The End-user is manufacturing steering components for automotive vehicles. The customer is machining a rack steering component made out of medium carbon steel using a specialized Japanese HMC running with water soluble coolant.
Previously the customer was using a Seco Crownloc drill running at the following parameters: 1400 RPM, 259 SFM, 0.010 IPR, and 14.0 IPM. The tool drilled a 0.7080″ diameter hole 2.0″ deep and had a cycle time of 8.6 seconds and a life of 400 holes. Using the Seco tooling, the customer was having a problem evacuating stringy chips in their machine. The machine then had to be shut down for nearly 15 minutes every hour to be cleaned out. Seeking to improve their process, the customer wanted to improve chip control and decrease their cost of production.
Allied recommended the GEN3SYS® High Penetration Drilling System using insert item #5C118H-18 and holder #60318S-25FM running at the suggested parameters of 1400 RPM, 259 SFM, 0.010 IPR, and 14.0 IPM. The results of the test met the customer’s expectations. While matching the previous tool’s cycle time of 8.6 seconds and tool life of 400 holes, the GEN3SYS® tooling achieved superior chip control. The AMEC tooling eliminated the stringy chips that had previously clogged the machine and reduced the machine’s downtime. Therefore, the customer was able to decrease their cost of production saving $1,479.66 per 13,000 holes.
The GEN3SYS® tooling ultimately increased productivity while decreasing costs generating a cost savings of 25%.