An End-user is manufacturing automotive components using an Okuma LB115 Lathe with synthetic coolant. The part being machined is a pinion gear made out of 8620 alloy steel.
Previously, the customer was using 3 tools to complete the process. First they used a YG-1 Spade drill to create a 0.400″ deep hole with a 1.000″ diameter. The tool had a cycle time of 6.4 seconds and a life of 300 parts. Next they used a Kennametal Finish Turn Face/OD tool to create a 2.500″ deep hole with a 2.500″ diameter. The tool had a cycle time of 4 minutes 15 seconds and a life of 400 parts. Finally they used a Valenite Finish Bore and Chamfer to create a 4.000″ deep hole with a 1.000″ diameter. The tool had a cycle time of 6 minutes 9 seconds and a life of 400 parts. The total cycle time for the operation was 10 minutes 30 seconds. Unsatisfied with their current process, the customer wanted to decrease their cost of production.
AMEC suggested using an EcoCut insert item #XCNT 130408EN GM40 with holder #EC 25R-2.25D 13-E. They used a 4-pass program to complete the operation which included a facing pass, turning pass, drilling pass, and boring pass. The facing pass created a 2.500″ deep hole with a 0.9840″ diameter and had a cycle time of 3 minutes 13 seconds. The turning pass created a 0.500″ deep hole with a 0.9840″ diameter and had a cycle time of 19 seconds. The drilling pass created a 0.400″ deep hole with a 0.9840″ diameter and had a cycle time of 4 seconds. The boring pass created a 0.400″ deep hole with a 1.0039″ diameter and had a cycle time of 16 seconds. The results of the test were excellent. The AMEC process completed the operation using only one tool compared to the previous process’s use of 3 tools. With a total cycle time of only 3 minutes 52 seconds, the EcoCut tool reduced total cycle time. Additionally, the tool increased tool life to 600 parts and lowered the customer’s cost of production by $3,320.10 or 63.0%.
The EcoCut tooling met the customer’s expectations and decreased their cost of production while increasing tool life and lowering cycle time.