i-Xmill Achieves
Automotive Mold Manufacturing Success
in Türkiye

YG-1 is thrilled to share a compelling success story featuring the outstanding performance of our i-Xmill exchangeable carbide insert copy mill. The central figure behind this accomplishment is our customer, a distinguished mold manufacturer in the automotive sector.

Recognized for their excellence in turnkey sheet metal tool manufacturing, our valued customer, a metalworking mold manufacturer in Türkiye, stands out in the local dynamic automotive sector. Their commitment to precision and efficiency has positioned them as a pivotal player, with a focus on Price-Quality-Delivery.

The customer manufactures punch and trim dies, which are substantial structures with dimensions of 2500x2100x800mm (98.42x82.67x31.49 inch). The material of the mold to make is 1.2343 steel (JIS: SKD6, DIN: X38CrMoV5-1, AISI: H11) at a hardness of 60 HRc.
< The punch and trim dies crafted by the customer, machined in a highly sophisticated shape >

The primary objective for our customer was to enhance the surface quality of their dies while simultaneously achieving extended tool life, a critical factor in their complex metalworking processes.

In response to the unique challenges posed by the application, YG-1 representatives recommended an i-Xmill Ball Nose insert for high hardened steel (Mill diameter 25mm (~1 in) with Z-Coating, paired with a straight neck i-Xmill steel holder optimized for ball nose inserts.
< i-Xmill Z-coated insert for high hardened steel & i-Xmill steel holder with neck >

To validate the effectiveness of our solution, a 3-axis vertical machining center with external emulsion coolant was employed for the machining test. The i-Xmill performed a face milling operation in the finishing process, at 3,000 RPM, a feed rate of 4,000 mm/min (157.5 IPM) with an axial depth of cut of 0.9mm (.035 in) and a radial stepover of 1.5mm (.059 in).

< The machining process with i-Xmill >


< i-Xmill finishing HRc 60 hardened steel >

The results were noteworthy. i-Xmill with Z-Coating demonstrated a 25% higher tool life compared to the competitor's tool. Furthermore, it achieved superior surface quality, surpassing the performance of the competitor's tool in both durability and finish.

The successful application of i-Xmill has not only addressed our customer's challenges but exceeded expectations by achieving both enhanced tool life and superior surface quality. This showcases YG-1’s ability to provide cutting-edge solutions tailored to meet the unique demands of the automotive industry.