An End-user is manufacturing battery packs made out of hard plastic for the aerospace industry. They are using a Haas VMC cat 40 taper VF3 running without coolant to produce their products.
Previously, the customer was using a 2-Step process to drill a 7.0″ deep hole with a 1.0625″ diameter in the hard plastic. First they used a Morse cobalt twist drill running at a speed of 630 RPM and 0.008 IPR. This tool had a cycle time of 1 minute 23 seconds. They then used the Kennametal boring process to finish the hole. Running the tool at a speed of 1168 RPM and 0.003 IPR, the tool’s cycle time was 1 minute 59 seconds. With both operations taking 3 minutes 22 seconds to complete, the customer wanted to decrease cycle time and reduce the cost of production to become more cost effective.
AMEC’s Application Engineers suggested using a T-A® insert, item #1C22A-0102, with holder #24025H-125F. It was advised that the tool be run at a speed of 1200 RPM with a feed of 0.004 IPR. The results were outstanding. Using the T-A® tooling, the customer eliminated the boring operation and therefore reduced the cycle time to only 1 minute 57 seconds. Additionally, the T-A® tooling achieved a superior hole finish and lowered the customer’s production costs.
Due to the successful performance of our tooling, the customer reduced cycle time and received a substantial costs savings. The AMEC cost per hole was only $2.87 compared to the competitor’s cost per hole of $13.41. Therefore, the customer received a total cost savings of $1,053.81 or 78.60%.