Master Brake Cylinder: GEN2 T-A 
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The Challenge
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 blaster oil soluble coolant.

Tool used: Solid carbide drill
  • Hole diameter = 0.8559"
  • Hole depth = 3.937″
  • 4463 RPM
  • 0.010 IPR
  • Cycle time = 5.29 seconds
  • Tool life = 10,000 holes (with 6 regrinds per tool) 
The customer needed to reduce the cost-per-part while maintaining the quality of the through hole size and straightness.
The Solution
Allied Machine recommended the GEN2 T-A insert (item 4C21N-.8559) with a laser clad holder.
  • 4463 RPM
  • 0.015 IPR
  • Cycle time = 3.53 seconds
  • Tool life = 12,000 holes
The Advantages
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.
  • Reduced cutting forces and increased tool life from 10,000 holes to 12,000 holes
  • Reduced cycle time from 5.29 seconds to 3.53 seconds
  • Total savings of $11,558 or 31.25%.