GEN3SYS® Structural Steel Heat Exchanger
 
The End-user is manufacturing components for industrial heat exchangers, pressure vessels, and process equipment. Using a Mazak VMC running with 140-210 PSI thru-tool coolant, the customer was machining a heat exchanger plate made out of A105 structural steel.
Previously the customer was using an AMEC T-A® drill insert and holder running at the following parameters: 775 RPM, 130 SFM, 0.0078 IPR, and 6.04 IPM. The tool drilled a 1.732″ (44 mm) deep hole with a 0.6406″ (16.27 mm) diameter. The tool had a cycle time of 17 seconds and a life of 340 holes. Seeking to streamline their production while maintaining their existing excellent hole quality, the customer wanted to reduce cycle time and lower their cost of production.
 
AMEC's Solution
AMEC recommended the GEN3SYS® High Penetration Drilling System using insert item #5C116H-.640 and holder #60317H-20FM running at a speed of 1498 RPM, 251 SFM, 0.010 IPR, and 14.98 IPM. The results were excellent. The GEN3SYS® tool reduced the cycle time to 7 seconds and increased the tool life to 500 holes while achieving superior chip control. Therefore, the customer was able to decrease their cost of production.
 
Benefit
By increasing productivity and decreasing downtime, the customer was able to achieve their goals. Once again, AMEC has proven their dedication to providing their customer with the best tooling available.