The end-user is manufacturing compressor components for the oil and gas industries. The customer is machining these parts made out of 4150 steel, using a vertical boring mill, with flood coolant.
Previously the customer was using an HSS twist drill running at the following parameters: 325 RPM, 0.007 IPR (0.18mm/rev), resulting in 2.3 IPM (58.4 mm/min). The tool drilled a 0.938" diameter hole to a depth of 4.5". The tool had a cycle time of 40 minutes per part and a tool life of 80 holes, before having to regrind. Looking for improvements, the customer wanted to decrease cycle time, but was limited to a machine that had no through-tool coolant, reducing the efficiency in chip-breaking and evacuation. To compensate for this, the end-user was forced to repeatedly incorporate a pecking cycle of 1/8" pecks and full retracts, a time consuming practice that resulted in this long cycle time.
Allied recommended the GEN3SYS® High Penetration Drilling System, using insert item #5C122H-0030 and holder #60522H-100F. The tooling ran at a speed of 814 RPM, 0.010 IPR (0.25 mm/rev), which resulted in 8.1 IPM (205.7 mm/min). The results were excellent as the tool life moved from 80 up to 120 holes while the cycle time dropped significantly to 5.5 minutes per part, down from 40 minutes per part. This significant time savings was a result of Allied’s ability to achieve superior chip control and evacuation with only flood coolant, eliminating the need for an elaborate pecking cycle. This time savings could have been an even greater if the machine had through tool coolant capabilities! GEN3SYS® met the customer’s goals of decreased cycle times, while providing a superior hole finish.
Allied Machine & Engineering Corp. and the GEN3SYS® High Penetration Drilling System greatly reduced the cycle time, by an amazing 86%! The pleased customer was able to achieve superior results while saving both time and money. The cost of the twist drill, at least on paper, was less than that of the GEN3SYS®, but the bottom line, or cost per hole dropped by an equally amazing 84.3%. The best quality and performance always translates to the best value.