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T-A GEN2
Semi-Truck Engine Block: T-A GEN2 
Code:
1110
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The Challenge

The customer is manufacturing engines for semitrucks using a Mazak HMC MC1516 with water soluble coolant. The engine blocks are made out of cast iron.

Seeking to improve the production process, the customer needed to reduce cycle time, eliminate tool regrinding, and increase tool life.

The T-A GEN2 drastically increased the tool life and completely eliminated the need for regrinding. Additionally, the customer was able to lower their cost of production.
 

Product: T-A GEN2
Objective: (1) Decrease cycle time
(2) Eliminate tool regrind
(3) Increase tool life
Industry: Automotive
Part: Semi-truck engine block
Material: Cast iron
Hole Ø: 0.402" (10.211mm)
Hole Depth: 1.100" (27.940mm)

 
The Solution
The T-A GEN2 drilling system
  • Holder: 060830-31
  • Insert: 4C2YH-10.2
Measure Competitor T-A GEN2
RPM 2350 3600
Feed Rate 0.007 IPR (0.178 mm/rev) 0.005 IPR (0.127 mm/rev)
Cycle Time 5.01 sec 4.67 sec
Tool Life 625 holes 4000 holes
The T-A GEN2 offered 64% cost per hole savings over the competitor tooling.

 
The Advantages
The T-A GEN2 drilling system provided:
  • 540% tool life increase
  • Decreased cycle time
  • Decreased cost per hole
  • Eliminated tool regrind