Comprehensive testing, avoid errors

The SBN10 milling cutters are suitable for copy milling, ramping, helical interpolation, slot milling, plunge milling, face milling and corner milling. © Dormer Pramet

When the project started in 2015, the target was to launch the new BNGX inserts in November 2017. "However, we had pressure from our sales teams who wanted the inserts sooner! Our aim was to push the process forward as quickly as possible, and we kept to the schedule," says tool development engineer Jan Bittner happily. The test phase ran until mid-2016. Field trials with customers were important. "This is the only way we can check practical suitability. We were confident that it was a good product, but no tests in our own development center in Šumperk can replace practical use cases at the customer's premises." Ultimately, so much was learned from the practical tests that further product improvements were identified. One example was the test at a customer in France, where a titanium-containing, austenitic chromium-nickel stainless steel was machined - an extremely tough and ductile material. The machining process requires a powerful machine that is capable of high feed rates at slow spindle speeds. "We compared it with a competitor's high-feed milling tool, which has similar properties to our SBN10." And the results were impressive: After machining three parts, the cutting edge of the competitor's insert was worn, forcing the operator to check and change the cutting edge in order to continue production. After machining eight parts with the SBN10 and BNGX inserts, the cutting edge showed only minor flank wear and was still in good condition to continue machining. Jan Bittner explains: "In addition to longer tool life, the cutting rate was 20 percent higher. The customer was so impressed that he immediately bought one of the new milling cutters and pre-ordered seven more at the beginning of 2018."

The newly developed BNGX and ANHX indexable inserts. This year, 30,000 BNGX inserts in various sizes and chip breakers are to be manufactured. © Dormer Pramet

In the end, the development team had conducted over 20 practical tests with customers in France, Brazil, Poland, China, Italy, the Czech Republic and Germany. A total of five of these tests did not meet expectations, but helped the team to further improve the product. "The tests are an important process for us, as they contribute directly to improving product performance and reducing restrictions." It is crucial to react as quickly as possible during the testing process, eliminate problems and improve the design of the tool in a timely manner before it is used again for further tests. "In July 2017, we returned to Germany to a customer where one of the tests didn't go so well. When we return to the same location, we can create exactly the same test conditions. This is important to check whether the improvements we have made are having an effect. The use case went very successfully and it was great to present the new and improved version to the customer."

This was also the time to launch the new product on the market. Beforehand, it was once again clarified with the IP that the patent was available and that everything was ready for the market launch. Production ensured that enough indexable inserts could be produced for the launch.

Launching products on the market

Dormer Pramet was finally able to present its product range of BNGX indexable inserts and SBN10 milling cutters in November 2017, almost three years after the initial design preparation. By the end of 2018, the plant in Šumperk, Czech Republic, will have produced more than 30,000 BNGX indexable inserts in various sizes and chip breakers as well as 450 milling cutters in three different variants: end mills with threaded shank, end mills with cylindrical shank and shell end mills.

Jan Bittner sums up: "Product development is very much a team effort. Many colleagues around the world are involved in the development of our new cutting tools. From product management to design, the technology teams, production, test phases through to sales and marketing. No department is independent of the others. We are all interconnected, no department can be successful without the support of the others. Everyone has to pull together to successfully launch a product on the market. Our job in product management at a precision tool manufacturer is to look to the future, what do customers need, what will be important in five to ten years' time."

According to documents from Dormer Pramet / ag