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.

Tooling Spotlight: ThermoGrip® Tool-Holding System

In our tooling spotlight, we break down what you need to know about our most effective tooling solutions. This month’s MVP is ThermoGrip CNC Tool-Holding System.

The Tool:

The Leitz ThermoGrip® heat-shrink tool-holding system offers unrivaled precision. The one-piece chuck design eliminates excess tool run-out common to collet and hydro tool-holding systems. Heat shrink technology allows for higher machine output, while yielding optimized cut quality and significantly extended tool life.

Heat shrink chucks offer the simplest and most rigid link between the machine spindle and cutting tool. Heat shrink chucks are inexpensive, one-piece tool holders, without moving or mechanical parts to wear or maintain.leitz, thermogrip, tooling, woodworking toolsThe ThermoGrip® tool holding system uses an inductive heating concept to provide stronger, more concentric tool clamping. This leads to increased tool life, better surface finishes, and improved cost efficiency.

What makes it better:

  • Highest torque transfer; essentially a one-piece tool and HSK-F63
  • Safe, rigid balanced to 36,000 RPMs
  • Optimized tool performance, finish quality
  • Increased cutting speeds (by 30%)
  • Improved machine productivity
  • Compact, solid design with no wear parts; right or left rotation
  • Easy cleaning/maintenance; unlimited lifespan
  • Reduced tooling costs; fast tool changes

When to use it:

With CNC and other precision machining.

The results:

The annualized savings utilizing Leitz ThermoGrip can be astounding. You will reduce tooling costs by a minimum of 25% and increase machine and operator productivity by at least 20%. ThermoGrip users have noted annualized savings of at least $15,000 per shift, with expanded production capacity. The ThermoGrip system generally pays for itself within months, and the maintenance-free chucks provide virtually unlimited service life.

Add this MVP to your line-up:

Check out our current promotion for the ThermoGrip Tool Holding System. Offer valid now through December 31, 2918.

Download our ThermoGrip PDF.

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

Cutting Edge Furniture Making – Haworth & Leitz Tooling Solutions

Haworth’s sustainable manufacturing practices help give the contract furniture giant an edge in the marketplace.

One of the top three U.S.· based contract furniture manufacturers, Haworth Inc. is renown worldwide for its quality office furniture and innovations. Founded in 1948 in Holland, Ml, by G.W. Haworth, it remains a family-owned and privately-held company serving markets in more than 120 countries through a global network of 650 dealers and 6,500 employees. 2014 net sales for the furni­ture giant were $1.8 billion.

Spurring the company’s success is its focus on research and design, which help drive the company’s deep understanding of agile workplace needs, said Haworth spokesperson Ryan McCall.

“Globally, Haworth improves workplac­ es with award-winning furniture, interior architecture, and technology solutions to help customers achieve business goals and transform culture, as well as support collaboration and innovation,” said Mc­ Call. “Haworth is committed to protecting and restoring the environment, creating economic value as well as supporting and strengthening its communities .”

As part of Haworth’s sustainable manu­facturing efforts, the company made changes to the production of its furniture and components. Among the technology upgrades in the panel processing area was the implementation last year of Leitz tooling to the edgebanding line.

“We upgraded our double-sided edge­ bander with the Leitz WhisperCut EdgeEx­ pert milling head program,” said McCall. “We were looking for a sizing tool on the edgebander that would greatly increase finished cut quality and greatly decrease the frequency of tool changes.

“Before developing this tooling program, machine operators were spending an aver­ age of 45 minutes every shift changing carbide insert tooling to maintain a quality cut. When we implemented the Whisper­ Cut EdgeExpert program, the PCD milling heads dramatically decreased the need for tool change frequency,” he said.

Feedback from the lead operator on the double-sided edgebander indicates he is now changing the diamond-tipped knives every six to eight weeks, McCall added.

“Work surface production was specifically targeted with this tooling development. We manufacture over 1,200 rectangular work surfaces per day with standard color offerings or a customer’s own material,” he said.

In addition to the edgebanding pro­cess, a number of machines are integral to the production of Haworth’s wide range of products. Among the workhorses in use at the company’s factories are beam and angular saws for cutting panels and sheet goods to size. Laminating is done in-house, utilizing a hot platen press. CNC routers and machining centers are also used extensively within the production area as the furniture manufacturer continuously looks for ways to improve the productivity and profitability of its products and processes.

The Leitz Tooling program is an integral part of this goal. “The WhisperCut EdgeExpert ROI is well under a year based on labor savings alone,” McCall said. “We have had great success with this tooling program.”

Originally published in FDMC Magazine October 2015. Download the PDF here.