GEN3SYS® Mild Steel Forging Tubesheet
 
The end-user is manufacturing Tubesheets. The customer is machining these parts made out of mild steel forging using an Eagle drill table-gantry, with semi-synthetic coolant.
Previously the customer was using a High Impact AM200® Super Cobalt Spade drill running at the following parameters: 611 RPM, 161 SFM, .009 IPR, and 5.5 IPM. The tool drilled a 1.008″ diameter hole to a 4.125″ depth. The tool had a cycle time of 45 seconds and a life of 194 holes. Looking for improvements, the customer wanted to reduce his cycle time.
 
AMEC's Solution
Allied recommended GEN3SYS® using insert item #5C124H-1.008 and holder #60524S-100F. The tooling ran at a speed of 1086 RPM, 286 SFM, .0143 IPR, and 15.5 IPM. The results were excellent and met the customer’s goals of reducing cycle time. The GEN3SYS® High Penetration drill increased tool life to 436 holes and delivered a cycle time of just 16 seconds. The customer succeeded in reducing their cycle times and costs. What was $1.22 per hole fell to $.81, a savings of $.41 per hole.
 
Benefit
GEN3SYS® High Penetration Drilling System improved the customer’s production by reducing cycle time and generating a cost savings of over 34%.