An end-user is manufacturing Pitman shafts made out of 9310 Alloy Forged Steel for the automotive industry. They are using a Mori Seiki CNC Lathe with Water Sol thru-spindle coolant on this application.
Previously the customer was using a SECO Crownloc drill, running at a speed of 2314 RPM, 323 SFM, 0.006 IPR and 13.88 IPM. The tool had a cycle time of 6 minutes 48 seconds and a tool life of 400 holes. Based on previous success with the AMEC GEN3SYS® High Penetration Drilling System, the customer wanted to see if a special form insert design on the GEN3SYS® tool would provide similar outstanding results as its ‘off the shelf’ cousin. Seeking to improve their production process, the customer wanted to test AMEC against SECO.
Allied designed and manufactured a special form GEN3SYS® insert drill.
The parameters were identical to those of the SECO Crownloc…2314 RPM, 323 SFM, 0.006 IPR and 13.88 IPM. The tool had the same cycle time of 6 minutes 48 seconds. The GEN3SYS® produced an amazing 1,400 holes… an extra 1,000 holes at the same speeds & feeds. And the customer simply switched from a good tool to an outstanding one in the GEN3SYS® Special Form Drill Insert.
The cost per hole dropped from $0.335 to $0.188. This project required 600,000 holes, which initially cost the customer $201,146.16. AMEC and GEN3SYS® reduced the cost to $112,918.06. What a truly amazing success story. The customer saved $88,280.10, or 43.86%.
The GEN3SYS® with the Special Form Insert met, even exceeded the customer’s expectations. By running in a head-to-head competition with the Crownloc tool, Allied was able to reinforce its standing as the leader in the metal cutting industry.