An End-user is manufacturing components for the automotive industry using a Daewoo VMC running with 1000 PSI ChipBlaster through-spindle coolant. The part being machined is an automotive transmission component made out of 9% silicon aluminum.
Previously, the customer was using a PCD Dihart Remax Reamer Monobloc running at the following parameters: 2425 RPM, 800 SFM, 0.025 IPR, and 60.63 IPM. The tool created a 3.0″ deep hole with a 1.2600″ diameter. The tool had a cycle time of 5 seconds and a life of 10,000 holes. To improve their production process, the customer wanted to lower their cost of production while maintaining the existing hole quality.
AMEC recommended the Alvan® Reamer item #050120-3 with a Special Length Arbor to accommodate the PCD Ring item #050120-2 also used in this application with a Cerit adjustable holder. The tools were run at the recommended parameters of 2425 RPM, 800 SFM, 0.025 IPR, and 60.63 IPM. The tools had a cycle time of 5 seconds and a life of 10,000 holes. The results of the test satisfied the customer’s expectations by lowering their cost of production while maintaining the previous hole quality. The customer saved a total of $4,336.07 or 13.5%. The cost savings was achieved because the AMEC tool was able to be reground 6 times compared to the competitor’s tool only being capable of 2 regrinds. The AMEC tooling also achieved superior chip control and expandability.
Using the AMEC tooling, the customer achieved their goals and lowered their cost of production to save 13.5%. They also maintained their excellent hole quality and improved chip control.