Test 1 Parameters:Material Type: Titanium 6AL6V |
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| SGS | Competitor | ||
| A | Number of parts to produce | 22 | 22 |
| B | Hourly shop rate (dollars) | $65.00 | $65.00 |
| C | Total milled or drilled length per part (inches) | 1000.0000 | 3000.0000 |
| D | Revolutions per minute (RPM) | 1100 | 864 |
| E | Feed per revolution (inch) if drilling | ||
| F | Feed per revolution (inch) if milling | 0.0104 | 0.008 |
| NET | Cost of a new tool | $80.50 | $71.00 |
| H | Time to change tool (minutes) | 3 | 3 |
| J | Parts produced by a new tool | 1 | 0.25 |
| M | Axial depth of cut when milling (inches) | 0.6000 | 0.2000 |
| N | Radial width of cut when milling (inches) | 0.4375 | 0.3750 |
| O | Drill or End Mill Diameter | 0.6250 | 0.7500 |
| P | Surface feet per minute (D x .262 x O) | 180 | 170 |
| Q | Feed in inches per minute (D x E or F) | 11.4 | 6.9 |
| S | New tools required to complete job (A / J) | 22 | 88 |
| U | Total hours of machining time (C x A) / (Q x 60) | 32.05129 | 159.14352 |
| V | Total machining cost (U x B) | $2,083.33 | $10,344.33 |
| W | Total new tool cost (G x S) | $1,771.00 | $6,248.00 |
| X | Tool change cost (S) (H x B / 60) | $71.50 | $286.00 |
| Z | Total cost (V + W + X) | $3,925.83 | $16,878.33 |
| Cost per part (Z / A) | $178.45 | $767.20 | |
| Material Removal Rate (in_ / min) - Milling | 3.00 | 0.52 | |
| MRR Difference - Milling | 2.48 | 0 | |
| Material Removal Rate (in_ / min) - Drilling | 0.00 | 0.00 | |
| MRR Difference - Drilling | 0 | 0 | |
| Savings / Part - Dollars | $588.75 | 0 | |
| Total Savings / Job | $12,952.49 | 0 | |
Test 2 Parameters:Material Type: 718 Inconel |
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| SGS | Competitor | ||
| A | Number of parts to produce | 25 | 25 |
| B | Hourly shop rate (dollars) | $95.00 | $95.00 |
| C | Total milled or drilled length per part (inches) | 36 | 36 |
| D | Revolutions per minute (RPM) | 1200 | 800 |
| E | Feed per revolution (inch) | 0.009 | 0.00375 |
| F | Cost of a new tool | $22.50 | $20.00 |
| G | Time to change tool (minutes) | 10 | 10 |
| H | Regrind cost | $0.00 | $0.00 |
| I | Parts produced by a new tool | 6 | 4 |
| J | Parts produced by a regrind | 0 | 0 |
| K | Number of regrinds available per tool | 0 | 0 |
| L | Axial depth per pass (milling) or per hole (drilling) | 0.0200 | 0.0200 |
| M | Radial width per pass when milling (inch) | ||
| N | Drill or End Mill Diameter (inch) | 0.4530 | 0.4530 |
| O | Surface speed - feet/minute (D x .262 x N) | 142 | 95 |
| P | Feed - inches/minute (D x E) | 10.8 | 3.0 |
| Q | Total parts available per tool (J x K) + I | 6 | 4 |
| R | New tools required to complete job (A / Q) | 5 | 7 |
| S | Regrinds required to complete job (A-(I x R) / J | 0 | 0 |
| T | Total hours of machining time (C x A) x / (P x 60) | 1.38889 | 5.00000 |
| U | Total machining cost (T x B) | $131.94 | $475.00 |
| V | Total new tool cost (F x R) | $112.50 | $140.00 |
| W | Tool change cost (R + S) (G x B / 60) | $79.17 | $110.83 |
| X | Regrind cost (S x H) | $0.00 | $0.00 |
| Y | Total Cost (U + V + W + X) | $323.61 | $725.83 |
| Z | Cost / Part (Y / A) | $12.94 | $29.03 |
| Material Removal Rate (in_ / min) - Milling | 0.00 | 0.00 | |
| MRR Difference - Milling | 0 | 0 | |
| Material Removal Rate (in_ / min) - Drilling | 0.00 | 0.00 | |
| MRR Difference - Drilling | 0 | 0 | |
| Cutting Time / Part - Minutes | 3.33 | 12 | |
| Savings / Part - Dollars | $16.09 | 0 | |
| Total Cost Savings / Job - Percentage | 55.42% | 0 | |
| Total Cost Savings / Job - Dollars | $402.22 | 0 | |