GEN3SYS® Alloy Steel Heavy Equipment
 
The customer manufactures locomotive diesel engine components. The customer is machining a connecting rod for diesel engines made out of 4140 alloy steel using a Giddings & Lewis HMC with thru-tool coolant.
Previously the customer was using an AMEC T-A® drill insert and holder running at the following parameters: 990 RPM, 150 SFM, 0.007 IPR, and 6.93 IPM. The tool drilled a 0.5780″ diameter hole 1.305″ deep and had a cycle time of 16 seconds and a life of 96 holes. Looking for improvements, the customer wanted to reduce the cycle time and improve chip control while maintaining the existing excellent hole quality.
 
AMEC's Solution
Allied recommended the GEN3SYS® High Penetration Drilling System using insert item #5C114H-.578 and holder #60514S-075F running at a speed of 1850 RPM, 280 SFM, 0.0095 IPR, and 17.58 IPM. The results of the test were excellent and met the customer’s expectations. The GEN3SYS® tooling reduced the cycle time to 9 seconds and increased the tool life to 336 holes while achieving superior chip control. Therefore, the customer was able to decrease their cost of production and save $330.47 per 1000 holes.
 
Benefit
Once again, AMEC has proven their dedication to providing their customer with the best available tooling. The GEN3SYS® tooling improved the customer’s production process and generated a cost savings of 41.5%.