GEN3SYS® Alloy Steel
 
An End-user is manufacturing hydraulic cylinders and hydraulic manifolds for heavy equipment. They are using a Mori Seiki 45/50 VMC with flood coolant to machine hydraulic cylinders made out of alloy steel.
Previously, the customer was using a Sandvik Delta Brazed Carbide drill running at the following parameters: 1525 RPM, 299 SFM, 0.011 IPR, and 16.78 IPM. The tool drilled a 2.10″ deep hole with a 0.7480″ diameter. The tool had a cycle time of 12.5 seconds and a life of 225 holes. Seeking to improve their production process, the customer wanted to increase tool life and decrease their cost of production.
 
AMEC's Solution
AMEC suggested the GEN3SYS™ High Penetration Drilling System using insert item #5C118H-0024 with holder #60518H-100F running at the recommended parameters of 1525 RPM, 299 SFM, 0.011 IPR, and 16.78 IPM. The tool created a 2.10″ deep hole with a 0.7500″ diameter and had a cycle time of 12.5 seconds. The results met the customer’s every expectation. The GEN3SYS™ tool increased tool life to 300 holes and also lowered the customer’s cost of production. The customer saved a total of $5,852.80 or 33.5%.
 
Benefit
Due to the successful performance of our tooling, the customer succeeded in lowering their cost of production while increasing tool life. The customer has now ordered additional sizes of the GEN3SYS™ tool for other applications.