quantified Performance Improvements
After dix months of operation, Northtech Precision documented substantial improvements across all KPIs.
Enhancements to Tool Life
The most significant improvement out of all was the enhancement to tool life longevity. Here are the results delivered by DLC-coated end mill technology.
- Average tool life: 315 parts per tool (75% increase).
- Maximum recorded tool life: 428 parts.
- Consistent performance throughout tool life.
- 40% reduction in overall tool wear compared to previous solutions.
This improvement translated directly into reduced tool change frequency. In other words, it was from every 3.2 hours to every 5.8 hours. This was able to significantly reduce production interruptions.
Surface Quality Improvements
Northtech Precision was able to experience significant surface finish consistency improvements as well. Here are the details on those improvements:
- Consistent Ra 0.6 μm maintained throughout tool life.
- Elimination of built-up edge formation.
- Improved dimensional accuracy with reduced tool deflection.
- Enhanced part cosmetics meeting automotive OEM requirements.
Gain in Operational Efficiency
The combination of longer tool life and improved performance created multiple operational benefit. They include:
- Reduced setup time: 30% fewer tool changes per shift.
- Increased machine utilization: 12% improvement in cutting time.
- Lower labor costs: Reduced operator intervention requirements.
- Improved delivery performance: More predictable production schedules.
Cost Analysis and Savings
Performance Metric | Previous Tooling | Huana DLC Tools | Improvement |
Parts per Tool | 180 | 315 | +75% |
Tool Cost per Part | $0.28 | $0.19 | -32% |
Setup Time (hours/day) | 2.4 | 1.6 | -33% |
Scrap Rate | 2.1% | 0.6% | -71% |
Overall Cost per Part | $1.85 | $1.31 | -29% |
The data clearly demonstrates the value proposition of investing in high-performance milling tools instead of continuing to operate with lower-cost alternatives.
Client Testimonials – Real World Impact
“The transformation to Huana DLC-coated end mill technology has been remarkable”, stated David Chen, the Production Manager at Northtech Precision Manufacturing.
“When Huana first proposed their DLC-coated tools, I was skeptical about it. The higher upfront costs made me wonder whether we should be spending so much money on them. However, I’m happy with the decision I took to go ahead with Huana Tools.”
“The numbers don’t lie. We are now producing more parts with better quality. On top of that, we are experiencing lower costs than before. The consistency improvements alone is a great investment. Our operators know that when they set up a Huana tool, it is going to perform reliably for the entire shift and even beyond that. This predictability was able to change the way how we schedule and manage our delivery commitments”.
Transforming Aluminum Machining Through Advanced Technology
The experience that Northtech Precision had with Huana Tools DLC coated end mill technology was impressive. They were able to experience a 40% reduction in tool wear, while improving surface quality and operational accuracy. Moreover, they were able to create a compelling business case that extends beyond simple tool cost considerations.
Any manufacturer that struggles with similar challenges to Northtech Precision can get in touch with us. We can provide you with high-performance milling tools that address all challenges in aluminum machining. We don’t just offer advanced coating technology. We also provide expert technical support and comprehensive implementation planning. That’s why we can deliver results that can change the economics of your production operations.
Are you ready to transform your aluminum machining operations? Get in touch with our team at Huana Tools today. We are happy to discuss more on how our custom CNC tools and DLC coating technology can reduce tool wear. You can discover the Huana difference and join our list of growing manufacturers who transformed their operations with cutting edge tool technology.