An End-user is manufacturing engine block molds made out of H13 tool steel for the automotive industry. They are using a Mazak 7550 VMC with 300 PSI through tool coolant to produce their products.
Previously the customer was using a star gun drill running at a speed of 1600 RPM and 0.0006 IPR. The tool had a cycle time of 14.58 minutes and a tool life of 35 holes. Additionally, the tool required 5 regrinds. Seeking to improve their production process, the customer wanted to reduce cycle time and decrease their cost of production.
AMEC’s Application Engineers recommended using the GEN2 T-A® drilling process. They suggested using the GEN2 insert item #450H-15 with holder #29000S-075L. It was advised that the tool be run at a speed of 809 RPM and 0.007 IPR. The tool had a life of 35 holes and did not require a regrind. The results were outstanding. With a cycle time of only 2.47 minutes, the GEN2 tool lowered the machine’s total cycle time by 12.11 minutes. Additionally, the tool eliminated the need for regrinding. With the AMEC cost per hole being only $3.83 compared to the competitor’s cost per hole of $18.26, the customer significantly lowered their cost of production. The total cost savings was $7,214.43 or 79.01%.
Our GEN2 T-A® tool met the customer’s every expectation. By reducing the machine’s cycle time, AMEC ultimately made the End-user’s production process more efficient and cost effective.