An End-user is manufacturing components for the aerospace industry using a Mori Seiki Lathe with a bar feeder running with 300 PSI oil coolant. They are machining an aerospace connector made out of 6061-T6 aluminum.
Previously, the customer was using a Kennametal drill running at the following parameters: 3000 RPM, 1129 SFM, 0.012 IPR, and 36.0 IPM. The tool drilled a 3.0″ deep hole with a 1.4375″ diameter. To achieve the required 6.0″ deep hole, the customer had to use a 2-pass program by drilling one side of the part 3.0″ deep then flipping the part over and drilling another 3.0″. The Kennametal tool had a total cycle time of 45 seconds and a life of 1250 holes. Unsatisfied with this procedure, the customer wanted to complete the entire drilling process in one operation and increase tool life.
AMEC recommended the T-A® drill insert item #1C23A-0114 with holder #23030S-150L running at the following parameters: 3000 RPM, 1129 SFM, 0.022 IPR, and 66.0 IPM. The tool drilled a 6.0″ deep hole with a 1.4375″ diameter. The results were outstanding and allowed the customer to drill the 6.0″ deep hole in one operation. The tool reduced cycle time to 10.5 seconds and increased tool life to a stunning 10,500 holes. Additionally, the customer lowered their cost of production and saved a total of $18,295.86 or 76.3%.
Using the AMEC tool, the customer succeeded in completing their drilling process in one operation while reducing cycle time, increasing tool life, and lowering their cost of production.