An End-user is manufacturing knife tips for saw mill and pulp mill chipping machines. They are using an Okuma HMC running with water soluble coolant to machine knife blades and components made out of Hardox alloy steel at 400 BRN.
Previously the customer was using a 20 mm Sandvik Delta drill running at a speed of 900 RPM, 186 SFM, 0.0089 IPR, and 8.01 IPM. The tool had a cycle time of 12.4 seconds and a life of 400 holes. The drill created a 1.25″ deep hole. Looking to improve their production process, the customer wanted to decrease tooling costs.
Allied suggested the GEN3SYS® High Penetration Drilling System using insert item #5C120H-20 and holder #60520H-100. Running at a speed of 900 RPM, 186 SFM, 0.0089 IPR, and 8.01 IPM, the tool had a cycle time of 12.4seconds. The tool also had a life of 400 holes. The GEN3SYS® tool reduced chatter and created a superior finish. Additionally, the customer decreased their cost of production and received a total cost savings of $1,985.00 or 32.33%. The cost savings is based upon the customer only having to replace the drill tips instead of replacing an entire tool as in the previous process.
The customer was satisfied with the GEN3SYS® tooling because instead of replacing the whole Sandvik tool at $200.00, they were now able to simply replace the drill tips at $75.75.