ALVAN® Reamer Automotive
 
A contract production and short run job shop is manufacturing automotive steering knuckles made out of ductile cast iron. They are using 5 Mori Seiki NH5000 horizontal machining centers with a 40 taper spindle and 1000 PSI thru-spindle coolant.
Previously, the customer was drilling 3 different holes that each required a separate set of tools. Holes #1 and #2 both used a core drill, a twin bore, a single point bore, and a chamfer. Hole #3 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's Solution
AMEC’s application engineers suggested two different solutions for the holes. For holes #1 and #2, 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 hole #3, 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.
 
Benefit
Not only did the customer obtain extended tool life, but they also reduced the number of tools they used. They also achieved a lower cycle time while still maintaining the proper hole tolerance. Additionally, the customer received a total cost savings of 58%.