The customer supplies gears and gear assemblies. They are manufacturing transmission gear carriers for the Hummer H3. The holes are drilled into a composite consisting of two powder metal steel components joined by sinter-brazing. The customer is expecting to produce 50,000 carrier assemblies.
Tool used: A special solitude carbide TiN coated twist drill
- Hole Diameter = 0.551" (14 mm)
- 1600 RPM
- 0.010 IPR
- The tool held true position requirements
Allied Machine suggested the GEN2 T-A Drilling System. The tool needed to at least match the 16 IPM achieved by the original tool.
Tool used: GEN2 T-A insert (item 4C20H-14) with a special chrome helix holder
- 1600 RPM
- First 0.156" to start the hole = .005 IPR
- First 0.156" to start the hole = 8.00 IPM
- Finish the hole = .010 IPR
- Finish the hole = 16.00 IPM
The GEN2 T-A met the customer's requirements and provided significant cost savings.
- The savings were $82.03 (38.29)
- Total savings for 50,000 assemblies = $13,650