CUSTOM CUTTING TOOL ENGINEERING AND DESIGN
In a perfect world, there would be a standard tool waiting on the shelf for every machining application. In reality, tooling specifications are so precise and applications so specialized, that there is often no standard tool configured exactly as you need it for optimal performance in the task at hand. Knight Carbide provides custom-designed, application-specific tool inserts that are surprisingly cost effective. In fact, at Knight Carbide, custom inserts are priced at the same rate as standard.
Knight Carbide’s success is built on our cutting tool engineering expertise, and nowhere is this better exemplified than in our application-specific, custom inserts that maximize productivity. Whether streamlining production with a custom tool that performs two moves in a single pass, or adjusting insert geometry to optimize chip breakage and extraction in a complicated setup, Knight Carbide custom tools are always engineered to deliver superior performance and repeatability with maximum tool life.
Some avoid the custom option completely, assuming that the cost will be prohibitive. More enlightened machinists will confirm that just the opposite is true; custom tools are designed to maximize efficiency and lower your cost per part.
LETTING THE JOB DETERMINE THE TOOL
At Knight Carbide, we believe the application, not the budget, should determine the tool you use, whether it’s right off the shelf or a custom-engineered solution. That’s why Knight produces standard tools, blueprint specials and custom inserts all at the same rate and reasonable turnaround.
SAVE TIME AND MONEY WITH A CUSTOM TOOL SOLUTION FROM KNIGHT CARBIDE
The best solution to a custom application may in fact be a simple one, requiring nothing more than a slight alteration to a standard insert off the shelf. Often, however, reconsidering the entire process and insert geometry will reveal potential for even greater efficiency through custom tooling.
TAKE A LITTLE TIME TO SAVE A LOT OF TIME
Knight Carbide can engineer a tool to perform optimally within any existing machining setup. Nuanced factors like machine horsepower and vibration levels influence the geometry of the ideal cutting edge for your job. In far less time than most of our customers expect, Knight engineers can deliver a custom tool that will begin shaving valuable seconds off your production time the moment it is installed.
THE MANY ADVANTAGES OF GOING CUSTOM
Application-specific, custom engineered tools can be game-changing on the production line:
- Reduced cutting time
- Minimized downtime
- Increased tool life
- Optimal performance
- Simplified handling
- Improved accuracy
- Increased efficiency
Best of all, every custom tool we manufacture becomes a permanent part of our archive. That means we can produce more for you at any time, for the same price and turnaround as any standard tool. All it takes is a phone call.
CASE STUDIES IN CUSTOM TOOL SOLUTIONS
CASE STUDY 1: TIE RODS
When standard threading inserts failed to meet part radius requirements for a hollow mill operation, Knight Carbide paired production versatility and innovative thinking to produce a custom solution that eliminated bird nesting, reduced machine downtime and increased overall performance.
From excessive bird nesting and low parts-per-edge, to daily machine downtime, the current supplier’s standard inserts could not perform to customer expectations. Using the customer’s current tooling, Knight modified the chip breaker geometry, changed the radius and selected the ideal grade encoding for optimizing tool life.
Knight’s custom cutting solution reduced machine downtime to ten minutes a day, improved chip control, eliminated bird nesting and increased parts-per-edge. Knight expanded the customer’s tooling capabilities and increased productivity and profit beyond the cost of custom tooling. Knight Carbide custom solutions make sense.
CASE STUDY 2: TRANSMISSION DOG GEAR
A leading manufacturer of automotive transmission systems required a custom cutting tool to mill a profile into a transmission dog gear made of 9310 stainless steel. Timing was critical and they needed the tooling quickly. After soliciting bids from several companies, the client was disappointed to receive quotes for eight-week delivery. Fortunately, Knight Carbide knew we could do better.
The blueprint called for an insert designed to geometry with a titanium aluminum nitride coating. Additionally, the tool holder had to be as short as possible for maximum rigidity against vibration. Using our MK Dog Cutter, Knight Carbide was able to produce the tooling system in just two weeks.
Make Knight carbide your fast-track provider of quality cutting tool solutions.