An End-user is manufacturing boat components for the marine industry made out of stainless steel using a Daewoo Puma TT CNC Lathe with 1000 PSI through-tool coolant. The part they are machining is a high profile case that houses a push button on the control panel of a boat.
Previously, the customer was using 2 Sandvik boring tools that completed the operation in 3 passes. The tool used for the 1st pass had a life of 100 parts and was used to bore a 0.080″ deep hole with a 0.5200″ diameter. The 2nd tool had a life of 500 parts and was used for both the 2nd and the 3rd passes. The 2nd pass bored a 0.009″ deep hole with a 0.5380″ diameter. The 3rd pass bored a 0.010″ deep hole with a 0.5300″ diameter. The total operation had a cycle time of 51.87 seconds. Looking for improvements, the customer wanted to reduce cycle time and lower the cost of production.
AMEC’s Application Engineers suggested using the EcoCut process and recommended the operation be completed with 2 tools in 3 passes. The 1st tool, holder #EC 12R-2.25D 06-E outfitted with insert #XCNT 060204EN with CM40 grade, was used for the roughing operation and had a tool life of 100 parts. The 2nd tool, holder #EC 08R-3.0D 04 H-E outfitted with insert #XCNT 040104ER, was used for the finishing operations for both the 2nd and 3rd passes and had a tool life of 3000 parts. The results were outstanding. The EcoCut tooling reduced cycle time to a total of 22.88 seconds and increased tool life. Additionally, the customer lowered their cost of production.
Due to the successful performance of the EcoCut tooling, the customer reduced cycle time, increased tool life, and significantly lowered costs. The total cost savings was $54,900.69 or 50.73%.