GEN3SYS® Cast Steel Contract Machine Shop
 
The End-user is a contract machine shop that manufactures hydraulic pumps and motors. The customer is machining a motor housing made out of mild carbon cast steel using a Mazak VMC running with 1000 PSI through-tool coolant.
Previously the customer was using a WNT solid carbide drill running at the following parameters: 1365 RPM, 197 SFM, 0.0071 IPR, and 9.69 IPM. The tool drilled a 0.5512″ (14 mm) diameter hole to a 1.1810″ (30 mm) depth. The tool had a cycle time of 8 seconds including a pecking cycle and a life of 500 holes. Unsatisfied with their current production, the customer wanted to decrease their costs.
 
AMEC's Solution
Allied recommended the GEN3SYS® High Penetration Drilling System using insert item #5C114H-14 and holder #60314H-20FM running at a speed of 1935 RPM, 279 SFM, 0.010 IPR, and 19.3 IPM. The results were excellent and went beyond the customer’s expectations. The GEN3SYS® tool reduced the cycle time to only 4 seconds and doubled the tool life to 1000 holes while achieving superior chip control. By increasing productivity and decreasing downtime, the customer succeeded in lowering their costs.
 
Benefit
Due to the successful performance of the GEN3SYS® tooling, the customer met their goal of lowering their costs and was thoroughly satisfied with the results of the test.