Rotary Tech Product Testimonials
Metal Masters Rock! I've used their Metal Master tools for years and years and years. Nothing better for the money. Just had to have it. Can't live without it.
Making small parts of AMPCO-21 an aluminum-bronze alloy. This material is very hard and it is very gummy and difficult to machine. The distributor suggested a Metal Master MFS205 (2" diameter, 5-flute shank style). The cutting parameters settled on were 2600 rpm (1400 sfpm) and 10 ipm
feed rate. The combination of high speed/slow feed works
particularly well with Metal Masters in gummy materials. This cut produced the required 32 RMS finish and the tool life was
Mobil Chemical Plant, Shawnee, OK
We were machining hot rolled structural steel, the surface was 1 1/2 inches wide by 6 inches long. We were using a 2 inch diameter standard flycutter with a brazed carbide tip. It was taking 9-10 minutes to machine each part to print, much too long to be a profitable operation. When we began using a Metal Master MM200 (2 inch diameter single-flute) we were able to machine full depth in one pass. Cycle time was less than 3 minutes per part and the finish produced was excellent.
We now remove metal at three times the speed and our tool life has increased 400%.
Rotary Technologies Corporation
We found the MFS203 to be far better than previously used flycutters in cutting depth and how freely it ran without beating the machine to death. The Metal Masterís finished product is so good that we have eliminated the grind operation.
We had a 10,000 piece run that was going to take a full 2 weeks, which was very time consuming and despite our efforts the finish was still not acceptable. We decided to try the Metal Master MM200 and increased speed to 500% and the finish produced was much better than a conventional
tool. A full 10,000 piece production run was completed in 2 days instead of the 2 weeks required with the old method.
Production Piece Parts
Milling solid blocks of 1018 on a 2 hp Comet machine. Using the Metal Master MM300 (3 inch diameter single-flute) enabled us to cut machining time on this job in half and had the best all around feed and speed that we had found for this material. The surface finish was so good that the customary finish pass had been eliminated in some cases.
J & J Metalcraft
Milling hard tool steel for components of a large steam generator, we began using the MFS205 (2" diameter, 5 flute) shank style Metal Master. On the finishing pass we cut a chip load down to .004" (20ipm). This produces a finish that is remarkable. We are able to run an entire shift without indexing.
General Electric Company - Large Steam Generator Division, Schen
Had been using a brazed carbide toolbit in a single-point flycutter arrangement. The main problem lied in the area of the operator's safety. According to shop supervisor Stan Webb his operators didn't like them because the toolbits occasionally worked themselves loose. This was clearly a potentially dangerous situation. A salesman had a Metal Master in his trunk and brought it in for Stan and his operators to try. They saw right away that the Metal Master had a much safer design because the insert is completely surrounded by the body. This feature allowed them to run the cutter with confidence, even in tough cuts. As it turned out the Metal Master could run significantly faster than their conventional flycutter and tool life improved as well.
Manufacturer of extruded plastic parts for automobiles
Machining cast iron heat sinks on a 2 hp Wells mill. Castings are very rough when received with heavy sand inclusions. All faces must be machined to make the part square and prepare for later operations. Originally we were using a high-positive carbide flycutter, but later switched to a 3" diameter
HSS milling cutter because the carbide tool couldn't hold up in the interrupted cut. It was taking 18 hours to complete each 200 part run, and the cutter was good for only 400 parts before it needed resharpening. At the suggestion of the distributor salesman we tried an MM300 (3" diameter, single flute) Metal Master. The machining parameters settled on were 2100 rpm and 19 ipm. At this shallow depth of cut many indexes are available from our Frustrum insert. They are machining over 1200 parts per side, over 2400 per insert. The faster feeds and speeds and the greatly reduced downtime combine for a tremendous increase in over-all productivity. The floor-to-floor time for a 200 part run has been reduced from 18 hours down to 4 hours!!!!!
Elliott's Precision in Glendale, AZ
Facing small blocks of 6061 Aluminum on a Mazak CNC. Total material to be removed is between .150 - .160, and the drawing specifies a 32 finish. We were using a 4" diameter, 2-flute indexable flycutter. The cutter was set up with one carbide insert and one diamond insert, with the diamond set .005 lower. With this set up it was necessary to make two roughing and one finishing pass. The machining parameters for roughing were: 750 rpm (800 sfm), and 15 ipm (.010" ipt). The multiple passes made this job very time consuming, even with a finishing pass, the finish was not consist with specs. Tried a MFS205 (2" diameter, 5-flute) on this job, and settled on 3000 rpm (1600 sfm), and 60 ipm (.004" ipt). This cut consistently produces a finish better than 32. Even better, this cut is made in one pass, eliminating the two roughing passes required by the old tool.
Nuemo Precision, Keene, NH
Large production machine shop produces fixturing on Bridgeports and Tree mills. Material is usually 300-series stainless, but a variety of other steels and non-ferrous materials are also being cut. Conventional flycutters and indexable insert tools aren't capable of high metal removal rates nor can they handle deep depths of cut. The 2" diameter Metal Master allowed the machine operator not only to cut deeper, but to also increase the feed rate. The net result has been a significant improvement in metal removal rate, and a decrease in over-all floor-to-floor machining costs.
The Industrial Products Division of Hughes Aircraft Company
Facing a variety of complex parts of 6061 and high precision
A356 castings on a 7.5 hp HP VQC Mazak. Prior cutter was a 4" diameter, 8-flute Kennametal, running 4 inserts to improve the finish. Maximum feed rate with this tool was less than 50 ipm. Using the 3" diameter, single-flute MM300 feeds and speeds improved dramatically. Currently the machine is programmed for 6000 rpm and 180 ipm. Depth of cut is .070 - .100". This works out to 4700 sfm and a chip load of .030" per tooth. Even at this heavy feed rate the Metal Master produces a 16 finish, and does not burden the machine. Successive passes on wide parts blend smoothly with no step, and insert life is quite satisfactory.
Job Shop Specializing in the Communication, Aerospace and Roboti
Machining a variety of modern plastics and Bridgeports using standard flycutters with brazed carbide bits. One of the most common materials is G-10 which is used extensively for printed circuit boards. It is fiberglas reinforced, with a resin binder and is very abrasive. Another job is facing blocks of black plexiglas which is prone to chipping at the edges. The flycutters were very limited as far as speed and depth of cut.
They put so much heat in the workpiece that the G-10 frequently burned at the cut surface.
After switching to the Metal Master MFS203 (2" diameter, 3-flute) they began to see some impressive results. Now cutting G-10 at .040" D.O.C. at 1400 rpm and 35 ipm with no surface burning. In black plexiglas it's even better, at a .060" D.O.C, cutting at 1800 rpm and 20 ipm. The edge chipping has been eliminated and they feel that the special FRUSTRUM geometry is the reason. What's more they can consistently produce between a 32 and 63 finish in one pass.
Plastic Distributors & Fabricators, Haverhill, MA
We had a difficult cutting job, we tried the Metal Master HP and found spindle speed could be increased by 60% compared to our old cutter and the feed rate was tripled. The insert life was twice as good and the finished product was much improved.
Outboard Marine Corporation
Machined a wide variety of aluminum component parts for
local manufacturers. The flycutter they were using tended to leave a step between successive passes and the cutters had to be resharpened fairly frequently. The plant manager tried a Metal Master HP305 (3" diameter, 5 flute) on the next production run. The metal removal rate improved immediately. They are now cutting at 6000 rpm and 90 ipm, 4 1/2 times faster than before. They are able to cut wide parts
with no step between passes and even at this much higher feed rate the finish is well within spec's. They also discovered that after indexing, the Frustrum inserts maintain repeatability within tenths. "The cutter has paid for itself several times over".
Southern California Job Shop
A large customer calls with an important rush job, a very expensive piece of earth moving equipment is down. The shop mananger started with an HSS end mill, after a day and a half of trying all that he had done was break some end mills and scratch the paint. At the suggestion of a distributor the shop manager tried the MFC303 shell mill with the 55P insert. After having spent 12 hours trying to make conventional tools work, he was glad to find a cutter that enabled him to complete all three parts in one 8 hour shift.
General Purpose Machine Shop in Phoenix, AZ
Machining parts of Inconel 718 on a #3 Cincinnati. These parts are "butterflies" used in very high temperature valves. The surface of the part is machined at an angle, so the depth of cut varies from zero to .100". Maximum thickness of the stock to be removed is .250". Each insert was modified with a special grind operation that brought the per insert cost to over $40.00. Cutting at .56 ipm and 125 rpm, a standard 60 part batch used 70 - 80 inserts. This job was much too costly both in terms of machining time and in terms of carbide costs.
By switching to the MFC305 (3" diameter, 5-flute) Metal Master shell mill, they were able to increase the feed rate from .56 to 2.50 ipm, saving over 30 hours of machining time per batch. In addition, only using 30 inserts so the carbide cost has been reduced by 85%.
Rotary Tools Generation I
"No one can touch the Rotary Technologies Corporation Milling Cutter for performance in cast iron."
Ford Motor Company, Cleveland, OH
Using the C45 (4 inch diameter 5-flute Rotary Technologies
Milling Cutter) has slashed their machining cost by 50%.
I like using the C34 for face milling. We get exceptional insert life so we're not constantly changing inserts.
Condor Tool and Manufacturing Inc.