Published 3/18/2019

Cutting Tool Manufacturer Grows on Diversification, Automation

A new, heavily automated facility helps Tool-Flo supply new customers with grooving, threading and other indexable cutting tools.

Matt Danford

Former Senior Editor, Modern Machine Shop

New machines with robot-tending, such as these Ewag Compact tool grinders from United Grinding, have been a prime focus of Tool-Flo’s recent equipment investments. The company still maintains a line of 10 manual grinders for quick-turnaround of orders ranging from 10 to 20 pieces, but the plan is to eventually automate these operations as well.

A robotic cell performs wire-brush honing, which prevents the carbide from fracturing and is among various automated processes that were previously done by hand.

Inserts must not touch one another during physical vapor deposition (PVD) coating, which Tool-Flo performs in house.

Tool-Flo has invested in more than grinders and robots. Tool bodies for the company’s inserts also require milling. This DMG MORI DMU 80 T is one new investment.

In addition to consolidating operations from four facilities to one, Tool-Flo’s new 88,000-square-foot indexable cutting tool manufacturing plant in Houston, Texas offers room to grow. More specifically, it offers room to automate.

As seen in the photo gallery above, many investments have already been made. Lines of new insert grinders incorporate robot-arm tending so that one person can supervise multiple machines. Processes previously performed manually have also been automated, and new machining resources are available to cut tool bodies.

Much of the company’s recent growth has been driven by diversification into new markets, says Charlie Mendez, advertising director. He credits membership in the IMC Group, a 13-member conglomerate of carbide cutting tool manufacturers, for helping the company expand its focus beyond energy and its customer base beyond Houston, and for helping facilitate investments in facilities and equipment.

Consolidating the operation brings benefits as well. Productivity, lead time, quality and service are expected to improve, as are internal communications between sales, engineering and manufacturing. Scroll through the photo gallery above for a look inside the new plant.