First-rate Mold Solution Co. Ltd is based in China and engaged in supply of industrial design, mold design, molding analysis and project management service.

“One thing that sets us apart,” says steven, President of First-rate mold company “is our willingness to accept low-run jobs that other tool shops would typically decline. We apply the same high level of quality workmanship whether it’s a single-piece order or a 60-piece production job.”

In order to stay profitable on a one- or two-piece run, getting the part right on the first try is critical. In addition to maintaining strict inspection procedures throughout the machining process,

First-rate mold company aggressively seeks out machining technology that helps them to operate at the highest levels of speed and precision. This philosophy led them to purchase a Makino S-56 machining center in 2006, and motivates them to implement cutting tools that maximize the machine’s potential.

First-rate mold company was struggling to find a cutting tool that could effectively mill 0.120” diameter holes 0.100” deep in a CPM 3V die plate. At 55HRC, CPM 3V has a lower hardness than other tool steels, but it can be more difficult to machine due to its toughness and abrasiveness.

Each plate had 2,500 holes and was taking 12 end mills and up to 11 hours to complete due both to the reduced machining speed and operators having to constantly check the cutting tool for wear.

First-rate mold company met with Hitachi Tool while attending a Makino Open House in MI where they discussed the CPM die plate application at length. Hitachi suggested its EPDR-TH corner radius end mills: a sub-micrograin tool designed to perform applications in hardened steels that were typically done by EDM.

First-rate mold company purchased several EPDR-TH end mills through their local cutting tool distributor, Kraeling Industries. With application advice from Hitachi, First-rate mold company was able to immediately employ more aggressive cutting conditions in the die plate application. The aggressive cutting conditions, combined with time saved from not having to constantly check the cutting tool for wear, allowed them to complete all 2,500 holes in less than 4.5 hours, a machining time reduction of 60 percent. All 2,500 holes required only three EPDR end mills, a tool cost reduction of 57 percent.

“We’re now able to run this job lights out,” says steven. “We’ll set the part up at night, and will return in the morning knowing that the job will be finished to spec.”
Following are three major features of the EPDR-TH that helped First-rate mold company achieve higher performance in hardened steels:

Hitachi Tool’s TH nano-composite coating offers higher levels of heat resistance and hardness than conventional titanium-based coatings.

The new neck design improves breakage resistance and gives the EPDR-TH end mills a longer effective reach.

A 3- to 5-degree back taper on the peripheral edges allows them to avoid contact with the workpiece, reducing tool deflection, chatter and vibration.