How to Build a Streamlined Tool Kit

Many OEMs rely on vertical integration to offset outsourcing issues or for prototype purposes. There are several reasons to pursue vertical integration, specifically around in-house machining capabilities:

• Cost savings
• Small batch runs
• Manage inventory levels
• Addressing engineering changes and modifications

In-house machining is an ideal solution when volumes are low, the required machining capabilities are modest, advanced machining expertise isn’t required, and stringent in-process inspection isn’t necessary. It’s critical, though, to have a thorough understanding of the true cost of in-house machining, and while the machines themselves are the heaviest-hitting item on the budget, tooling is also a significant cost contributor.

With countless variations in material, geometry, application, coating, and finish, the cutting tool market is massive and it’s easy for costs to get out of hand.

Is there an ideal tool kit you could put together that would satisfy most of your needs? The short answer is yes; the longer answer is still yes, but there are factors to consider.

When it comes to tooling management, the goal should be to standardize as much as possible. While you will compromise some on speeds and feeds, you will minimize cutting tool inventory and the number of cutting tool holders required.

Let’s walk through some best practices on how to develop an effective tool kit and build strategic relationships with your tool vendors that will support your team’s in-house machining efforts.

Best Practices for Cutting Tool Management

Understand the Purchasing Need 

Considering the sheer size, scale, and variety of the tooling market, you can't test every tool or vendor available, and since the aim is to standardize, begin by understanding the reason for the purchase decision.

Ruling out experimentation as a valid reason for acquiring a new tool, these are two of the most common motivations for purchasing a new cutting tool:

• There’s a problem with an existing tool
• You need to address a challenging application

Start with the why and go from there.

Strategically Build Vendor Relationships 

Another tactic for streamlining your tool kit is to shortlist your list of tooling vendors, and you can do this with a pretty simple strategy. There are a few qualities to look for in a tooling vendor that can improve both the quality and effectiveness of the buying process and how your team sources the tools that end up in your machines.

First, start with the vendor rep. The "people element" of the tool purchasing process is crucial, so it's important to establish a strong relationship with the rep. Does your team have a good rapport with them? Do they reciprocate? Are they knowledgeable and able to provide value beyond just the product? Are they considerate of your team's time and schedules?

These questions can help you evaluate your current list of tooling vendors or serve as criteria when selecting a new one.

Second, look for online resources. The buying process is becoming an increasingly solo, online endeavor. We often conduct our own research and compile a list of potential solutions before reaching out to a sales team. By the time we engage with a rep, we are more knowledgeable about our potential purchase.

This research relies on third-party resources, and while general information about a tool can be found online, the ideal source for information is the manufacturer's website.

When searching for a new tooling vendor, prioritize those with extensive technical content on their website (speed and feed data.) Look for safety data sheets, simulation files, brochures, charts, and detailed product videos.

Third, identify the top manufacturer of the specific tool. The majority of tool manufacturers are comparable, but depending on the specific tool your team intends to purchase, some stand above the rest.

For example, Harvey excels at micro tools, while Sandvik leads in turning and milling tools and Helical in end mills, respectively.

Choose the Most Suitable Tool

We’ve examined reasons for purchasing a new tool and how to build strategic vendor relationships so that you’re building the most streamlined and effective tool kit possible. Now, let's concentrate on choosing the tool itself.

Address these key considerations to determine the cutting tool that’s the best fit for your needs:

Application. Is the tool primarily going to be used for profiling, surface machining, slotting, or drilling. If drilling, will reaming be required? Will the tool be used for roughing or finishing?

Workpiece Material. Will High Speed Steel work for your application or will carbide be required? The cutting tool needs to be compatible with the material being machined. Consider if a coating will help with cutting tool life.

Parameters. Be sure to consider speeds, feeds, and cutting depths; tooling manufacturers will often have this information on their websites. Start here and then tweak those parameters for your application.

Rigidity. Use the largest diameter and shortest out of collet tool for the application for minimal tool deflection. Stick with common diameters in a few different lengths to accommodate most applications.

Geometry (end mills). Consider the number of flutes, helix angle, variable helix angle, chip breakers, long reach, reduced shank, and “form” tools.

Developing a purchasing strategy like the one outlined here will enable your team to build a streamlined tool kit for your in-house machining efforts. Adhering to that strategy will prevent your tool kit from getting too big and too diverse, and knowing what tools are at your disposal will ensure you’re not purchasing tools with only slight differences all the time – all of which will ultimately protect you from excessive tooling costs.