An End-user is manufacturing gear housings made out of grey cast iron for the gear and pump industry. They are using a Makino A88 running with 500 PSI water soluble coolant to produce their products.
The customer had previously tested two different tools to complete the operation. First, they tested a Seco Crown Loc tool running at the following parameters: 1867 RPM, 328 SFM, and 0.012 IPR, 22.41 IPM. The tool had a cycle time of 7.4 seconds and a life of 79 minutes. The customer then tested a Sumitomo Replaceable Tip drill running at the same parameters. This tool had a life of 239 minutes. Unsatisfied with their current process, the customer wanted to increase tool life and lower their cost of production.
AMEC suggested using the GEN3SYS® High Penetration Drilling System with insert #5C217H-.671 and holder #60517H-075 running at the recommended parameters of 1867 RPM, 328 SFM, AND 0.013 IPR, 24.27 IPM. The results were excellent. The GEN3SYS® tool lowered the cycle time to 6.8 seconds and increased the tool life to 252 minutes. They saved a total of $13,925.72 or 24.6% against the Crown Loc tool and saved a total of $1,116.80 or 2.6% against the Sumitomo tool.
AMEC enabled the customer to reduce their cycle time and increase tool life which lowered the customer’s cost of production.