The customer is machining V35 vane pump rings made from 52100 using a Mazak vertical machining center with 1000 PSI through tool synthetic coolant.
Tool used: KSEM drill with insert grade KC 7315 HP (M)
- Hole diamater = 0.984" (25mm)
- Hole depth = 2.5 inches (63.5mm)
- 1200 RPM
- 0.012 IPR (0.30 mm/rev)
- 14.4 IPM (365.76 mm/min)
- Cycle time = 10 seconds
- Tool life = 40 holes
Looking for improvements, the customer asked Allied to provide a tool that would lower their cost per hole. The KSEM was $2.59 per hole due to poor tool life and sporadic catastrophic failures.
Allied recommended the GEN2 T-A Drilling System.
Tool used: GEN2 T-A insert (item 452H-25) and holder (item 22020S-125F)
- 1200 RPM
- 0.012 IPR (0.30 mm/rev)
- 14.4 IPM (365.76 mm/min)
- Cycle time = 10 seconds
- Tool life = 104 holes
The large increase in tool life met the request by eliminating catastrophic failures during the entire operation.
The GEN2 T-A Drilling System made a significant difference for the customer
- Increased tool life nearly 3x compared to the KSEM tool
- Eliminated catastrophic failures
- Reduced the cost-per-hole from $2.59 to $0.71
- Total savings of 72.6%