The End-user is manufacturing electro-mechanical components such as solenoids, valves, and flame arrestors for the aerospace industry. They are using a Wasino A12 transfer line with 600 PSI water soluble coolant to machine a valve component made out of 1215 free machining steel.
Previously, the customer was using a Dihart 6 flute uncoated cermet reamer running at the following parameters: 3800 RPM, 374 SFM, 0.020 IPR, and 76.0 IPM. The tool created a 2.0″ deep hole with a 0.3755″ diameter. The tool had a cycle time of 4.4 seconds and a life of 10,000 parts. Unsatisfied with their current process, the customer wanted to increase tool life while maintaining the existing penetration rate.
AMEC recommended the Alvan® Reamer Series 92431 with uncoated P01 cermet and G lead running at the following parameters: 4000 RPM, 393 SFM, 0.019 IPR, and 76.0 IPM. The tool had a cycle time of 4.4 seconds. The results of the test met the customer’s every expectation. The Alvan® Reamer had a life of 9200 parts and was then capable of being reground to yield an additional 4200 parts. The total tool life was 13,400 parts. This created a 34% increase in tool life because the Dihart reamer was worn beyond being capable of regrind after 10,000 parts. Additionally, the AMEC tool maintained the existing penetration rate.
Using the AMEC tool, the customer succeeded in increasing tool life because the Alvan® Reamer was capable of being reground to yield a total of 13,400 parts while the previous tool was not.