Pump Housing: GEN2 T-A 
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The Challenge
The customer is manufacturing automotive pump housings made from Grey Cast Iron using a Haas VF4 machining center with water soluble coolant.

Tool used:  YG-1 spade drill
  • Hole diameter =  0.843" (21.41mm)
  • Through hole depth = 1.5" (38.1mm)
  • 1400 RPM
  • 0.008 IPR (0.203 mm/rev)
  • 11.2 IPM (284.48 mm/min)
  • Cycle time = 8 seconds
  • Tool life = 1,500 holes
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 Solution
Allied Machine recommended the GEN2 T-A Drilling System.

Tool used:  GEN2 T-A insert (item 4C21H-0027) with a special holder
  • 1650 RPM
  • 0.008 IPR (0.203 mm/rev)
  • 13.2 IPM (335.28 mm/min)
  • Cycle time = 7 seconds
  • Tool life = 3,200 holes
The Advantages
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.
  • Reduced cost-per-hole from $0.02 to $0.017 (over 15%)
  • Saved time, tool life, and eliminated machine down-time