GEN3SYS® Ductile Iron Contract Manufacturing
 
The end-user is manufacturing wheel hubs made out of Ductile Iron using a Vertical Machining Center, with through-tool, 250 PSI water soluble coolant.
Previously the customer was using a KSEM drill running at the following parameters: 1250 RPM, .010 IPR (0,25 mm/rev), which resulted in 12.5 IPM (317,5 mm/min). The tool drilled a 0.669" (17 mm) diameter hole through 4.35" (110,49 mm). The tool had a cycle time of 20.9 seconds, and a tool life of 150 holes. The customer was looking for ways to lower their cost per hole on a large volume part. They had heard about the success Allied was having versus KSEM, so they decided it was time to investigate.
 
AMEC's Solution
Allied recommended GEN3SYS® using insert item 5C217H-17-CI and holder 60717H-075F. The tooling ran at a speed of 1450 RPM, 0.0103 IPR(0,262 mm/rev), which resulted in 15.0 IPM (381 mm/min). GEN3SYS® delivered a cycle time of 17.4 seconds, and an extraordinary tool life of 1067 holes. The outcome was excellent and met the customer’s goals of lowering the cost per hole.
 
Benefit
The cost per hole was reduced from $0.997 to $0.556, providing a savings of over 44%. This operation went from 653 linear inches to an astounding 4341 linear inches, for an 85% increase in tool life.