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Examples

Boring

53 Hours faster

Boring and chamfering of a pre-cast bearing hole in a transmission housing, cast iron GG25. The Dia. 34.5 is subsequently fine-bored to tolerance H7.

Previous: Boring and chamfering of a pre-cast bearing hole in a transmission housing, cast iron GG25. The diameter 35 H7 is subsequently fine-bored.

New: customer invested in 2 Lothmann Step-drills at Euro 578. each. Boring of both diameters and chamfers with one tool in one operation. Savings: 3 tool changes, 2 tool magazine places opened up. Operation reduced by 0.8 minutes per part.

Example for cost savings:
4,000 parts x 0.8 minutes x 1.3 Euro per minute
4.160 €
2 Lothmann Step-drills at Euro 578. each
1.156 €
Gains
3.004 €
+ Total machining time reduced by 53 hours
Boring and chamfering
20 µ tolerance fit

Complete machining of a transmission housing, Grey cast iron GGG50 with an older Machining Center. Tolerance fit requirement within 20 µ.

Previous: both fitting holes are machined with a fine-boring head. Tool change leads to tolerance problems.

Now: customer invested in 2 Lothmann combination tools at Euro 1155. The previously used fine-boring heads are free to be used in other applications. The machining of the 2 fitting holes are completed in one machining cycle. The Dia. 50 is machined as soon as the Dia. 40 has been completed. No tool change needed and the fit is assured. One spot in the tool changer magazine is opened up.

Complete machining of a transmission housing
3 Minutes quicker

Semi finish boring of a seat for T-11A valves into a cylinder body, steel St52 (S355). The hole was pre-drilled to Dia. 13.5.

Previous: all diameters and chamfers are machined with a HSS form-tool. Machining cycle is slow and the HSS tool dulls quickly.

Now: customer invests into 3 Lothmann step-drills at Euro 506. each. ISO carbide cutting inserts with chip-breaker geometry avoid long, spiral chips. Feed rate is increased five-fold and tool life quadruples vs. the HSS form tool.

Example for cost savings:
800 parts x 3 minutes x Euro 1.50 / minute
3.600 €
Previous tool cost: 2 HSS form tools at Euro 450. plus resharpening cost 1 x Euro 120€
1.020 €
Now: 3 Lothmann step-drills at Euro 506
1.518 €
Gains
3.102 €
+ Reduction of machining time by 3 x 800 parts / 60 = 40 hours
Boring Example
Adjustable Diameters

Finish boring and chamfering to a tolerance of 0.1 mm with standard ISO carbide inserts.

Previous: finish boring of Dia. 36 and 44 with one each adjustable fine boring head (at a cost of ca. Euro 1200 each). Circular interpolation milling of the chamfer. The tolerances are too tight for step-drills with fixed insert seat pockets.

Now: 3 Lothmann step-drills at Euro 587. The insert seat can be adjusted in diameter with the adjustment wedges. Savings: 2 tool changes eliminated and 2 tool changer pockets freed up. Cycle time reduced by 1.6 minutes per part.

Example for cost savings:
2000 parts x 1.6 minutes x Euro 1.40 / minute
4.480 €
3 Lothmann step-drills at Euro 578 each.
- 1.734 €
2 fine boring heads freed up for other uses.
+ 2.400 €
Gains
5.146 €
+ Manufacturing time reduced by 47 hours
Finish boring and chamfering to a tolerance of 0.1 mm with standard ISO carbide inserts

Drilling

Final grinding eliminated and cycle time reduced by 36%

Semi-finishing of a connecting hole on a distributor cover, grey cast iron GGG40. Both holes are subsequently finish reamed.

Previous: Pre-drill Dia. 22 with a carbide insert drill, semi-finish bore Dia. 33.7, Dia 35.7 and 2 chamfers with special tool with brazed carbide cutting edges.

Now: customer invests in 4 Lothmann step-drills at Euro 591. each. One operation into solid without pre-drilling. Interchangeable ISO carbide cutting inserts eliminate final grind. Higher cutting data due to modern insert coatings and cutting geometry.

Example for cost savings:
6500 parts x 0.45 minutes x 1,50 Euro / minute
4.388 €
Resharpening cost of approx. 6 x Euro 200
1.200 €
Savings
5.588 €
+ Total machining time reduced by 49 hours
Drilling Example
24 second faster per connecting rod

Drill through solid, semi finish bore and subsequently chamfer front and rear.

Previous: drill through solid, semi-finish bore and circular interpolation mill 2 chamfers wit 4 different tools.

Now: 6 Lothmann step-tools at Euro 648 each. The diameter of the semi-finish bore is pre-set by adjusting the pre-setting insert wedge. 3 tool changes and one circular interpolation cycle eliminated. Cycle time reduced by 0.4 minutes per part.

Example for cost savings:
60,000 parts x 0.4 minutes x Euro 1.20 per minute
28.800 €
6 Lothmann step-tools at Euro 648 each
- 3.888 €
Gains
24.912 €
+ Manufacturing time reduced by 400 hours p. a.
Example Solid drill
Countersink combination tool

Two step counter bore, finish bore and chamfer a hydraulic block, grey cast iron GGG50.

Previous: rough bore Dia. 26, circular interpolation mill Dia. 26.5, 28 and 39.5. Circular interpolation mill 3 chamfers

Now: 3 Lothmann combination tools at Euro 516 each. 3 tool changes eliminated and 2 tool pockets in tool changer freed up. Cycle time reduced by 2.2 minutes per part.

Example for cost savings:
900 parts x 2.2 minutes x Euro 2.1o per minute
4.158 €
3 Lothmann combination tools at Euro 516 each
1.548 €
Gains
2.610 €
+ Manufacturing time reduced by 33 hours
Two step counter bore Example

Backboring

Fit is correct and re-clamping is eliminated

Machining of a slide bore on two sides. Required fit tolerance of 3 diameters within 0.05 mm.

Previous: drill Dia. 30 with chamfer, ream 2 clamping holes to tolerance H7 to be used as locating holes for re-clamping part, and machine Dia. 30 and chamfer in second clamping position.

Now: customer invests in 3 Lothmann step-boring tools at Euro 475. each. Bore Dia. 20. Front and rear chamfer machined in one operation. Second part clamping is eliminated.

Example for cost savings:
700 parts x 3 minutes x Euro 2.20 per minute
4.620 €
3 Lothmann step-boring tools at Euro 475
1.425 €
Gains
3.195 €
+ Total machining time reduced by 35 hours
Machining of a slide bore Example
Back-boring tool

Back boring of a valve housing, cast stee

Previous: feeding in of a long arbor and manually mounting a HSS back boring tool during machine stop.

Now: 2 Lothmann back boring tools at Euro 530. No machine stop and manual mounting. 6 minutes cycle time saved.

Example for cost savings:
400 parts x 6 minutes x Euro 1.40 per minute
3.360 €
12 manually mounted HSS Back boring tools at Euro 75 saved
900 €
2 Lothmann back boring tools at Euro 530
- 1.060 €
Gains
3.200 €
+ Manufacturing time reduced by 40 hours
Back-boring toll example

O.D turning

11 Minutes Faster Per Part

Machining of 5 different diameters and 2 flat seating surfaces in a filter head.

Previous: Pre-machining of Dia. 39.5 and 44.5 with adjustable twin cutters, circular interpolation milling and chamfering of the remaining diameters with end mills and chamfering mills.

Now: customer invests in 2 Lothmann step-drill at Euro 1103 each. 3 tool changes eliminated, 3 tool changer pockets are feed up. Cycle time is shortened by 11 minutes / part.

Example for cost savings:
2 Lothmann step-drills at Euro 1103
2.206 €
Savings per part 11 minutes x Euro 1.40
15,40 €
Amortization after tool costs are covered: Euro 15.40 per part
144 parts 1.020 €
Gains at 500 parts
5.494 €
+ Machining time reduced by 92 hours
Example od turning
Bell tool for outside diameter turning

OD turning of a forged transmission shaft in large production series

Previous: OD turning with turning tool in 4 passes.

Now: 8 Lothmann bell OD turning tools a Euro 683. Cycle time reduced by 11 seconds.

Example for cost savings:
300,000 parts x 0.183 minutes x Euro 1.40 per minute
76.860 €
8 Lothmann bell OD turning tools a Euro 683
5.464 €
71.396 €
Profit per year
71.396 €
+ Manufacturing time reduced by 38 days per year
Bel tool example

Other examples

Tapered countersinking tool

Pre-machining of a tapered hole 7 degrees for subsequent finish reaming on a lathe with bar loader.

Previous: Internal turning with 2 separate boring bars in 4 passes.

Now: 3 Lothmann taper boring tools at Euro 680. Cycle time reduced by 9 seconds.

Example for cost savings:
40,000 parts x 0.15 minutes x Euro 1.10 per minute
6.600 €
3 Lothmann taper boring tools at Euro 680
2.040 €
Gains
4.560 €
+ Manufacturing time reduced by 100 hours
tapered countersinking tool example
T-nut milling tool

Milling of a T-nut slot in a plate of Cast iron GG25 in one pass. The base slot of 15 mm has been milled already.

Previous: milling of the T-slot with a standard milling tool in 4 passes.

Now: 3 Lothmann T-slot cutters at Euro 454. The T-slot is now milled in one pass.

Example for cost savings:
200 parts x 12 minutes x Euro 1.60 per minute
3.840 €
3 Lothmann T-slot cutters at Euro 454
1.362 €
Gains
2.478 €
+ Manufacturing time reduced by 40 hours
T-nut milling tool example
Fixed diameter tools to Dia. 210

Machining of 2 seats in a Aluminum Transmission bell housing

Before: circular interpolation milling of 2 diameters and 2 chamfers in a total of 8 machining cycles

Now: 2 Lothmann large diameter step-tools at Euro 1331 each. Both diameter and chamfers are now machined in one pass and 14 seconds.

Example for cost savings:
3.6 minutes x Euro 2.10 per minute
7,56 €
2 Lothmann large diameter step-tools at Euro 1331 each
2.662€
Break-even after 2662 / 7.56 =
352 housings
Profit after 1000 housings
4.898 €
+ Plus manufacturing time reduced by 60 hours
Fixed diameter tool example
Crank slot semi finishing and chamfering

Boring of Dia. 49.5 and front and back chamfering of 3 bearing diameters in an Aluminum crankshaft housing.

Previous: boring with a twin cutter tool and front and back chamfering in 6 circular interpolation machining cycles.

New: boring and and milling of 2 chamfers in 2 circular interpolation machining cycles

Example for cost savings:
24,000 parts x 0.62 minutes x Euro 1.52 per minute
22.618 €
3 Lothmann combination tools at Euro 1397
4.191 €
Gains
18.427 €
+ Manufacturing time reduced by 248 hours
Crank slot semi finishing and chamfering example
Multiple Bridge Tool

Boring of 3 diameters and 2 chamfers on a Aluminum Transmission housing on a large Machining Center

Previous: Circular interpolation milling in a total of 10 machining cycles.

Now: Boring and chamfering of all diameters in one in-feed cycle

Example for cost savings:
600 parts x 18 minutes x Euro 2.80 per minute =
30.240 €
2 Lothmann multiple bridge tools at Euro 3720 =
7.440 €
Gains
22.800 €
+ Manufacturing time savings: 180 hours
Multiple bride tool example

Tools

Tool shanks and cutting inserts

Lothmann tool designs feature standard shank designs to ISO and ANSI standards, as well as shanks compatible to many tool manufacturer's popular tool connections. Customers save the investment in new tool adapters and are much more flexible when shifting production to another machine with a different spindle taper.

Lothmann tools are designed and fitted with world standard ISO cutting inserts. This enables the customer to source cutting inserts from a large number of producers with variety of carbide insert grades, chip breakers and coatings.

Tool shanks and cutting inserts
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