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DGK costs less in most production applications than other tooling options. Even in short runs of 2,500 lineal feet, one regrind of the knives results in justifying the use of DGK knives. MSI M2 substrate coated with DGK. Tests have shown a minimum of 50% increase in tool life, withstands heat in excess of 2200º F. DGK lowers the cutting friction, and grinds easily.
COST COMPARISON
- In 2006, M2 steel cost between $4 - $5 per inch.
- Carbide Inlay cost between $12 - $35 per inch.
- Piggy Back cost between $25 -$45 per inch.
- DGK-ACT cost between $6 - $7 per inch.
GRINDING COSTS
- Diamond wheels for carbide cost between $150 - $320 each. Cost per inch to grind is approximately $18.00.
- Top-of-the-line ceramic wheels for M2 and DGK-ACT cost under $35.00.
- Cost per inch to grind is approximately $3.00
COST FACTORS
- Dramatically decreases downtime for dull tools.
- Resetting of dulls after sharpening.
- Material waste for incorrect dimensions.
- Material waste for resetting of the machine after sharpening.
- Grinding time.
REAL COSTS
- Small moulders worth minimum $125/hour, most are valued at over $300/hour.
- Average downtime for dull or nicked tools is 20 minutes.
- Average cost for single downtime is at least $41.67.
- Run length 10,000 lineal feet or a short run in MDF or maple.
- M2 estimated 2 regrinds @ $41.67 each = $83.34.
TOTAL COST OF USING TOOLING
- M2 initial cost $40 + $24 grinding costs + downtime cost $83.34 = $147.34
- DGK-ACT initial cost $58 + $24 grinding costs + 0 downtime = $80.00
- Carbide initial cost $280 + $144 grinding costs + 0 downtime = $424.00
- This does not include wasted material and improperly dimensioned material.
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