A worldwide valve manufacturer is machining hydraulic manifolds made out of nodular iron. They are using Makino M3000 Pallet Line with a through-coolant delivery system to manufacture their products.
Previously, the customer produced the ports using three, sometimes four tools, and finishing with a formed reamer. This process resulted in long cycle times and increased downtime as a result of multiple tool changes. Because the customer is now running multiple transfer lines and unmanned machining centers, this method is no longer acceptable. Therefore, the customer was looking to increase production efficiency to keep up with product demand.
AMEC’s application engineers recommended the AccuPort432® process. They suggested the customer use several AccuPort432® port contour cutters including contour cutter 5, item #J1926-05Z-063F, cutter 6, item #J1926-060-075F, cutter 8, item #J1926-080-075F, cutter 10, item #J1926-101-100F, and cutter 12, item J1926-122-125F. They suggested running these tools at a speed of 300 SFM and 8 IPM. The results were excellent. Adhering to AMEC’s recommended parameters, the customer was able to reduce their cycle by 85% with the AccuPort432® tooling. This reduction does not include the reduction in downtime due to tool changes and re-sharpening
Because they no longer had to regrind the special form reamers, the customer eliminated their tool room re-sharpening area. Due to the success of our tooling, the customer has now converted all their porting operations to the AccuPort432® tool.