Custom cutters and indexable inserts from U.S. Tool are helping Genesis Machining Services to increase productivity and prolong tool life. Since 2001, the Calgary, Alberta-based company has been manufacturing its TorqStopper™ -- a custom-designed torque anchor for use in progressive-cavity pumps in the oil and gas industries -- for one of its largest customers.
During operation, progressive-cavity pumps can produce thousands of ft-lb of torque. A torque anchor prevents tubing backoff while maintaining superior flow by acting as a conduit for the actual pump and the resulting flow of oil or gas, while eliminating any torque loading in the surrounding tubing or pump casing. Straightforward in design, a TorqStopper can be installed in production tubing as narrow as 2 7/8 in. diameter or in casings as wide as 10 3/4 in. diameter.
The patented TorqStopper underwent a major evolution last year when a D-slot was incorporated into its main body. While a TorqStopper can be easily serviced with an allen wrench, the D-slot prevents the body's door detail from being torn off if a power wrench is accidentally used.
Genesis Machining's problem was that no standard tooling was available to machine the D-slot efficiently.
"We supply several thousand TorqStoppers per year," says Ned Polancec, Genesis Machining general manager. "In the prototype stage for the new model, we used a regular brazed carbide single-point fly cutter and soon realized this just wasn't going to work on larger production runs."
Initially, the company supplied its own cutting tools. "For the maiden production run of 200, we made four 6-toothed cutters, incorporating 6 brazed-on carbide inserts that were sent out for grinding to match the D-slot profile," Polancec says. "This improved quality and machining time substantially from the prototype stage, but tool life was nowhere near what we needed. The cutters were good for maybe 10 or 20 TorqStopper bodies at most, and way too much time was spent changing cutters and running measuring probes to ensure that tolerances were within specifications."
Investigating custom tooling suppliers via the Internet, Genesis Machining came across U.S. Tool Inc (Farmington Hills, MI). Established in 1942, U.S. Tool specializes in designing and manufacturing toolholders and indexable inserts with unique forms, dimensions, and tolerances for a wide range of applications. In fact, the company's slogan is, "When everyone tells you it can't be done, call U.S. Tool."
"We sent them a concept drawing of the milling cutter and indexable inserts we wanted," Polancec says. "Within a day, they provided us with detailed drawings for both cutter and inserts, along with a pricing and delivery schedule."
Genesis placed an initial order for three milling cutters and 50 indexable inserts, 25 of which were TiALN-coated. "The day they arrived, we put them in use and realized significant performance improvements," Polancec says. "We were able to increase speeds and feeds by 100% and went from a 5-minute cycle time down to 2 minutes for the D-slot profile. And tool life is up to well over 100 TorqStopper bodies before we have to change the inserts."
In addition, obtaining custom cutting tools need not be inordinately expensive, thanks to U.S. Tool's Ready 2 Ship(sm) program.
"Customers like Genesis can place a volume order for six months' or a year's worth of tooling, or for whatever length of time they feel comfortable forecasting," says Jim Brady, U.S. Tool senior vice president. "We manufacture the entire quantity, store it, then release it to the customer on a monthly basis, or whenever they need it. Not only do they get a volume discount because we manufacture the entire order at once, we invoice only on the amount we ship. The customer retains control over shipping schedules and paying the bills, and they receive special custom tools at standard tool prices."
