An End-user is machining a turbine housing sensor made out of 347L stainless steel. They are using a Kiwi HMC with a water soluble coolant-through to produce their products.
Previously, the customer was using four tools to complete the operation. They were using a Vermont 0.860″ diameter Spot Drill with a cycle time of 1 minute, 30 seconds and a tool life of 100 parts, followed by a Vermont 0.375″ diameter Cobalt Drill with a cycle time of 1 minute, 26 seconds and a tool life of 50 parts. Next, they used a Vermont 0.4687″ diameter Cobalt Drill with a cycle time of 1 minute, 36 seconds and a tool life of 50 parts. Finally, a 0.5″ diameter Line Bore with a cycle time of 7 minutes, 18 seconds and a tool life of 70 parts was used. Drilling to a depth of 1.25″, the tools had a total cycle time of 11 minutes 50 seconds. The total tool cost was $50.00. Looking for improvements, the customer wanted to reduce cycle time and decrease tooling costs.
AMEC recommended EcoCut insert item #XCNT 060202 EN CM40 grade with holder #EC12R-3.0D 06 H-E. The tool was to be run at a speed of 2832 RPM, 350 SFM, 0.004 IPR, and 11.33 IPM. The results were excellent. The EcoCut tool significantly lowered cycle time to only 51.6 seconds while eliminating a total of three tools. The tooling also increased tool life to 70 parts. Additionally, the customer lowered their cost of production and saved $1,323.82 or 92.2%.
Due to the successful performance of the EcoCut tooling, the customer dramatically reduced their cycle time by eliminating three tools in their production process. Also, the customer saved a stunning 92.2%.