GEN3SYS® Alloy Steel
 
A contract job shop is using an Okuma Lathe running with 500 PSI coolant to machine a bushing made out of alloy steel for heavy equipment.
Previously the customer was using an Ingersoll Quick Twist drill running at the following parameters: 2000 RPM, 361 SFM, 0.010 IPR, and 20.0 IPM. The tool drilled a 3.25″ deep hole with a 0.6890″ diameter and had a cycle time of 14.8 seconds. The tool had a life of 1000 holes which included 1 tool regrind yielding 500 holes per regrind. Looking for improvements, the customer wanted to reduce cycle time and increase tool life while eliminating the need for tool regrind.
 
AMEC's Solution
AMEC recommended the GEN3SYS™ High Penetration Drilling System using insert item #5C217H-17.5 and holder #60517H-075F running at a speed of 2100 RPM, 379 SFM, 0.012 IPR, and 25.20 IPM. The results were outstanding. The GEN3SYS™ tool not only reduced cycle time to 12.7 seconds, it also increased tool life to 2986 holes and eliminated tool regrind. Also, the tool achieved a superior chip formation. The customer lowered their cost of production and received a total cost savings of $6,577.80 or 18.3%.
 
Benefit
Due to the successful performance of the GEN3SYS™ tooling, the customer increased tool life and reduced cycle time while lowering their cost of production.