An End-user is a large Structural Steel and Ductwork Specialty Contractor in the construction industry. They are manufacturing I-Beams and H-Beams made out of structural steel using a Peddinghaus with soluble oil mist coolant. The customer’s annual production is over 100,000 tons of steel beams, bars, and ductwork.
Previously the customer was using a Cleveland Twist Drill 1-3/16 HSS TS running at a speed of 350 RPM, 0.003 IPR, 109 SFM, and 1.05 IPM. The drill created a 0.8″ deep hole with a 1.1875″ diameter. The tool had a cycle time of 45.7 seconds and a life of 500 holes. Wanting to take advantage of new technology, the customer wanted to increase productivity while decreasing the cost of production.
AMEC’s Application Engineers recommended using a T-A® drill insert, item #152A-0106-SS, with holder #24020H-004IS100. It was advised that the tool be run at a speed of 320 RPM, 0.011 IPR, 99 SFM and 3.52 IPM. The T-A® tool had a life of 500 holes. The results were outstanding. The T-A® drill inserts not only reduced the machine’s cycle time to only 13.6 seconds, but it also lowered the customer’s cost of production. The total cost savings was $427.56 or 49.9%.
Due the excellent performance of our tool, the customer reduced the machine’s cycle time and also lowered the cost of production while increasing productivity.