GEN3SYS® A516-70 Tubesheet
 
The end-user is machining steel plates made from A516-70 using an Anayak Horizontal Boring Mill with 125 PSI of coolant pressure.
Previously the customer was using a Sumitomo drill, running at the following parameters: 1250 RPM, 0.012 IPR, (0,30 mm/rev) which resulted in 15 IPM (381 mm/min). The tool drilled a 1.01" (25,68 mm) diameter hole to a depth of 1.25" (31,8 mm). The tool had a cycle time of 5.0 seconds and a tool life of 390 holes. The Sumitomo drill offered inconsistent tool life and poor chip control. Looking for performance improvements, the customer asked if Allied had a better solution.
 
AMEC's Solution
Allied recommended the GEN3SYS® High Penetration Drilling System, using insert item 5C124-1.011 and holder 60324S-100F. The tooling ran at a speed of 1300 RPM, 0.012 IPR, (0,30 mm/rev) which resulted in 15.6 IPM (396 mm/min). The tool had a cycle time of 4.8 seconds and a tool life of 630 holes. The outcome met the customer’s goals of extended tool life, and better consistency.
 
Benefit
Allied Machine made a significant difference for the customer. The tool life improved from 390 to 630, for a 61.5% increase. Not only did the GEN3SYS® provide increased and more consistent tool life, the actual cost per hole dropped from $0.37 to $0.29, for a cost savings of 21%.