Grand Prize Winner! Kevin West, VP-Operations Application: Trepan Housing Casting Industry: Automotive parts supplier

Success Story:
We are a large automotive support shop, and have used Manchester extensively through the years on various grooving and cutoff operations with great success. So when our company was awarded the production of a transmission carrier by a member of the "Big 3", we naturally planned on using Manchester to trepan out the castings.

We selected a 508-310 in grade M24 to get the fastest cycle time possible. We are running these ductile iron castings at 1100 SFM, at .008 IPR, and the tools are lasting an entire shift (about 300 parts per edge). The finish is also excellent, due in large part to the rigid design of the Manchester holders.

As I have known for some time, I always feel I can rely on Manchester to meet our production cycle times, with a lower cost per cut. Kevin W., VP-Operations

"When our company was awarded the production of a transmission carrier by a member of the "Big 3", we naturally planned on using Manchester to trepan out the castings."

Challenge:
The applications are to back turn, and turn a spherical shape. The machine is a Daewoo Puma 10S, 15 HP CNC lathe.

Specifics:
Material 316SS
MTC product : MTC SLS Toolholder, 581-103-13 M-43 PC .094 woc. Insert
SFM: 225
Plunge FD .004
Turn FD  .008

Results:
Manchester
MRR  2.03 CU/IN Per Min
PPE  7-8 Parts per edge

Competition
MRR 1.8 CU/IN Per Min
PPE  3 Parts Per Edge

Manchester more than doubles the Parts Per Edge!

Challenge:
The application is to eliminate a cut-off burr cutting into a hole on an1 5/8-RA 6 National Acme Screw Machine.

Specifics:
Material 1018, ¾  Diameter, .200 wall.
RPM 768
Feed .0016
MTC Product: MTC Separator Acme holder, with A22344-5070 M-40
F-2 insert with a 22-degree RH lead.

Results:
Manchester
MTC production of acceptable parts was 1788, 2342, and 2000 pieces.

Competition Production  957, 777, 734,1234.

Based on performance, MTC is now running on three machines making these parts.

Challenge:
A customer using a competitor's tools and inserts was face grooving in 8620H and having major chip control issues.

Results:
Manchester
We brought in a Chipmaker 95 in grade M53 (508-435-47) ran them at 800 SFM and .012 IPR taking several seconds out of the cycle and achieving great chip control. 

We took several seconds out of the cycle and achieved great chip control!

Challenge:
A customer using a competitor's tools and inserts was attempting a large face groove in Inconel 625. They were running at 80 SFM and .002 IPR. However, they could not even make it through one cycle without losing an edge.

Results:
Manchester
We put in a 251-140 with a MTC PT insert (582-106) in grade M43, ran at 125 SFM and .0035 IPR. We took minutes off the cycle and easily completed full parts with a decent edge left.

We took minutes off the cycle!

Application:
Swiss Machining

Industry:
Medical

Success Story:
"The customer was having a difficult time with tool change frequency on a short cycle time stainless steel job, hoping to get an insert with more tool life to keep the machine running longer. The competitor's insert was achieving 700 parts per edge as a maximum...but the Manchester, running the same speeds, lasted an average of 3,000+ pieces. Customer is in the process of changing everything over to the Manchester. Jon R., Sales Engineer

"The customer is in the process of
changing everything over to Manchester."