The end-user is machining structural steel tubes for galvanized towers, using a custom built, Air Liquid machining center with mist coolant.
Previously the customer was using a Kyocera Inserted Drill, running at the following parameters: 800 RPM, 0.004 IPR, (0,10 mm/rev) which resulted in 3.15 IPM (80,00 mm/min). The tool drilled a thru hole, diameter 0.709" (18,00 mm) to a thickness of 0.236 inches (6,00 mm). The tool had a cycle time of 4.4 seconds and a tool life of 2100 holes.
The current holders were failing on a regular basis. Looking for a reliable solution and performance improvements, Allied was asked to provide the answers they were looking for.
Allied recommended GEN2 T-A® using insert item 451H-18 along with a special length, diameter specific body. The tooling ran at a speed of 800 RPM, 0.010 IPR (0,26 mm/rev) which resulted in 8.19 IPM (208,00 mm/min). The tool had a cycle time of 1.7 seconds and a tool life of 4000 holes. Allied Machine and GEN2 T-A® made a significant difference for the customer, as the outcome met their goals of tool performance and reliability.
GEN2 T-A® provided the reliable solution the customer was looking for. Allied helped to reduce the machine run time from 4.4 to 1.7 seconds, for a time savings of 61.3%, resulting in the cost per hole dropping from $0.14 to $0.11, for a dollar savings of 21.4%.