An End-user is manufacturing printing rolls made out of aluminum bar for the label industry. They are using a Mori Seiki Lathe with coolant through the tool to produce their products.
Previously the customer was using an HSS twist drill running at a speed of 900 RPM and 0.004 IPR. Drilling to a depth of 10.0″ and creating a 1.0″ diameter hole, the drill had to dwell every 0.300″ to break up chips that were clogging the machine. With a cycle time of 55.56 seconds, the customer wanted to improve their production process by reducing their cycle time and decreasing their cost of production.
AMEC’s Application Engineers recommended using a T-A® drill insert, item #1C22T-0100, with a holder, item #25020S-125L. It was advised that the tool be run at a speed of 1800 RPM and 0.018 IPR. The tool’s cycle time was only 18.52 seconds. The results were outstanding. Using the T-A® drill inserts, the chips were small and easily evacuated therefore eliminating the need for the drill to dwell after 0.300″. Additionally, cycle time was reduced from 55.5 seconds to 18.5 seconds.
Due the excellent performance of our tool, the customer reduced the machine’s cycle time and lowered the cost of production. Compared to the competitor’s total hole cost of $1,159.26, the AMEC total hole cost was only $442.15. Therefore, the customer received a total cost savings of $717.11 or 61.86%.