The customer is manufacturing engines for semitrucks using a Mazak HMC MC1516 with water soluble coolant. The engine blocks are made out of cast iron.
Seeking to improve the production process, the customer needed to reduce cycle time, eliminate tool regrinding, and increase tool life.
The GEN2 T-A drastically increased the tool life and completely eliminated the need for regrinding. Additionally, the customer was able to lower their cost of production.
| Product: |
GEN2 T-A |
| Objective: |
(1) Decrease cycle time
(2) Eliminate tool regrind
(3) Increase tool life |
| Industry: |
Automotive |
| Part: |
Semi-truck engine block |
| Material: |
Cast iron |
| Hole Ø: |
0.402" (10.211mm) |
| Hole Depth: |
1.100" (27.940mm) |
The GEN2 T-A drilling system
- Holder: 060830-31
- Insert: 4C2YH-10.2
| Measure |
Competitor |
GEN2 T-A |
| RPM |
2350 |
3600 |
| Feed Rate |
0.007 IPR (0.178 mm/rev) |
0.005 IPR (0.127 mm/rev) |
| Cycle Time |
5.01 sec |
4.67 sec |
| Tool Life |
625 holes |
4000 holes |
| The GEN2 T-A offered 64% cost per hole savings over the competitor tooling. |
The GEN2 T-A drilling system provided:
- 540% tool life increase
- Decreased cycle time
- Decreased cost per hole
- Eliminated tool regrind