Customer & Challenge:
A Maine-based, precision 5 axis capable CNC shop needed to machine complex 15-5PH stainless steel nose cones, requiring intricate internal finishes and significant material removal. Their initial 4-flute ball mill approach was slow and costly, taking 240 minutes per part. They needed a faster, cost-effective solution to reduce cycle time and minimize workpiece vibration without a significant tooling cost increase.
Butler Bros. Solution:
After assessing the process and tooling, Butler identified that a Conical Ball Mill would be more efficient than the standard ball mill for material removal. Collaborating with our customer and Walter, we introduced the Walter MD838 Solid Carbide Circle Segment Cutter, significantly improving material removal speed and maintaining workpiece stability and finish.
Customer Result:
The change in tooling and machining strategy from a standard ball mill to a conical ball mill resulted in $65,577 in annual savings. Butler was able to decrease the cycle time from 240 minutes to 55 minutes, a 77% reduction in cycle times.
Want to learn more about how Butler Bros. can save your business money? Reach out to us today!
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