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T-A GEN2
Master Brake Cylinder: T-A GEN2 
Code:
1109
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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 (69 Bar) blaster oil soluble coolant.

The customer needed to reduce the cost per part while maintaining the quality of the through hole size and straightness.

The T-A GEN2 product not only maintained the quality of the hole size and straightness, but it also achieved optimal chip control at a high feed rate.

Product: T-A GEN2
Objective: Decrease cost per part
Industry: Automotive
Part: Master brake cylinder
Material: Aluminum die cast
Hole Ø: 0.856" (21.742mm)
Hole Depth: 3.937" (100mm)

 
The Solution

The T-A GEN2 drilling system

  • Laser clad holder
  • Insert: 4C21N-.8559
Measure Competitor T-A GEN2
RPM 4463 4463
Feed Rate 0.010 IPR (0.254 mm/rev) 0.015 IPR (0.381 mm/rev)
Cycle Time 5.29 sec 3.53 sec
Tool Life 10,000 holes 12,000 holes

 
The Advantages
The T-A GEN2 drilling system provided:
  • 33% cycle time decrease
  • Increased tool life
  • Decreased cost per part