Customer & Challenge:
A North Carolina-based manufacturer of aerospace and defense components was struggling with their rough milling process in Inconel 625. They had to change their 1/2" end mill every 40-45 minutes, which meant they needed 7-8 end mills for every 6-hour process. This was causing excessive downtime, increased tooling costs, and reduced productivity.
Butler Bros Solution:
Butler’s account representative analyzed the problem and brought in Fullerton’s application specialist to test their V-Mac 5-flute, high-performance end mill. The V-Mac, designed for high-temperature and high-pressure applications, was ideal for machining superalloys like Inconel. Using the same speeds and feed rates as the previous end mill, the V-Mac outperformed competitors, lasting twice as long—1.5 hours compared to their 40-45 minutes.
"We were amazed at the increased productivity, reduced downtime, and cost savings that the V-Mac end mill provided. We are now using the V-Mac end mill for our rough milling needs and couldn't be happier with the results." - Scott N, Director of Engineering
Customer Result:
The increased tool life of the V-Mac end mill reduced tool change-out times by 50%, significantly reducing downtimes. The increased life of each end mill and the reduction in purchases resulted in a $39,600 savings for the customer for each 6-hour process, with an annual expected savings of $130,000.
Want to learn more about how Butler Bros. can save your business money? Reach out to us today!
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