A contract machine shop is manufacturing components for the railroad industry using an Ecoca CNC Lathe SJ-35 HT running with 100 PSI coolant. They are machining a stainless steel latch.
Previously, the customer was using 2 tools to complete the process. First they drilled a 1.1560″ diameter hole with an AMEC holder item #21020S-125F. The tool created a 1.720″ deep hole and had a cycle time of 55 seconds with a life of 100 parts. They then used a boring bar with insert #TCMT-2(1.5)1 for the rough and finish bore operations. Using a 4-pass program, the tool bored a 1.620″ deep hole with a 1.270″ diameter. The tool had a cycle time of 2 minutes 34 seconds and a life of 25 parts. The total cycle time was 3 minutes 29 seconds. Seeking to improve their production process, the customer wanted to reduce cycle time and lower their cost of production.
AMEC suggested using an EcoCut insert item #XCNT 130408 EN CTP 2440 with holder #EC25R-2.25D-13-E. The tool created a 1.620″ deep hole with a 0.9900″ diameter. The tool had a cycle time of 37 seconds and a life of 75 parts. Then, the same EcoCut insert and holder was used for the rough bore operation. The tool created a 1.620″ deep hole with a 1.270″ diameter. The tool had a life of 40 parts and a cycle time of 25 seconds. Then, the same EcoCut holder with the previously used boring insert #TCMT-2(1.5)1 was used for the finish bore operation. The tooling created a 1.620″ deep hole with a 1.1560″ diameter and had a cycle time of 9 seconds with a life of 40 parts. The results were excellent. The EcoCut tooling lowered the total cycle time to only 1 minute 11 seconds and achieved superior chip control. Additionally, the customer lowered their cost of production by decreasing tooling costs and saved $11,209.43 or 60.4%.
Not only did the customer succeed in lowering cycle time, but they also lowered their cost of production and saved 60.4%.