Maximize the Benefits of Diamond Tooling with Continuous Education, Expert Service, and High-Quality Tooling

A premier office furniture manufacturer located in the Midwest increases the benefits of diamond tooling through education, service, and quality tooling.

Diamond tooling offers several benefits over traditional carbide tooling. However, if you are not getting longevity out of your diamond tooling, the cost benefits rapidly diminish.

This is the exact issue a market-leading office furniture manufacturer was experiencing. Unusual amounts of wear and damage to their diamond tooling and exceedingly long turn-around times from their tooling service provider were increasing production expenses and ruining efficiency.

Working with their Leitz representative, the manufacturer was able to identify and implement four areas of strategic improvement.

Tooling Quality

More PCD tip height on a tool’s cutting wing = more serviceable tool life. A taller PCD tip height will allow you to sharpen the tool more times before having to replace the tool. There are currently no industry standards for custom tool tip heights, so it’s important customers understand this significant tooling characteristic. Leitz designs their custom tools with maximum amount of usable tip height more than any other tooling provider and, therefore, provides the customer with more efficient, lowest applied cost tooling solutions.

Continuous Education

Diamond tooling is harder than carbide tooling. As such, it is also much more brittle. Most machine operators lack an understanding of the gravity of the cost difference between diamond and carbide tooling as well as how to properly handle diamond tooling to ensure the longevity of the tools. Leitz is providing ongoing education to teach the operator team how to handle and protect diamond tooling and increase tool life.

These photos show PDC damage due to improper tool handling. There is layered breaking within the PDC layer itself, similar to how shale rock would break. This can only be caused by side impact to the PCD.

Material Improvement

In addition to damage from mishandling, through extensive tool evaluation after running, including high-resolution photographs, the Leitz service team was able to identify and document frontal impact damage to the tool caused by impurities in the materials being cut. The manufacturer was able to return to their material provider and discuss reimbursement for damage and investigate alternative material options.

These photos show PCD damage due to impurities in the material. Damage is straight down through the entire layer of PDC and into the tool body.

Expert Service

Because of the multiple Leitz service centers located around the country, Leitz can provide a faster turn-around time for tool servicing. The manufacturer is now able to carry less tooling in-house with results in cost savings on their overall tooling inventory.

Although the furniture manufacturer was using a quality competitor, Leitz has provided a total tooling solution for the customer that will deliver more efficiency and maximize their investment. By understanding the difference in tooling service and handling, the manufacturer has watched their efficiencies grow and has realized positive downstream effects from the changes implemented during the manufacturing process.

Let’s talk about increasing the benefits of your PCD tooling through better service and education. Contact Leitz at (800) 253-6070 or fill out the form below.

Leitz at IWF 2018 – Solutions in New Dimensions

In addition to displaying new and innovative tooling solutions, Leitz Tooling is driving home the important message of Right Tool, Right Service at IWF 2018. As a thought leader in the tooling space, Leitz is helping manufacturers maximize their investment in tooling by ensuring the right tool is selected for the machine and the application, and that the tool is properly serviced for optimized use and longevity. 

“Tooling selection, especially in today’s smart manufacturing landscape, is a 360-degree decision. You need to have a tooling partner that has your ongoing best interests and desired outcomes in mind,” comments Michael Lind, Leitz CEO. “The right tool results in quality and productivity; the right service ensures long-term success.”

Leitz educates manufacturers on what to consider when selecting a tool, how to improve the partnership between the tool and the machine, and the best service practices to get the most from their tooling investment.

Visit the Leitz booth #5752 at IWF 2018 to learn more.

Want to chat before the show? Fill out the form below and we’ll be in touch:

Tooling Spotlight: WhisperCut Cutterhead

In our tooling spotlight, we break down what you need to know about our most effective tooling solutions. This month’s MVP is PCD WhisperCut Pre-Mill cutterheads. leitz whispercut edgebander woodworking woodcutting wood manufacturing tool

The Tool:

Leitz WhisperCut is the premium low-weight PCD jointing head for edgebanders, and the first to utilize field replaceable/sharpenable precision diamond inserts.  The light-weight aluminum alloy cutter body reduces machine spindle wear while damping cutting noise by as much as 5dB(A).  WhisperCut technology provides the most efficient and economical pre-milling solution available.

What Makes it Better:

Features Benefits
Field replaceable/sharpenable PCD inserts ·         Replace inserts instead of heads, at a far lower cost

·         Significantly reduced tooling inventory, replacement knives only

·         Send knives for service instead of heavy steel cutterheads

Light-weight body ·         Reduced spindle bearing weight

·         Jump spindle moves smoothly in and out of cut

·         Absorbs and reduces cutting noise -5db(A)

·         Safe, easy handling

High shear (Edge Expert) versions available ·         Optimal cut quality due to dramatically reduced cutting pressure

·         Exponentially longer tool life due to reduced cutting pressure

·         Exceptional cut quality in fragile or textured laminates

·         Reduced or eliminated plucking of loose core material

DFC gullets ·         Improved chip evacuation and reduced knife wear/damage

When to Use It:

For pre-milling in preparation for edgebanding, on both classic and CNC based edgebanders.  Custom versions are available for jointing, rebating, v-grooving and angular cuts in abrasive materials.

Suitable Raw Materials:

  • Particleboard, MDF, and abrasive materials
  • Uncoated, veneered and laminated materials
  • Paper-coated, fiber reinforced plastics (glass fiber reinforced, carbon fiber reinforced plastic etc.).

The Results:

Exceptional finish, tear-free edges, and a straight edge on double-sided laminates.

Add this MVP to Your Lineup:

Download our WhisperCut PDF.

Contact your local Leitz consultant at (800) 253-6070, or fill out the form below, and we’ll get in touch.

Tooling Spotlight: ProfilCut Q Insert Tooling System

In our tooling spotlight, we break down what you need to know about our most popular tools. This month’s MVP is the Profil Cut Q & ProfilCut Q Premium.

The Tool

ProfilCut Q, ProfilCut Q Premium, and ProfilCut Q PCD are the fastest and most precise dedicated profile insert systems available.  The ProfilCut family of tools is designed to optimize process efficiency through perfect cut quality, highest yield, and fastest production cycles.

What makes it better

  • Modular body design offers profile flexibility and economic operation
  • Precision knife locating and retention prevent knife movement due to centrifugal forces
  • All knife changes can be made at the spindle, without disassembly of cutterhead
  • Knife clamping elements are protected from dust & resin build-up for ease of maintenance
  • Longest service cycles with Marathon or TDC (diamond) coated, and RipTec knife options
  • Lightweight aluminum alloy body allows for better balance and, in turn, reduced vibration
  • Certified and approved to operate at knife velocities up to 120 meters per second (50% faster than any competing insert system)

When to use it

  • Five-piece cabinet doors (cope/stick/style/rail/edge detail)
  • Wood interior and exterior doors
  • Wood windows
  • Architectural millwork and mating profiles
  • Miter lock or v-folding applications
  • Finger and glue jointing applications
  • Profiling of non-ferrous metals and advanced materials

Suitable raw materials

  • Soft, hard and exotic wood species
  • Panel materials such as plywood, raw or laminated particleboard and MDF
  • Plastic, foam, resin and composite materials
  • Non-ferrous metals

The results

  • Perfect sand-free finish quality at high knife marks per inch
  • Prevention common defects such as grain plucking, tearing and fuzzing
  • Reduced scrap loss, rework, and post machine sanding and repairs
  • Exact profile dimensions are maintained with every knife change
  • Maximum tool life
  • Multiple profiles can be achieved through simple knife change or exchange of modular cutter disks
  • Reduced machine downtime, with no need for machine recalibration
  • Larger profiles and limited machine spindle wear
  • Lowest possible cost per unit of production

Add this MVP to Your Lineup:

Contact your local Leitz representation by calling (800) 253-6070, or fill out the form below and we’ll get in touch.

Learn More About the ProfilCut Q Insert Tooling System
Contact us for more information.