GEN3SYS® Automotive Truck Brake Carriers
 
An end-user is manufacturing brake carrier components for trucks, in the automotive industry. They are using a Hitachi Seiki, 50Kw, outfitted with water-soluble thru-spindle coolant. The part being machined is made of SG Iron. The production run for this application requires drilling 2 holes per carrier. Depth of Hole: 14mm ( 0.5512"), Hole Diameter: 12.05mm (0.4744")
Previously the customer was using a Guhring solid carbide drill, with a TiAlN coating. The Speeds & Feeds of this drill were 95 M/min, (311 SFM), 2509 RPM, .20mm/rev (.008 IPR),500 mm/min (19.68 IPM), with a cycle time of 1.7 seconds. Tool life achieved was 9600 holes. The cycle time was acceptable, but the tool life was not what the end-user expected, so AMEC was brought into the project.
 
AMEC's Solution
Allied suggested using the GEN3SYS® High Penetration Drilling System with insert item #5C212H-12.05 and holder #60312S-20FM. This drilling system came with a price tag at about half of what the Guhring tool costs. AMEC recommended the running parameters of 102 M/min (334 SFM), 2706 RPM, .20 mm/rev (.008 IPR), 541.2 mm/min (21.31 IPM), with a cycle time of 1.55 seconds. The results were positive. The GEN3SYS® tool increased the tool life from 9600 to 10,280 holes, in nearly identical cycle times, actually, about one and a half tenth of a second faster.
 
Benefit
AMEC enable the customer to increase tool life and output in the same time frame, drilling an additional 680 holes at half the tooling cost to customer, enabling a significant savings in all manufacturing costs.