GEN3SYS® Oil & Gas
 
An End-user is manufacturing heat exchangers for the oil industry. They are using a QuickDrill™ Gantry running with 1000 PSI coolant to machine tube sheet for heat exchangers made out of A356 structural steel.
Previously the customer was using an Iscar ChamDrill running at the following parameters: 2000 RPM, 397 SFM, 0.013 IPR, and 26.0 IPM. The tool had a cycle time of 18.7 seconds and a life of 375 holes. The tool created a 3.75″ deep hole with a 0.7580″ diameter. Looking to improve their production, the customer wanted to increase tool life and reduce their cost of production.
 
AMEC's Solution
AMEC suggested the GEN3SYS™ High Penetration Drilling System using insert item #5C118H-.758 and holder #60718H-100F running at a speed of 1798 RPM, 355 SFM, 0.0145 IPR, and 26.0 IPM. The tool had a cycle time 18.7 seconds. The results were excellent. The GEN3SYS™ tooling increased tool life to 560 holes and achieved a superior surface finish. Additionally, the customer lowered their cost of production. With the AMEC cost per hole being only $0.266 compared to the competitor’s cost per hole of $0.418, the customer saved a total of $1,525.76 or 36.5%.
 
Benefit
Not only did AMEC enable the customer to increase tool life and achieve a superior surface finish, but we also lowered the customer’s cost of production.