The end-user is manufacturing brake shoe mounts made out of A36 steel for the Marine & Mining industry. These components are being machined in a Haas VF-2 machining center, with flood coolant.
Previously the customer was using an Iscar Chamdrill running at the following parameters: 1057 RPM, 0.0023 IPR (0,058 mm/rev), which resulted in 2.5 IPM (63,5 mm/min). The competitive tool drilled a 13/16" (20,62 mm) diameter thru-hole to a 1.25" (31,75 mm) depth. The tool had a cycle time of 30 seconds and a tool life of 200 holes. Iscar was unable to meet the production requirement fast enough, so the customer asked if Allied could deliver what they needed.
Allied delivered! The GEN3SYS® Drill was recommended, using insert item 5C120H-0026 and holder 60320S-100F. The Allied tooling ran at a speed of 1245 RPM, 0.003 IPR (0,0762 mm/rev), which resulted in 3.74 IPM (95 mm/min). The GEN3SYS commanded a lot of attention as it completed the job at a reduced cost. The customer was spending $0.902 per hole with Iscar, but when GEN3SYS® came in at $0.63 per hole, it was clear who was providing the better value. The cost savings allowed by GEN3SYS® were a result of a significantly increased tool life, from 200 to 300 holes. Plus, the end-user enjoyed a decrease in cycle time to 20 seconds per hole, which is a significant drop from 30 seconds required by the competitive tool.
GEN3SYS® was given this opportunity because Iscar was out of stock. After an outstanding performance, GEN3SYS® became the new tool of choice for the end-user, who also preferred the fastening mechanism. The cost savings were impressive as well. More holes were drilled at less cost, for a ‘bonus’ dollar savings of 30.11%.