The customer is a wellhead company that manufactures equipment and provides field service to the oil and gas industry. They are machining a casting valve body made out of 4130 and 4140 alloy steel. They are using both Toyoda and Monarch 25 HP machining centers using 600 PSI and 1000 PSI though-tool coolant.
Previously, the customer was using an Iscar Chamdrill running at the following parameters: 1800 RPM, 360 SFM, 0.0055 IPR, and 9.9 IPM. The tool created a 1.50″ deep hole with a 0.7650″ diameter. The tool had a cycle time of 14 seconds and a life of 325 holes. Seeking to streamline their production, the customer wanted to reduce cycle time and increase tool life.
AMEC recommended the GEN3SYS™ insert item #5C118H-.765 with holder #60318H-100F running at the following parameters: 1800 RPM, 360 SFM, 0.0083 IPR, and 14.94 IPM. The results of the test exceeded the customer’s expectations. The GEN3SYS™ tool increased tool life to 900 holes and reduced cycle time to 11 seconds. Additionally, the customer lowered their cost of production. In machining 5000 holes, the customer received a total cost savings of $850.69 or 33.5%.
Based on the success of the AMEC tooling, the customer was thoroughly satisfied. As a result of reducing cycle time and increasing tool life, the customer was able to lower their cost of production.