A Tier 1 automotive supplier is manufacturing a diesel engine front cover made out of grey cast iron for the automotive industry. They are using a Mitsubishi 800mm HMC with 300 PSI coolant through the tool to produce their products.
The customer was originally using a spot drill, solid carbide drill, and a solid carbide port form tool. The customer needed to make a special angled insert to meet the customer specification. The cycle time for the engine front cover was not keeping pace with
production demands. Solid carbide tooling
also added cost to the bottom line in the form
of setup time, regrind and recoat, and extra
AMEC’s application engineers suggested using a special AccuPort432® tool, a modified ISO-6149 #8 port contour cutter. They also recommended a modified port form insert and a Cast Iron T-A blade, item #1C30A-16.2-CI. The suggested running parameters for this tool are a speed of 1765 RPM, 300 SFM, .009 IPR, and 15.75 IPM. The results were excellent; the part was now able to be produced with only 1 tool instead of 3. With the operation no longer a bottleneck, the customer was able to produce their products more efficiently. By using the AccuPort tool to lower the cycle time, the customer saved 7 minutes on each piece. This resulted in a savings of 2090 labor hours per year.
Using the AccuPort tooling, the customer was able to add 9000 pieces per year to their production capability. Additionally, they saved $35,000 per year due to cycle time reductions.