Consider tooling cost and machining time together
A low purchase price does not automatically mean low manufacturing costs. What matters is how many conforming parts a tool reliably produces and how much machine time it requires. Caglar İnovasyon considers tooling cost, machining time and process reliability together.
Tool life and productivity
Cutting speed and feed affect machining time and tool loading. A change may save time while increasing wear or changing surface quality. Economic settings depend on the material, tool, engagement, cooling and stability of the machine and workholding. Maximising tool life alone is not a sufficient optimisation target.
An illustrative calculation
These are assumed tools performing the same operation and meeting the same quality requirements. All figures are invented for illustration; they are not customer results.
| Comparison | Tool A | Tool B |
|---|---|---|
| Tool price | 100 € | 150 € |
| Conforming parts per tool | 500 | 1.000 |
| Tooling cost per conforming part | 0,20 € | 0,15 € |
| Machining time per part | 12 s | 9 s |
| Machine hourly rate | 60 €/h | 60 €/h |
| Machine cost for this operation | 0,20 € | 0,15 € |
| Combined cost per conforming part | 0,40 € | 0,30 € |
Interpreting the result
Tool B costs 50% more to buy, but reduces the costs considered per conforming part by 25%. For 10,000 parts, the calculated difference is €1,000. This is not a complete part-cost calculation: tool changes, regrinding, scrap and other process costs are excluded. Saved time has a corresponding financial benefit only if freed capacity is used or costs are actually avoided.
Include regrinding correctly
Add the purchase price and the costs of all reconditioning actually used, then divide by the total number of conforming parts produced across those uses. Record output for each use: a reground tool may not achieve the same output as a new one.
Compare your own data
Tooling cost per conforming part = total tool and reconditioning cost ÷ total conforming parts. Machine cost for the operation = machining time in seconds × hourly rate ÷ 3,600. Add tool changes, scrap and other relevant costs for a fuller comparison. Use the interactive calculator below with your own assumptions.
Discuss your machining process
Send the material, tool, operation, cutting parameters and current output per tool. Together we can assess technically appropriate changes and their economics. Calculations do not replace trials under your actual production conditions.
Compare costs at the same quality requirement
Hypothetical comparison: a more expensive tool needs fewer changes but may increase machining time. Record tool price, usable edges, good parts, machine time, change time and scrap together. If life drops unexpectedly, investigate material batch, runout, coolant and damage pattern. Change one significant factor at a time and repeat comparable trials; a single best result is not a reliable costing basis.