Customer: Leading Automotive Component Manufacturer
Application: Machining Ø47.00mm bore in ductile iron steering knuckles
Volume: 30,000+ parts annually
Industry: Off-Road Vehicle Production
“The Diatool reamer helped us eliminate tool setting headaches, cut cycle time, and finally get consistent results. It’s been a game-changer for this program.”
— Engineering Manager, Automotive Manufacturer
The Challenge
John, the Engineering Manager at a top-tier automotive components manufacturer, was tasked with reducing machining costs for a new line of off-road vehicle steering knuckles. Each knuckle, made from ductile iron, required a precise Ø47.00mm bore held to a tight tolerance of ±0.0125mm.
His team had been using a traditional single-point boring process, but several persistent issues were impacting production:
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Frequent tool changes due to rapid tool wear
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Inconsistent bore tolerances, leading to high scrap and rework rates
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Excessive machine downtime during tool adjustments and setups
With over 30,000 parts annually, the inefficiencies were compounding quickly.
The Solution
After researching alternative solutions, John reached out to Monaghan Tooling Group, known for their high-performance tooling expertise. Upon reviewing the application data, Monaghan's engineering team recommended a Diatool monoblock reamer with 8 precision-ground cermet cutting teeth—designed specifically for high-volume ductile iron applications.
Key features of the Diatool reamer included:
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Pre-set diameter for easy installation—no manual sizing required
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Consistent surface finish and size across extended tool life
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Increased stability and process repeatability
Results Achieved
John approved a trial of the Diatool reamer—and the performance exceeded expectations:
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Cycle Time Reduction: 54 seconds saved per part
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Annual Cost Savings: $36,000 in machining and scrap reduction
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Tool Life Improvement: 400% increase compared to previous boring tools
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Setup Time Elimination: No more difficult adjustments—reamers came preset and ready to run
The stability and repeatability of the Diatool solution allowed John’s team to eliminate the variability of manual boring, freeing up skilled personnel to focus on other critical process improvements.
Conclusion
Partnering with Monaghan Tooling Group delivered measurable value to John’s team. The Diatool high-performance reamer not only solved key process challenges but also drove substantial cost savings, improved part quality, and boosted productivity—all while reducing operator burden.
For more information on Diatool reaming visit: www.MonaghanTooling.com