An End-user is manufacturing automotive spot welding electrodes made out of copper. They are using a Daewoo Puma MS running with a ChipBlaster coolant pump to produce their products.
Previously, the customer was using three tools to complete the process. First they used an MA Ford Solid Carbide drill to create a 0.710″ deep hole with a 0.3750″ diameter. This tool had a cycle time of 3 seconds and a life of 7500 parts. Next they used an MA Ford Carbide Bar to create a 0.710″ deep hole with 0.4375″ diameter. This tool had a cycle time of 19 seconds and a life of 9500 parts. Finally they used a SECO Turning/Facing tool with a 2-pass program. The first pass created a 0.650″ deep hole with a 1.50″ diameter and had a cycle time of 24 seconds. The second pass created a 0.025″ deep counter bore with a 0.625″ diameter and had a cycle time of 1.2 seconds. This tool had a life of 11,500 parts. The total cycle time for the operation was 47.2 seconds. Looking for improvements, the customer wanted to reduce cycle time, increase tool life, and lower their cost of production.
AMEC suggested using an EcoCut insert item #XCET 040102FR-27P H216T with holder #EC 08R-2.25D 04-E. They used a 4-pass program to complete the operation. The first pass created a 0.710″ deep hole with a 0.3150″ diameter and had a cycle time of 4.5 seconds. The boring pass created a 0.710″ deep hole with a 0.4375″ diameter and had a cycle time of 6 seconds. The turning operation created a 0.650″ deep step with a 1.50″ diameter and had a cycle time of 7.8 seconds. The final pass created a 0.025″ deep counter bore with a 0.6250″ diameter and had a cycle time of 0.2 seconds. The results of the test were excellent. The EcoCut tooling greatly reduced cycle time to only 18.5 seconds and achieved superior chip control. Additionally, tool life increased to 50,000 parts. As a result, the customer lowered their cost of production and saved $34,461.80 or 61.2%.
Thanks to the successful performance of the EcoCut tooling, the customer reduced cycle time and increased tool life thereby decreasing their production costs.