EcoCut Railroad
 
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's Solution
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%.
 
Benefit
Not only did the customer succeed in lowering cycle time, but they also lowered their cost of production and saved 60.4%.