When a machining process requires four different tools to complete a single part, inefficiencies don’t add up: they multiply.
Each tool change involves machine downtime, setup time, dimensional checks, and an increased risk of positioning errors.
Managing multiple operations with different tools directly impacts cycle times and makes the process more complex to program and control.
The result is a fragmented production flow that is difficult to optimize and poorly predictable in terms of productivity and repeatability.
Starting from an in-depth analysis of the customer’s application, MADTOOLS completely rethought the machining approach.
The solution was the design of a dedicated core drill capable of integrating, into a single tool, all the operations previously carried out by four separate tools.
The tool, with mechanical clamping and an integrated BT30 BIG PLUS interface, was developed specifically for brass machining, ensuring stability, reliability, and process continuity.
THE RESULT
The introduction of the MADTOOLS core drill delivered immediate and tangible benefits.
Eliminating three tools led to a significant reduction in overall cycle times, making the process faster and more streamlined.
Machining, now concentrated in a single operation, offers greater dimensional stability and consistent repeatability.
Simplifying the cycle also had a positive impact on programming and machine operation, reducing the likelihood of errors and improving the overall efficiency of the production line.
BEYOND THE TOOL
This case study shows how MADTOOLS does not merely supply tools, but acts as a technical partner capable of analyzing, rethinking, and optimizing its customers’ production processes.
Because often, behind a complex process, you don’t need one more tool.
You need the right idea.
