Solving Problems
on All Fronts
Hill Engineering Limited works with global manufacturing entities
providing projects and components to a world class standard
utilising state-of-the-art machine tools and cutting tools.
Helping Hill Engineering to achieve its manufacturing excellence
is cutting too lsupplier ITC Tooling of Tamworth.
The South London based subcontractor works in the Petrochemical,
Vacuum, Aerospace and Automotive industries with an additional
business that runs alongside manufacturing Custom Ferrari Parts.
The ISO 9002 registered company has been working with ITC since
it received a door to door visit from a sales representative
in 1999. General Manager Paul Hill recalls: "We were using
a range of aluminium cutting tools from various suppliers until
ITC came along. We tried their 49N9 series of 3 flute aluminium
rippers and the 12mm & 16mm diameter cutters are exceptional."
Hill Engineering now uses the solid carbide cutters to rough
machine the majority of aluminium work. "What really impressed
us is the performance. We were initially running the cutters
at up to 4,000rpm and they were utilising 80-90% of the machine's
power. The ITC engineer started discussing the ideal torque
curve of our machines. We reduced our cutting speeds from 4,000rpm
to near 2,800rpm - the machine optimum. This improved tooling
performance and was only absorbing 60-70% of the machine power,
this allowed us to increase our feeds considerably whilst increasing
the depth of cut. We immediately took our machines from producing
40-60 parts per month to over 400. The productivity increase
has been phenomenal."
Working in situ with the productivity improvement is the chip
evacuation. The 49N9 series has a ribbed surface that reduces
the chip size, which in turn can be evacuated by the swarf conveyor.
Alternate cutters have two flutes and no ribbed surface; this
creates large chips that continually caused the machine to be
on stop for swarf clearing.
"The additional bonus of these cutters is the re-grind
service that ITC provides. Carbide cutters can prove expensive,
but ITC offers a re grind service with a rapid turnaround that
is very cost effective," continues Mr Hill.
"As a subcontractor, we have to be on the look out for
new strategies that will enable us to improve our productivity.
This ever evolving process has been supported all the way by
ITC. Dave Cleeve, the ITC sales engineer is always on hand to
support and advise us when striving for productivity gains.
This is not only the attitude of the representative, but of
the company in general," believes Mr Hill.
Hill has witnessed this support, not only with the expert advice,
support and re-grind service but also the ability to deliver
specialist tooling solutions. The company manufactures a number
of products for London Transport from drawings that date back
to the 1800's. The fast turnaround components are manufactured
using ITC's imperial range of cutters. "Manufacturing imperial
parts with ITC's imperial cutters takes any complexities out
of the situation. We use imperial ball nose cutters and the
multipurpose cutters are ideal for imperial parts," says
Mr Hill.
Another example of the ITC support has been demonstrated on
aluminium fitting for the automotive industry. The 18 inch long
part has a peripheral length of 3 feet. Mr Hill says: "We
were finish machining the part and then going around it again
with a chamfer tool. We explained the situation to ITC and they
soon came back to us with a specially developed cutter. The
6 flute carbide tool was produced from a 20mm blank; ground
to 16mm diameter with a 45 degree chamfer. Manufactured at ITC's
impressive production facility, the tool is now capable of eliminating
an entire chamfering operation."
Chamfering previously took 30 seconds and when added to the
tool change time, the special has reduced the process by up
to three minutes. This productivity gain is magnified because
the component is manufactured in batches of up to 3,500 per
month in its numerous variations.
The phenomenal savings now allows the machine operator to program
the next job whilst the current batch run is being machined.
Cutting at 1,500mm/min, the tool life and surface finish have
also been improved. "We have a lot to thank ITC for; we
have a very strong relationship with our representative and
this working partnership will undoubtedly continue to be fruitful
for both parties," concludes Mr Hill. |
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Carbide
cutters can prove expensive, but ITC offers a re grind
service with a rapid turnaround that is very cost effective |
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