CARBIDE INSERT QUOTATION,INDEXABLE CARBIDE INSERTS,CARBIDE INSERTS

Carbide grooving inserts have numerous durability benefits that make them an attractive option for many industrial applications. These inserts are an essential part of many machining processes and can be used in a variety of ways to improve the machining process and the quality of the finished product. Carbide grooving inserts are known for their long-term durability and resistance to wear, making them a viable option for many machining processes.

The main advantage of using Carbide grooving inserts is their resistance to wear. This means that they can withstand a variety of abrasive conditions, making them suitable for high-pressure and high-temperature environments. This makes them ideal for use in machining operations where there is a need for a long-term solution. Carbide grooving inserts are also resistant to corrosion, making them suitable for applications where there is a need for a long-term solution.

In addition to their resistance to wear and corrosion, Carbide grooving inserts are also known for their strength and durability. This is due to their strong construction and the fact that they are made of a hard material. This makes them suitable for use in difficult machining processes, as they can withstand intense pressure and temperature. This makes VCMT Insert them an ideal choice for machining processes that require a long-term solution.

Carbide grooving inserts can also be used in a variety of ways to improve the machining process. For example, they can be used to create tighter grooves or to reduce the amount of material that needs to be machined. This can lead to greater efficiency and a better overall product. They can also be used to create a more precise cut, which can improve the quality of the finished product and result in a better-looking finished product.

Overall, carbide grooving inserts are a great choice for many machining processes, as they offer long-term durability and resistance to wear, corrosion, and temperature. They can be used in a variety of ways to improve the machining process and the quality of the finished product. They are also a cost-effective Milling inserts solution, as they can be reused multiple times without needing to be replaced. Carbide grooving inserts are a great choice for many industrial applications and should be considered for any machining process.

The Carbide Inserts Blog: https://leopoldway.exblog.jp/

There has been tremendous progress made in recent years on ways to make roughing operations more efficient. But what about finishing? Long cycle times may be necessary to generate high-quality surface finishes, and frequent insert changes are often required, further increasing tooling costs and non-machining time. As the materials get more difficult, the issue grows larger.

So what’s the best insert for finish turning steel? To help answer that question, well-known cutting tooling manufacturer—Kyocera Precision Tools—ran a series of cutting tests to see which combination of cermet or carbide materials and coatings would provide the best total value in side-by-side comparisons. Here’s what they found out.

For roughing applications, shops can run at higher cutting speeds, larger depths of cut or higher feed rates to maximize the metal removal rate and shorten cycle times. However, in single-pass finishing operations, the depth of cut is usually fixed so that only cutting speed and feed can be addressed. Additionally, most workpieces have some surface finish specified that limits the maximum feed rate. On straight cuts, we can consider wiper inserts, but for profiling or angled cuts wipers are ineffective. In those cases, only an increase in cutting speed will reduce cycle time.

Cermet inserts have long been regarded as an excellent option for finishing steel. Chemically inert and thermally stable, the insert is highly resistant to edge buildup and crater wear which improves tool life while providing excellent surface finish. But the question remains about the best coating: CVD, PVD or no coating? For the test, these three versions of cermets were compared along with a CVD-coated carbide insert designed for machining steel.

The cutting test compared four inserts run at their maximum recommended cutting speed for finish turning 1045 steel.

All the inserts used in the test are manufactured by Kyocera. They are:

All insert grades were tested at the same depth of cut and feed rate. Cutting speeds were set at the maximum recommended speed for finishing the 1045 steel used in the comparison. The test was set so that each insert removed the same amount of material from the workpiece. All tools performed 100 passes at 0.5mm (0.020") depth of gravity turning inserts cut, and 0.1 mm/rev (0.004 ipr) feed.

Naturally, the inserts that run at higher speeds made it through the material faster than those run at slower speeds. As you can see from the chart below, Kyocera’s CCX CVD-coated cermet delivered shorter cycle times due to its ability to run at much higher cutting speeds than conventional cermet and carbide inserts.

But speed was only part of the test. How did the inserts perform in their wear properties and the ability to maintain good surface finish over time? As for wear, the inserts were measured at regular intervals with nose wear plotted versus both distance machined and time in the cut. Three of the inserts performed similarly well in wear resistance while the uncoated cermet started to exhibit high wear at about 2.5 miles into the cut. The wear shoulder milling cutters vs. time plot looks very similar, though by that measure, total time varied relative to each insert’s cycle time. See details on wear vs. distance and time.

Surface finish vs. distance was also plotted to see how well the inserts held up. There is no benefit to run at higher speeds if the tool life is unstable or too short. Kyocera’s PV710 cermet grade with its super smooth MEGACOAT NANO PVD coating provided the best surface finish and maintained the highest degree of consistency throughout the test, though at a slower cutting speed. Here too, the uncoated insert showed the most rapid decline due to its wear rate, and carbide was not able to achieve the levels of surface finish generated by the cermets.

Though this test showed that the CCX CVD-coated cermet insert offered the best overall performance in high speed finishing of steel and the PV710 PVD-coated cermet maintained the best surface finish, it’s important to remember that how any insert performs depends on the application. Here’s a bit more on what each insert in this test is designed for.

This newly developed CVD-coated cermet grade for finishing increases productivity with high-speed machining applications and provides excellent wear resistance for low carbon steel, general steel, and cast iron.

These PVD-coated and uncoated inserts are both part of Kyocera’s Hybrid Cermet line for high-quality surface finish machining that spans a range of general purpose and high-speed, continuous finishing applications. The Hybrid Technology combines conventional and high-melting point bonding processes to make inserts with improved fracture and wear resistance while providing excellent surface finishes.

The CA515 insert is designed for high-speed continuous to light interrupted cuts. It is part of the CA5 Series line of CVD-coated carbide inserts that offer long tool life and stable machining of steel across a range of applications including high speeds, continuous to light interrupted cuts, heavy interrupted cuts, high feed rates, and general purpose machining.

Go here for more information on Kyocera Indexable Tools for Turning.

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Ironmaking methods mainly include blast furnace method, direct reduction method, smelting reduction method, etc. the principle is that the reduced pig iron is obtained by physicochemical reaction of ore in a specific atmosphere (reducing substances Co, H2, C; appropriate temperature, etc.). In addition to a small part of pig iron used for casting, the vast majority is used as steel-making raw materials.

Blast furnace ironmaking is the main method of modern ironmaking and an important link in iron and steel production. Due to good technical and economic indicators, simple process, large production capacity, high labor productivity and low energy consumption, iron produced by blast furnace process accounts for more than 95% of the world’s total iron production.

Contents hide 1Schematic diagram of blast furnace ironmaking 2Raw materials: iron ore, solvent, fuel 2.1Iron ore 2.2solvent 2.3Fuel 3Combustion of fuel 4Reduction reaction in blast furnace 4.1Reduction of iron 4.2Carbonization of iron 4.3Slagging process 5Blast furnace products 5.1pig iron 5.2ferroalloy 5.3Slag, gas and dustSchematic diagram of blast furnace ironmaking

Blast furnace is similar to a cylindrical furnace, its outside is covered with steel plate, and its inner wall is lined with firebrick. The whole furnace is built on a deep concrete foundation.

During the production of blast furnace, iron ore, coke and slag making flux (limestone) are loaded from the top of the furnace, and preheated air is blown into the tuyere located at the lower part of the furnace along the circumference of the furnace. At high temperature, carbon monoxide and hydrogen generated by the combustion of carbon in coke and oxygen blown into the air remove oxygen from iron ore in the process of rising in the furnace, so as to obtain iron. The molten iron is discharged from the taphole.

Non reducing impurities in iron ore combine with limestone and other fluxes to form slag, which is discharged from slag port. The gas produced is exported from the top of the furnace and used as the fuel of hot blast furnace, heating furnace, coke oven and boiler after dust removal.

Raw materials: iron ore, solvent, fuel Iron ore

It is difficult to meet the requirements of blast furnace smelting in terms of chemical composition, physical state and other aspects of naturally mined ore. It must be prepared and treated by crushing, screening, beneficiation, briquetting and mixing to supply blast furnace with high grade, uniform composition and particle size.

There are four kinds of iron ore commonly used in metallurgical industry.

Mineral Types	Main components	Theoretical content of Iron	自然含铁量
Hematite	Fe2O3	70%	50%~60%
magnetite	Fe3O4	72.4%	40%~70%
limonite	2Fe2O3·3H2O	59.8%	37%~55%
Siderite	FeCo3	48.2%	低

solvent

Gangue in ore and ash in fuel contain some compounds with high melting point (for example, the melting point of SiO2 is 1625 ℃ and that of Al2O3 is 2050 ℃). They can not be melted into liquid at the smelting temperature of blast furnace, so they can not be well separated from molten iron. At the same time, the operation of furnace is difficult.

The purpose of adding flux is to form low melting point slag with these high melting point compounds, so as to completely liquefy at the smelting temperature of blast furnace and maintain considerable fluidity, so as to achieve the purpose of good separation from metal and ensure the quality of pig iron.

According to the properties of flux, it can be divided into basic flux and acid flux. Which flux to use depends on the properties of gangue in ore and ash in fuel. Since most gangues in natural ores are acidic and the ash content of coke is VNMG Insert acidic, alkaline fluxes, such as limestone, are usually used. Acid fluxes are rarely used.

Fuel

The heat needed by blast furnace smelting mainly depends on the combustion of fuel. At the same time, the fuel also plays the role of reducing agent in the combustion process, so the fuel is one of the main raw materials for blast furnace smelting. The commonly used fuel is mainly coke, anthracite and semi coke.

Physical and chemical process: reduction reaction at high temperature + slagging reaction

The purpose of blast furnace smelting is to reduce iron from iron ore and remove impurities. In the whole smelting process, the most important is the reduction of iron and slagging reaction.

In addition, it is accompanied by a series of other complex physical and chemical reactions, such as evaporation of water and SNMG Insert volatile matter, decomposition of carbonate, carbonization and melting of iron, reduction of other elements, etc., which can only be realized at a certain temperature. Therefore, the smelting process also needs fuel combustion as a necessary condition.

Combustion of fuel

C＋O2→CO2

Decomposition of burden

Evaporation of water and decomposition of crystal water; elimination of volatiles; decomposition of carbonate.

Reduction reaction in blast furnaceReduction of iron

In blast furnace, iron is not directly reduced from high valence oxide, but through a process of reduction from high valence oxide to low valence oxide, and then from low valence oxide to iron: Fe2O3 → Fe3O4 → FeO → Fe

The reduction of iron mainly depends on carbon monoxide gas and solid carbon as reducing agent. The reduction of carbon monoxide is usually called indirect reduction, and the reduction of solid carbon is called direct reduction.

The total reaction of indirect reduction is 3fe2o3 + 9co → 6fe + 9co2

The total reaction of direct reduction is 3fe2o3 + C → 2fe3o4 + Co

Carbonization of iron

The iron reduced from the ore is solid spongy, and its carbon content is very low, usually less than 1%. Because co decomposes at a lower temperature, and the decomposed C has a strong activity, when it contacts with iron, it is easy to form iron carbon alloy.

Therefore, the solid sponge iron begins to carburize at a lower temperature (400 ℃～ 600 ℃). The chemical reaction is as follows: 2CO + 3Fe → Fe3C + CO2 or 3Fe (liquid) + C (solid) → Fe3C

Slagging process

Slagging is a process in which gangue in ore and ash in fuel are combined with flux and removed from blast furnace. There are two kinds of slag formation in blast furnace

When smelting with ordinary acid ore, the flux is loaded into the blast furnace in the form of limestone, and the Cao in the flux can not be in close contact with the acid oxides in the ore. therefore, the slag initially formed is mainly fe2sio4 formed by SiO2, Al2O3 and a part of reduced FeO. Due to the existence of FeO in the slag, the melting point of the slag is reduced, and the slag has good fluidity. In the process of falling down (which is also the process of temperature rising), the FeO contained in the slag is gradually reduced and lost, while the content of Cao increases, and finally the final slag flows into the hearth.

When smelting with self fluxing ore, because the ore contains more Cao, and it can be in good contact with acidic SiO2, Cao immediately participates in the slagging reaction at the beginning of smelting, especially when smelting with self fluxing sinter, Cao forms slag with SiO2, Al2O3, etc. as early as in the sintering process, so the CaO content in the primary slag of this kind of ore is higher The composition of slag also changes little in the process of slag reduction.

Blast furnace products

The main products of blast furnace smelting are pig iron and ferroalloy, and the by-products are slag, gas and furnace dust.

pig iron

Pig iron is an iron carbon alloy with more than 2% carbon, which also contains Si, Mn, s, P and other impurities.

Pig iron can be divided into two categories according to its use and composition. One is steel-making pig iron: the carbon in the pig iron exists in the form of compound, and its cross section is silver white, also known as white iron; the other is casting pig iron: it is directly used to make machine parts.

ferroalloy

Iron and any kind of metal or nonmetal alloy are called ferroalloy (some are also called alloy pig iron). There are many kinds of ferroalloys, such as ferrosilicon, ferromanganese, ferrochrome, ferromolybdenum, ferrotungsten, etc.

Slag, gas and dust

Slag, gas and dust are by-products of blast furnace. They were discarded as waste before, but now they are widely used in building materials.

The Carbide Inserts Blog: https://carbideinserts.edublogs.org

This projectile is one of several air bag components made on Tornos multispindle automatics at the rate of 300 per hour. When previously made on a two-axis CNC single-spindle with a secondary operation, the rate was 50 parts per hour.

Fig. 2—The step-by-step production of the stainless steel demonstration part, completed in 17 seconds each. A single-spindle would run a minute or more.

One bank of Har Technologies' multispindle units and automatic bar loaders. The new technology has enabled Har to increase both business volume and profitability.

Fig. 1—This chart illustrates the relative productivity difference between single-spindle turning and multispindles. The comparison is based on cycle time and parts per cycle.

The basic look of the multispindle has changed little over the years. How it works, though, has undergone a veritable revolution with the implementation of CNC and the increasingly effective use of singlepoint cutting tools.

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Multispindle manufacturing for small parts looks, at first glance, like a breakthrough in production output. It seems logical that a six-spindle machine should outperform single spindle units by producing five times the parts per minute. And, when multispindle machines are totally dedicated to production of a single part, multispindle units often have time left over to further increase their profitability by taking on more business without additional investment in equipment or operation-related costs. In these cases, the benefits that CNC technology brings to faster job changeover are significant.

Discussion should start with an examination of the principle and operation of multispindle machines. Then we can explore the potential for increases in profitability as we climb the evolutionary ladder from single-spindle, cam-driven machines to investment in CNC-controlled multispindle screw machines.

More Spindles, More Work

In a very rough analogy, the multispindle gains its speed in very much the same way the old Gatling gun was able to increase its firing time. There's even a rough physical similarity. A multispindle machine subdivides the typical single-spindle operation cycle into more individually controllable segments.

In both multis and single spindles, tool movement and timing are controlled by a system of cams, a stored CNC program that actuates servomotors, or by a parallel operating system that is effectivly a blend of the first two. In this parallel mode, movement of tools is controlled by a central clock that electronically emulates the mechanical function of the main camshft and actuates the tool slides individually through servomotors.

In the single-spindle setup, one tool moves to the stock, completes its operation, returns to its home position, and the remaining operations are carried out in the same way, one step at a time. Some systems allow up to four tools to cut simultaneously—two turning tools and an endworking tool at the main spindle, and a back-working tool at the subspindle.

Still, on a single spindle machine only one part is being worked on per cycle. Cycle time might easily be 15 seconds per part, or just under four parts per minute—factoring in the time to feed new stock for the next cycle. While providing the flexibility of comparatively lightning fast changeovers, in general, cycle times for a CNC machine are slower than cams.

Multispindle machines begin with three, five, six or eight pieces of barstock, each secured in its own collet and mounted on an indexing headstock. With tools controlled at each index station in X and Y axes, and the provision for end working tools operating in conjunction with a subspindle, work progresses continually on parts in all spindles as they index from station to station.

As the cycle time is reduced, the number of parts produced per minute climbs. With the ability to attack the work multiple times per cycle, usually parts can be fully completed on a multispindle machine (see Figure 1).

Step By Step

The option of mounting up to three tools at any one position, including one from the end, allows the programmer to break each operation into smaller components that may be carried out at different points in the multi-station cycle. A part might be drilled to an optimum depth to suit the timing of a parallel operation at that station, then drilled further at another station, and tapped at yet another point along the process.

As an example, we'll step through the 17-second cycle SNMG Insert on the stainless steel part (see Figure 2). The cycle begins after the previous part is cut off at the sixth station. The machine is a Tornos MultiDECO 26/6, which is a six-spindle CNC machine.

The collet is opened and a new length of bar is fed in and locked; the entire barrel then indexes, in 0.8 second.

Position 1: A cross slide tool puts a chamfer on the back end of the part while a center drill, on the center slide, begins the drilling process with an oversize bit, just deep enough to create a chamfer at the beginning of what will be a threaded hole.

Position 2: The X2 cross slide, fitted with a turning tool, faces the part, then turns down a chamfer and three steps while the center slide, using a bit sized to the true hole diameter, feeds about two-thirds into the depth of the hole.

Position 3: The hole is drilled to its final depth and a turning tool finish-turns the two smaller diameters.

Carbide Inserts

Position 4: The ID of the completed hole is now tapped and the slide moves a tool with an insert to single-point thread a portion of the OD of the first diameter.

Position 5: This position's tool finish-turns the largest of the three machined diameters and creates a radius on the original raw stock diameter, finishing it back to the largest diameter, leaving the appropriate length of the chamfer cut in position 1.

Position 6: The couterspindle collet grips the part as it is cut off from the bar, and the back end of the part is given its finish and a radius.

All of the cutters used in this cycle are standard insert tools. Part of the CNC multispindle economy derives from the ability to effectively use insert turning tools rather than form tooling.

Justifying CNC Multispindles

Why not just consider a cam-driven multispindle machine? They're cheaper, for one. Or simply purchase additional single-spindle CNC or cam machines?

Operator familiarity with CNC programming for screw machines is a major consideration. If your shop operates exclusively mechanical equipment, who will program a new CNC machine? On the other hand, today's tech graduates are used to the laboratory-like cleanliness and programming-based nature of the CNC environment and generally are not trained in the old cam methods. It's a dilemma for shops. One thing is for sure, the skill sets needed for the operation and setup of cam-actuated machines are increasingly in short supply.

Arthur Mandell is the machine tool finance and leasing principal of Trans Capital Resources Limited (Carlstadt, New Jersey), which has 25 years invested in consultation with companies working to justify their major equipment purchases. He stands firm in the belief that the only true measure of a machine's profitability to a company is based on the cost per part and the number of the parts run. "Ultimately," he says, "the production of the parts is what's going to pay the bill, driven by the cost per part. The least important part of the formula is the cost of the equipment.

"In theory," says Mr. Mandell, "one hundred percent of the parts that are made on a multispindle machine could be made on some other machine—but it doesn't work in reverse. So, clearly, one kind of consideration is the types of parts you're making." He cites the example of male-female relationship parts, where multispindles outpace single-spindle machines in the ease and time of switching over from male to female for a partial run.

Even were there is no direct cost advantage per part produced, there would still be the time advantage, allowing the multispindle machine to begin to produce parts sooner than on a cam-operated multispindle. Certainly, when cam-driven multispindle machines were the only option, the time to set them up was rarely justified by their faster cycle time over single-spindle cam machines. And, as with most high technology-based products, the cost of multispindle centers has begun to decline somewhat.

Run The Numbers

Mr. Mandell, firm in his position that the cost per part tells all, regardless of machine cost, prepared a cost analysis to prove it. The equipment cost comparison chart (see Figure 3) shows not only the economy achieved by using a multispindle machine, it makes several points that go beyond economy to generate additional business and realize a disproportionately greater profit.

The premise of the chart is the difference between two single-spindle CNC-controlled machines and one CNC multispindle machine. While the multi costs $200,000 more and runs for the same number of production hours per week, the values begin to change when cycle times are compared. As the single turns out a part every 17.5 seconds, the six-spindle multi, because it performs at least six operations at a time, drops a part into the bin every 4 seconds; that's 3.43 parts per minute for a single, 15 for the multi.

Assuming a reasonable 85 percent efficiency for both types of machines, it will require two single-spindle machines to turn out the projected two million parts, versus 0.45 multispindle machines. Essentially, the multi is working less than half-time to produce the same as two singles. Remember that for later.

Mr. Mandell's example is based on 8 percent financing for a five-year period. While the monthly payment for the two singles is $5069.10 less than for the multi, a reduction of that cost to parts per minute, considering machine cost alone, puts the singles at $0.051, while the multi—working only half-time—came in at $0033. The additional profit realized from the reduced cycle time: $34,351.32.

The real bombshell comes in the "Other cost factors per machine per period," in this case, five years. Using a base overhead of $2.00 per machine, the doubling factor of the singles begins to add up already, and continues through labor, maintenance and repairs (which assumes a one-year manufacturer's warranty). Now, in addition to more than $34,000 of increased profit, our hypothetical shop owner saves $623,400 in additional expenses—plus $171,756.58 in potential additional profit from the other 55 percent of the multispindle machine's available production time.

Here's where a moderately aggressive shop owner can more than double profit from his or her investment in multispindle technology. Better yet, the shop can bid more aggressively, due to open time on a machine that's already turning a profit at 45 percent of capacity.

It takes little risk to grow business that way, yet many people still look at that big dollar-figure investment in a multispindle machine and fail to realize the cost-per-part savings that can accrue to those types of screw machine shop business styles that lend themselves to the multispindles' advantages.

Is A Multispindle Right For You?

Dividing screw machine shops into three categories can help that decision along. Consider the differences between a job shop, a multi-customer contract manufacturer, and a contract manufacturer whose output is dedicated to single-part production all year long.

The job shop owner responds to whatever variety of purchase orders cross his desk on any given day. He knows that he has a certain number of customers, but doesn't know what their parts requirements will be. This shop is not a likely candidate for multispindle operation. That said, it is possible that the shop specializes in parts particularly suited to multispindle manufacturing, as in the male/female example cited earlier. It would take a very sharp cost analysis to see whether the investment would turn a greater profit, but if it did, it would open a strong competitive advantage. Having a mixture of equipment to handle the next job coming in, cutting changeover time might help to expand the business, but there is greater risk here than in other situations.

The contract manufacturer knows that he already has orders for certain quantities of certain parts, so he will be making the same or similar parts over time. Making time for cost comparisons of multispindle machines against existing equipment is highly warranted in this scenario. The shop has already specialized in a line of parts, and the continuing business for the duration of the contracts allows for a much greater sense of security in making the multispindle change. Since the multispindle cost per part advantage almost automatically creates a greater profit with the machines running at only half capacity, this company can aggressively pursue more work—or simply purchase fewer CNC multispindle machines and reap the profit inherent in the faster cycle and changeover times.

Then there's the contract manufacturer whose equipment is at 100 percent capacity all year, making the same part, time after time, perhaps on a single-spindle CNC or a gang of cam-driven machines. If we're dealing in quantities of six million identical parts, it's even possible that a rotary transfer system has been set up. But, come the time that this company eyes a juicy order for a family of parts in the one to two million range each, get a cost comparison like our example, and strongly consider expanding beyond the single-part business with a CNC multispindle or two.

About the author: Ernie Grohs is a product manager for Tornos Technologies, U.S. Corporation (Brookfield, Connecticut).

In The Real World. . .

Har Technologies, in Harwood Heights, Illinois, had a pretty good business going for 46 years using single-spindle lathes and in recent years, CNC turning centers. Why would CEO Jeffrey Lampert switch to multis? After calculating the risk, he thought the payoff would be worth it—the opportunity to enter a new market that Har could not possibly serve with single-spindle CNCs: manufacturing millions of small air bag components. With eight Tornos-Bechler multispindle automatics, Har manufactures about 600,000 air bag components each week. Har has experienced 50 percent compound growth in less than five years, thanks to the new niche market the company has carved out for itself.

One component Har makes is the projectile that triggers air bag inflation upon impact. The production rate was 50 parts per hour on two-axis CNC lathes with subspindles, followed by a secondary operation on a manual lathe to remove the cutoff. The multis raised that rate to 300 and Har currently ships about 170,000 projectiles each week.

In operation, the spindle carrier indexes to position 1 where a cross slide faces the workpiece and an end slide moves in from behind. Then the carrier indexes to position 2 for OD grooving from a cross slide and partial hole drilling from an end slide. At position 3, the hole is drilled to its final depth. At position 4, the pointed end is formed, the hole is reamed to its final diameter and then flat bottomed. At position 5, the point is finish turned from a cross slide. At the final position, the point is cut off, supported by a subspindle. As the piece is cut off, the subspindle retracts, a back finishing tool moves into position, the part is finalized and sent down the part chute.

In addition to the increased productivity, Har is able to charge a great deal less for their parts. They are able to meet the quantities required by the automotive industry without additional investment in space to house more single-spindle machines. And Har's multi team, after minimal training on machine operation, often earns bonuses tied to quality and productivity.

  EQUIPMENT COST COMPARISON

Alternative 1:
Alternative 2: Make
Single Spindle
Multispindle  Autoloader
yes
yes Cost
$225,000
$650,000 Residual Percent
0.00%
0.00% Machines Required
2
1

Equipment Cost Each Machine Single Spindle
$225,000 Multi-
spindle
$650,000 
Production Hours Per Week 120 120
Cycle Time Per Part (In Seconds) 17.50 4.00
Number of Parts Per Minute 3.43 15.00
Efficiency 85% 85%
Quantity of Parts Per Year 2,000,000 2,000,000
Number of Machines Required 1.99 0.45
Total Equipment Cost $450,000.00 $650,000.00
Financing Interest Rate* 8.00% 8.00%
Financing Term (Stated in Months) 60 60
Residual Amount: $- $-
Monthly Payment Amount Total: $9,124.38 $13,179.66 Residual value of equipment if lease financing is used
Cost Per Hour Per Machine $8.84 $25.54 
Cost Per Minute Per Machine $0.17 $0.50 Calculated using efficiency factor stated above
Cost Per Part $0.051 $0.033 
Additional Profit Realized From Reduced Cycle Time $- $34,351.32 Difference in cost per part x number of parts per year

--------------------------------------------------------------------------------
Other Cost Factors Per Machine Per Part
 # of Years
5 
Overhead Per Machine Per Hour $2.00 $115.200.00 $57,600.00 
Labor Per machine Per Hour $19.00 $1,094,400.00 $547,200.00
Maint. Per Machine Per Year $120.00 $1,200.00 $600.00
Repair Per Machine Per Year $4,500.00 $36,000.00 +$18,000.00
Total Other Costs: $1,246,800.00 $623,400.00

--------------------------------------------------------------------------------
 
Cost Difference Over Life of Contract $ $623,400.00 Additional income realized from reduced expenses over life of contract
Savings Realized From Reduced Cycle Time  + $171,756.58

--------------------------------------------------------------------------------
 Additional profit realized from reduced cost per part x number of years for contract
Total Add'l Profit Realized Over Life of Contract $795,156.58

 
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