GEN3SYS® Structural Steel Heat Exchanger
 
The End-user is manufacturing components for industrial heat exchangers, pressure vessels, and process equipment. Using a Norma VMC running with 360 PSI thru-tool coolant, the customer was machining a heat exchanger plate made out of A105 structural steel.
Previously the customer was using a Sandvik Delta drill running at the following parameters: 1073 RPM, 213 SFM, 0.010 IPR, and 10.73 IPM. The tool drilled a 4.646″ (118 mm) deep hole with a 0.7579″ (19.25 mm) diameter. The tool had a cycle time of 26 seconds and a life of only 10 holes. Looking for improvements, the customer wanted to reduce cycle time and lower their cost of production.
 
AMEC's Solution
Allied recommended the GEN3SYS® High Penetration Drilling System using insert item #5C118H-.758 and holder #60718H-25FM running at a speed of 1312 RPM, 260 SFM, 0.0114 IPR, and 14.98 IPM. The results were outstanding. The GEN3SYS® tool not only reduced the cycle time to 18.5 seconds, it also increased the tool life to 600 holes while achieving superior chip control. Therefore the customer was able to decrease their cost of production.
 
Benefit
Due to the successful performance of the GEN3SYS® tooling, the customer increased tool life and reduced cycle time while lowering their cost of production. Thoroughly satisfied with the test results, the customer plans to order additional sizes of the product for use in other applications.