ALVAN® Reamer Hydraulics
 
The End-user is manufacturing hydraulic rams and cylinders using a Nakamura TW-10 lathe running with synthetic thru-tool coolant. The customer is machining a body relief valve made out of 4140 alloy steel.
Previously the customer was using a Proto-Cutter floating style reamer with 6 flutes running at the following parameters: 650 RPM, 62 SFM, 0.003 IPR, and 1.95 IPM. The tool created a 0.3625″ diameter hole at a 1.80″ depth and had a cycle time of 1 minute with a life of 80 parts. Unsatisfied with their current production process, the customer wanted to increase tool life.
 
AMEC's Solution
AMEC recommended the ALVAN® Reamer item #AL3610I02797 with an A lead running at a speed of 2000 RPM, 190 SFM, 0.003 IPR, and 6.0 IPM. The results were excellent and went beyond the customer’s expectations. The ALVAN® Reamer dramatically increased tool life to 400 parts. Additionally the tool reduced cycle time to only 23 seconds and improved surface finish. As a result the customer was able to lower their cost of production producing a total cost savings of $2,346.43 per 1000 holes.
 
Benefit
Due to the success of the AMEC tooling, the customer succeeded in increasing tool life and decreasing cycle time thereby lowering their cost of production to generate a cost savings of 65%.