GEN3SYS® Structural Steel Automotive Bushings
 
The end-user is manufacturing automotive bushings. The customer is machining these parts made out of 8620 Alloy Steel, using a Mazak Turning Center, with water-soluble coolant.
Previously the customer tested two competitive drills: the Iscar Chamdrill and the Kennametal Ken-Tip. Both were run at the following parameters: 1475 RPM, 280 SFM, .011 IPR, and 16.25 IPM.

The tools drilled a .734″ diameter hole to a 1.5″ depth. The tools had similar cycle times of roughly 11 seconds and a tool life of 76 and 155 holes, respectively. Looking for improvements, the customer wanted to increase his tool life.
 
AMEC's Solution
Allied recommended GEN3SYS® using insert item 5C118H-.734, and holder #60318H-100C. GEN3SYS® ran at the following parameters:
1560 RPM, 300 SFM, .012 IPR, and 18.72 IPM. The cycle time dropped by 2 seconds, from 11 to 9, but the real benefit was the number of holes produced. The results were amazing as they met the customer’s goal of increasing tool life. The GEN3SYS® High Penetration drill increased tool life from the competitor’s best results of 155 holes to an incredible 1200 holes. The customer succeeded in its quest for increased tool life far beyond what they expected. The cost per hole dropped from $1.158 to $0.067. The customer had never seen such a success story before GEN3SYS® was put to the test.
 
Benefit
GEN3SYS® High Penetration Drilling System saved the customer real time and money, while eliminating costly down-time.