The customer is manufacturing automotive pump housings made from Grey Cast Iron using a Haas VF4 machining center with water soluble coolant.
The tools had a tendency to break, and the customer wanted to eliminate the inconsistent tool life. The machine down-time increased the cost-per-hole.
The GEN2 T-A met the customer’s requirements by providing consistency and eliminating machine down-time. In the end, the lower-priced YG-1 tool ended up costing much more in terms of tool life, machine down-time, and the overall inconvenience of inconsistent tool performance.
| Product: |
GEN2 T-A |
| Objective: |
(1) Decrease tool inconsistency
(2) Decrease cost per hole |
| Industry: |
Automotive |
| Part: |
Pump housing |
| Material: |
Grey cast iron |
| Hole Ø: |
0.843" (21.412mm) |
| Hole Depth: |
1.500" (38.100mm) |
The GEN2 T-A drilling system
- Special Holder
- Insert: 4C21H-0027
| Measure |
Competitor |
GEN2 T-A |
| RPM |
1400 |
1650 |
| Feed Rate |
0.008 IPR (0.203 mm/rev) |
0.008 IPR (0.203 mm/rev) |
| Penetration Rate |
11.2 IPM (284.480 mm/min) |
13.2 IPM (335.280 mm/min) |
| Cycle Time |
8 sec |
7 sec |
| Tool Life |
1500 holes |
3200 holes |
| The GEN2 T-A offered 15% cost per hole savings over the competitor tooling. |
The GEN2 T-A drilling system provided:
- 113% tool life increase
- Decreased cost per hole
- Decreased cycle time