Transmission Gear Carrier: GEN2 T-A 
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The Challenge
The customer supplies gears and gear assemblies. They are manufacturing transmission gear carriers for the Hummer H3. The holes are drilled into a composite consisting of two powder metal steel components joined by sinter-brazing. The customer is expecting to produce 50,000 carrier assemblies.

Tool used:  A special solitude carbide TiN coated twist drill
  • Hole Diameter = 0.551" (14 mm)
  • 1600 RPM
  • 0.010 IPR
  • The tool held true position requirements
The Solution
Allied Machine suggested the GEN2 T-A Drilling System. The tool needed to at least match the 16 IPM achieved by the original tool.

Tool used:  GEN2 T-A insert (item 4C20H-14) with a special chrome helix holder
  • 1600 RPM
  • First 0.156" to start the hole = .005 IPR
  • First 0.156" to start the hole = 8.00 IPM
  • Finish the hole = .010 IPR
  • Finish the hole = 16.00 IPM
The Advantages
The GEN2 T-A met the customer's requirements and provided significant cost savings.
  • The savings were $82.03 (38.29)
  • Total savings for 50,000 assemblies = $13,650