A Tier 1 automotive supplier manufactures a diesel engine front cover made from grey cast iron. They are using a Mitsubishi 800mm HMC with 300 PSI through tool coolant.
- Spot drill
- Solid carbide drill
- Solid carbide port form tool
The customer needed a special angled insert to meet the specification. The cycle time for the part was not keeping pace with production demands. The solid carbide tooling also added large costs to the operation due to lengthy set-up times, regrinds, recoats, and extra inventory.
Allied recommended a special AccuPort 432 Port Contour Cutter.
Tool used: A modified ISO-6149 #8 AccuPort 432 with a modified port form insert and a Cast Iron T-A® insert (item 1C30A-16.2-CI)
- 1765 RPM
- 300 SFM
- 009 IPR
- 15.75 IPM
- Cycle time = reduced by 7 minutes per part
The special AccuPort 432 allowed the customer to replace three tools with one, which significantly decreased the cycle time. Also, the replaceable insert design greatly reduced the large stock of solid carbide tooling.
- Increased production capability by 9,000 pieces per year
- Reduced labor hours by 2,090 hours
- Overall savings of $35,000 per year