The customer is manufacturing master brake cylinders out of aluminum die cast for the automotive industry. They are using an HMC Twin Spindle with a 1000 PSI
(69 Bar) blaster oil soluble coolant.
The customer needed to reduce the cost per part while maintaining the quality of the through hole size and straightness.
The GEN2 T-A product not only maintained the quality of the hole size and straightness, but it also achieved optimal chip control at a high feed rate.
| Product: |
GEN2 T-A |
| Objective: |
Decrease cost per part |
| Industry: |
Automotive |
| Part: |
Master brake cylinder |
| Material: |
Aluminum die cast |
| Hole Ø: |
0.856" (21.742mm) |
| Hole Depth: |
3.937" (100mm) |
The GEN2 T-A drilling system
- Laser clad holder
- Insert: 4C21N-.8559
| Measure |
Competitor |
GEN2 T-A |
| RPM |
4463 |
4463 |
| Feed Rate |
0.010 IPR (0.254 mm/rev) |
0.015 IPR (0.381 mm/rev) |
| Cycle Time |
5.29 sec |
3.53 sec |
| Tool Life |
10,000 holes |
12,000 holes |
The GEN2 T-A drilling system provided:
- 33% cycle time decrease
- Increased tool life
- Decreased cost per part