GENTZ believes THREADMASTER hardened thread milling cutter
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Savings in processing: Shan Gaoxin's 3.96mm Threadmaster saves one hour of machining time and a complete pass. In addition, the manual tapping time was also reduced from an average of 90 minutes per part to 30 minutes.

GENTZ Industries, Inc. of WARREN, Michigan, USA, is a world-class supplier of complex commercial and military turbine engine parts. With over 50 years of manufacturing history, the company's commitment to quality is fully reflected in its ISO 9001:2000 and AS9100 certifications. Typical production is low-volume, high-precision parts for expensive and difficult-to-machine materials such as Inconel, titanium alloys, and stainless steel, and Gentz ​​does not allow mistakes or parts to be scrapped. So when Seco application engineer Belinda Smith asked Gentz’s purchasing manager Mark McWilliams, would he consider converting a combustion chamber part made of Inconel 718 heat-treated to HRC 42 to 0.156 inch (about 3.96mm)? She also held a bit of skepticism when she was using a high thread milling cutter. “In this application requiring the creation of 52 threaded holes, we have tested five competitor's 3.96 mm thread mills,” explains McWilliams. "All the results were tool breaks. When Smith said 'we'll be better,' we don't have real confidence." Stable enough to be able to complete the thread milling process, Gentz ​​has decided to use a 0.170 inch (about 4.3 Mm, thread milling cutter for cutting technology website, which can generate small holes. Then all 52 holes need to be tapped by hand to finish the process. To complete the threading process, 2 thread cutters are required for 3 passes and approximately 15 taps for manual tapping of the part. The total machining time for each part is locked in the 154-minute machining time plus another 1 to 2 hours of manual tapping. Although not the most efficient process, it proved to be the most stable. Stability is crucial for high-value parts. When the combustion chamber ring forging reaches Gentz's workshop, it already has a value of $14,500 per piece (about 99,000 yuan, a cutting-technology website note). In addition, it takes about 14 hours before the thread milling process. Understandably, Gentz's team does not like to play around with a process that is producing good parts. “We have a long-standing partnership with Seco and are very harmonious,” said Jim Stevens, an OEM production manager at Gentz. “However, experience tells us that the 3.96-mm thread milling cutter is just not suitable for this process. For this process, Belinda spent about a year to persuade us, and finally we agreed to give Seco's Threadmaster a hard thread milling cutter a test. Cut opportunity.
Partnership benefits: From left: Gentz ​​milling programmer Paul Jones, CNC milling operator Mike Napa, Seco Tools Technology Services Belinda Smith, Gentz ​​Plant Manager Jim Stevens, Seco Tools Regional Manager Lerry Lofkof, Seco Tools Regional Manager Curt Hasson, Gentz ​​Purchasing Agent Rod Alexander and Gentz ​​Purchasing Manager Mark McWilliams. Double speed now! Threadmaster differs from other hardened thread milling cutters in that its TiCN coating and fine grain structure provide good toughness and wear resistance. When Gentz ​​agreed to the trial cut, Curt Hassan, Seco's regional manager, insisted that Gentz ​​would increase the feed rate more than double, from 78 in/min (about 2m/min, cutting technology website note) to 194 in/min ( About 5m/min, cutting technology website note). In addition, he also requested that the machining center (a 4-axis dual table OKK KCH500) increase the speed to 5000 r/min, which is more than three times the 1500 r/min that Gentz ​​used in the past.
Thread milling cutters use Seco's Shrinkfit shank to improve stability and runout. "We are very timid about speed," Stevens said. "I can't imagine what this thread milling cutter can do except for crashing on the Inconel part." "It was because of Mark and Jim's support that we were able to test with Threadmaster at this speed and feed. Said Hasson. “Our figures are so high that everyone is frightened.” So what is the result? ShanXin's 3.96mm Threadmaster can perform thread milling in only 53 passes in 53 minutes, saving 1 hour of machining time and a complete pass. In addition, the manual tapping time was also reduced from an average of 90 minutes per part to 30 minutes. Moreover, the rest only needs to check whether any thread is tightly fitted. Perfection from the first cut helps to compensate for the increase in speed and feed, making several additional changes to the process. Programming parameters are corrected by Seco's thread milling wizard software. With this guide, the operator only needs to enter the thread type, diameter, depth, and the material group that he or she is working on. This software then generates the machining code, greatly reducing set-up time and producing perfect threads from the first cut. In addition, Gentz ​​switched from the hydraulic shank system used today to the Shrinkfit thermal expansion tool clamping system offered by Seco. “This has helped us achieve smaller runouts, better tool life and more uniform tool wear,” adds Stevens. “This machining center is really running at 5000 RPM, and the rigidity of the Shrinkfit expansion tool holder helps us achieve better tool balance performance.” The Shrinkfit system works so well that Gentz ​​is now applying it to other Occasions. A good start Hassan appeared humbled for the success of thread milling applications. “Threadmaster's 3.96mm milling tool is providing Gentz ​​with significant cost savings, but it does not necessarily make a big contribution to increasing production. The machining of this part needs to be at Gentz's. It takes about 16 hours in the workshop and we are only in the early stages of improving efficiency."
The Shrinkfit system works so well that Gentz ​​is now applying it to other occasions. "It's worth the change just to eliminate the manual tapping time," said Roger Bartolonmei, chief operating officer at Gentz. "Most of the manual work has been cancelled. Now we are processing the thread to the required size and improving the quality. And you can't despise the annual savings of 62,000 (about 420,000 yuan, cutting technology website note)." Seco is now Other work on this part is also being studied. It includes turning, roughing, bulging, heat treatment, and finishing, using Seco's Productivity and Cost Analysis (PCA) program (for more information about PCs, see the article on the growing number of competitive advantages ). Using this program, Seco can evaluate a simple machining process or the entire process flow of a workpiece in the workshop. The significance of partnerships Seco and Gentz ​​held monthly seminars with distributor E&R Industries, Inc. The team reviewed what was done in the Gentz ​​workshop and identified the projects that needed to be developed in the future. "We have gotten a lot of good things from this monthly seminar," said Mr. McWilliams. Hassan added: "Through these meetings, we help Gentz ​​identify their hot spots - where they need help. This helps us focus on where they are important." "This is where we stand out," said Largo Lefkof, manager of Seco region. Explained. “We developed an overall plan based on our customer's tooling needs. We examined everything from tooling to process to inventory requirements. We call this Seco Business Solutions. We do not charge for this, and our efforts are achieved in our business. When it's successful, it pays off.” Mr. Bartolomei concluded: “We are a fast-growing company. It is very important for us to work with a supplier who knows how to help us improve efficiency. One thing I’m sure, Seco understands. The value of partnerships."

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