A contract production and short run job shop is manufacturing a hydraulic pump housing made out of ductile cast iron. They are using a CNC horizontal machining center with a 1000 PSI semi-synthetic coolant to produce their products.
Previously, the customer was using a single point boring drill item using TCMT style inserts. With a cycle time of 64.61 seconds, they ran the tool at a speed of 1152 RPM with a feed of 0.005 IPR. Seeking to improve their production, the customer needed to decrease cycle time and produce a better cylindrical hole. Also, they wanted to reduce hassle factors due to the boring processes, such as producing an hourglass shape or over and undersize holes. However, the customer still wanted to maintain a 120 or better micro finish.
AMEC’s Application Engineers suggested using a Reamer ring, item # I2TLP-STV1 and a complete arbor, item # 4350-MC-030. They recommended running the tool at a speed of 375 SFM and 0.037 IPR. The results were excellent. With a cycle time of only 20.95 seconds, the machine’s cycle time was reduced by 43.66 seconds. Using this tool the customer was able to process 90,000 parts per year and receives a substantial cost savings. Additionally, the tool reduced the quality issues concerning hole size and shape while still maintaining an acceptable micro-finish.
Not only was the customer able to decrease the tool’s cycle time while still producing a high quality hole, but they were also able to lower the cost of production. Using the AMEC tool, the customer received a total cost savings of $188,257.25 or 64.60%.