Machined Investment Casting

Tool Life Management: Speeds, feeds, and tool paths must be finely tuned when cutting Inconel as there is little margin for error. The key to consistent performance, once the foundation is established, is managing tool life. LeanWerks uses a stringent program of cutting tool management so tools are changed before they fail, reducing scrap and increasing throughput. Broken tools not only cause unneeded and costly delays to replace the broken tool, but they often create a scrapped part or can cause damage to the fixture or machine tool. That is especially true in materials like Inconel as a dull tool hardens the material and often creates forces so high that the part is over cut, damaged by the work-holding, or ripped from the work-holding and/or machine tool causing sever damage. When operating to a tight schedule or working to ramp up to increased demand, tool failures can be devastating and must be avoided. LeanWerks uses experienced master machinists like Frank Purcell to inspect the cutting tools and create standard tool change increments through the development of a new program. LeanWerks uses charts like the one shown below to document the standards needed to run a part consistently so it can be run with confidence by a machine operator.