A contract production and short run job shop is manufacturing automotive steering knuckles made out of ductile cast iron. They are using five Mori Seiki NH5000 HMCs with 40 taper spindle and 1000 PSI thru-spindle coolant.
Previously the customer was drilling three different holes that each required a separate set of tools. Two of the holes both used a core drill, a twin bore, a single point bore, and a chamfer. The third hole used a core drill, an end mill, a twin bore, a single point bore, and a chamfer. Turning to AMEC for improvement, the customer wanted to decrease their cycle time while maintaining a 1.79 CPK level. They also wanted to minimize the amount of tools used but still maintain a hole tolerance of +\- .0005".
AMEC suggested two different solutions for the holes. For the first tow holes they recommended using EcoCut tooling. They suggested running the tools at speeds of 500 SFM and .008 IPR for the core, 300 SFM and .003 IPR for the bore, and 500 SFM and .006 IPR for the chamfer. The EcoCut tooling replaced the core drill, twin bore, single point bore, and the chamfer tool. For the third hole they suggested using a core and an ALVAN® Reamer. They recommended these two tools be run at speeds of at 200 SFM and .010 IPR and 180 SFM and .059 IPR respectively. These two tools replaced the core drill, end mill, twin bore, single point bore, and the chamfer tool. The reamers lasted for 2 months at 18 shifts per week and the inserts lasted approximately 3 shifts or 300 parts.
Due to the success of the AMEC tooling, not only did the customer obtain extended tool life, but they reduced the number of tools used. They achieved a lower cycle time while still maintaining the desired hole tolerance. Additionally, the customer received a total cost savings of 58%.