GEN3SYS® Grey Cast Iron Power Transmission Components
 
The end-user is machining Grey Cast Iron using a RoboDrill machining center, with 200 PSI through tool coolant.
Previously the customer was using Iscar ChamJet running at the following parameters: 1765 RPM, 0.008 IPR, (0,20 mm/rev) which resulted in 14.12 IPM (358,65 cm mm/min). The tool drilled a 0.563 " (14,29 mm) diameter thru hole to a depth of 1.88 inches (47,75 mm). The tool had a cycle time of 8 seconds and a tool life of 1100 holes.
Looking for performance improvements, specifying tool life and cycle times, the customer asked if Allied could do any better.
 
AMEC's Solution
Allied recommended GEN3SYS® using insert 5C214H-0018-CI and holder 60514S-075F. The tooling ran at a speed of 2030 RPM, 0.011 IPR (0,28 mm/rev) which resulted in 22.33 IPM (567,18 mm/min). GEN3SYS® had a cycle time of 5 seconds and a tool life of 2600 holes, more than double that of the competitor’s tool.
 
Benefit
The outcome met the customer’s goals of tool performance improvements by reducing cycle time by over 60%. In addition, GEN3SYS® more than doubled the tool life which helped to reduce the costly machine run time resulting in the cost per hole dropping from $.30 to $.17, for a considerable cost savings of 42%.