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.
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 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%.