Manufacturers are constantly under pressure to reduce costs without compromising quality or throughput.
In high-volume machining environments, even small changes to perishable tooling can have a significant impact on part quality, scrap rates, and overall operating cost. However, revising long-established machining processes often introduces unexpected challenges that are not immediately visible during early testing.
This whitepaper from Kennametal examines how Magna Powertrain Muncie addressed rising tooling costs while maintaining part quality on a high-volume transmission component. The case study follows the company’s evaluation of alternative turning inserts and highlights how the right tooling solution resolved both cost and quality challenges.
The project focused on machining a flange from 1035 steel for an eight-speed transmission component. While a lower-cost insert initially appeared promising, it introduced excess material along the inner diameter of a bored hole, creating downstream inspection issues.
You will learn how:
- Cost-driven tooling changes can introduce unexpected quality challenges
- Kennametal collaborated closely with Magna Powertrain to evaluate multiple insert geometries
- Excess material and burr formation can impact gauging and downstream processes
- Six different insert configurations were tested to balance performance and cost
- The KCP25C steel turning grade with KENGold CVD coating delivered the best results
- Improved chip control and edge geometry eliminated burr-related issues
- Standardizing tooling reduced variability and supported consistent production
The whitepaper explains how Kennametal’s KCP25C insert, combined with a medium versatile chipbreaker, delivered consistent chip control, smoother finishes, and reliable tool life. The refined CVD coating process produced a smoother, more uniform surface that improved heat and wear resistance during cutting operations.
Following successful test cuts, Magna Powertrain converted the entire machining cell to Kennametal tooling. The change resulted in approximately $50,000 in annual cost savings while maintaining process stability and reducing operator intervention.
Beyond the immediate cost benefits, the case study highlights the value of application-focused engineering support. Kennametal worked directly with Magna Powertrain during testing and implementation, ensuring the solution addressed real-world production requirements rather than theoretical performance targets.
This whitepaper is designed for manufacturing engineers, plant managers, and machining professionals seeking practical insight into how tooling selection impacts cost, quality, and process reliability in high-volume production environments.
Download the whitepaper from Kennametal to learn how the right turning insert can reduce burrs, lower tooling costs, and improve machining consistency
