GEN3SYS® Aluminum Aerospace
 
An End-user is manufacturing electronic connectors for the aerospace industry using a Mori Seiki Lathe running with 300 PSI oil coolant. They are machining an aerospace connector made out of 6061 aluminum.
Previously, the customer was using a Guhring Cobalt Twist drill running at the following parameters: 3800 RPM, 622 SFM, 0.013 IPR, and 49.40 IPM. The tool created a 1.50″ deep hole with a 0.6250″ diameter. The tool had a cycle time of 6.8 seconds and a life of 11,000 holes. Unsatisfied with their current process, the customer wanted to increase tool life and reduce cycle time.
 
AMEC's Solution
AMEC recommended the GEN3SYS™ High Penetration Drilling System with insert item #5C215H-0020 and holder #60315H-075F running at the following parameters: 4800 RPM, 785 SFM, 0.025 IPR, and 120.0 IPM. The results of the test were excellent. The GEN3SYS™ tool increased tool life to a stunning 54,000 holes and reduced cycle time to 5.8 seconds. Additionally, the customer lowered their cost of production receiving a total cost savings of $2,818.03 or 15.2%.
 
Benefit
Due to the success of the GEN3SYS™ tooling, the customer increased tool life and reduced cycle time while lowering their cost of production. Ultimately, the customer was thoroughly satisfied with the AMEC tooling.