An End-user is manufacturing gas compressor components for the oil & gas industry. They are using a Mazak HMC Mazatech FH-10800 running with 1000 PSI through-tool coolant. The part being machined is a compressor frame made out of grey cast iron.
Previously the customer was using a Carboloy brazed tip carbide drill running at a rate of 1861 RPM, 350 SFM, 0.013 IPR, and 24.19 IPM. The drill created a 3.0″ deep hole with a 0.7187″ diameter. The application had a cycle time of 17.4 seconds and a tool life of 200 holes. Looking to improve their production process, the customer wanted to reduce cycle time and decrease tooling costs.
AMEC suggested the GEN3SYS® High Penetration Drilling System using insert item #5C218H-0023 and holder #60518H-100F running at a rate of 2552 RPM, 480 SFM, 0.018 IPR, and 45.94 IPM. The results were outstanding. The tool lowered the cycle time to 13.9 seconds and increased the tool life to 250 holes. Additionally, the customer lowered their cost of production. With the AMEC cost per hole being only $0.562 compared to the competitor’s cost per hole of $1.080, the customer saved a total of $2,590.57 or 48.0%.
Using the GEN3SYS® tooling, AMEC was able to lower the customer’s cost of production while reducing the cycle time and increasing the tool life.