An aerospace manufacturer is producing high quality precision parts for commercial, military, and space components made out of stainless steel. They are using an Okuma NXVA 4 axis VMC with 1,000 PSI coolant through the tool.
Previously the customer was using 5 tools in a multi-step process in order to complete the job. They used a spot tool, a drill, two different sized end mills, and a special port form. Their cycle time was 18 minutes and 41 seconds per part. Using a total of 5 tools to produce their products created several problems for the customer. For example, they had to deal with elevated regrind and stocking fees, increased tool changes, and quality issues due to blending several tool operations. Additionally, the customer was also having a problem producing a quality port because of the required 10″ reach and needed a better finish.
AMEC’s application engineers suggested using the AccuPort432® port contour cutter. They recommended using a T-A® tool, item #1C5YA-.386, with a port form insert. Both tools were C5 inserts with TiAIN coating. They suggested the tool be run at a speed of 650 RPM and .006 IPR per revolution with pecks. With the AccuPort432® meeting all the finish requirements, the results were outstanding. With a cycle time of only 30 seconds per part, the customer lowered their cycle time by 18 minutes and 11 seconds. Additionally, the customer received a total cost savings of $81,684 per year.
Not only was the customer was able to significantly reduce their cycle time, but they also dramatically increased tool life. Therefore, the customer greatly decreased their cost of production.