An End-user is manufacturing parts for the railroad industry using a Mazak HMC with 400 PSI coolant through the tool. The part being machined is a railroad car component made out of flat structural steel.
Previously, the customer was experimenting with 2 different tools to complete their production process. They used a Guhring drill #RT800WP series 2485 with FireX coating running at a speed of 1747 RPM, 300 SFM, and 0.012 IPR. With a cycle time of 5.66 seconds, the tool drilled a total of 316 inches and drilled for 15 minutes. They also tried a Kennametal drill #KSEM0656HP grade KC7235 running at the same speeds but with an adjusted feed of 0.014 IPR. With a cycle time of 4.85 seconds, the tool drilled a total of 316 inches and drilled for 13 minutes. Both drills had a tool life of 160 holes. Unsatisfied with their previous tooling, the customer wanted to increase tool life while reducing tooling costs.
AMEC’s application engineers recommended using the GEN3SYS™ High Penetration Drilling System with the GEN3SYS™ drill insert, item #5C216H-0021, and holder item #60316H-075F. The suggested running parameters were 1747 RPM, 300 SFM, and 0.012 IPR. The results were outstanding. With a cycle time of 5.66 seconds, the tool drilled a total of 1265 inches and drilled for 60 minutes. The GEN3SYS™ tool had a stunning tool life of 640 holes compared to the previous tool life of 160 holes. Additionally, the customer received a substantial costs savings by using the AMEC tooling. Against the Guhring tool, AMEC generated a total cost savings of $713.00 or 68.54%. Against the Kennametal tool, AMEC saved the customer $724.38 or 68.88%.
With fewer insert changes and a dramatically increased tool life, the customer was exceptionally pleased with the performance of the GEN3SYS™ tool.