XT Pro Wins the Cycle Time Race on ATV Suspension Machining
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Dover, OH - Allied Machine & Engineering, a leading manufacturer of holemaking and finishing cutting tools for the metal-cutting industry recently worked with a motorsports manufacturer producing ATV suspensions from ductile iron.
This material is notorious for its high abrasiveness and inconsistent hardness.
Their current tooling had to be fed at or under .005 IPR to hold the required 63 Ra µin surface finish. The customer was frustrated with the low penetration rates, so they requested a test demo with the GEN3SYS XT Pro using the “K” geometry with AM440 coating designed to overcome wear from cast iron material. Allied Machine says, “this coating allowed them to spin the tool faster without losing the cutting edge to wear. The XT Pro was able to increase the penetration rate from 8 IPM to 43.7 IPM (a 446% improvement), all while holding the required 63 Ra µin surface finish.” By increasing the penetration rate, the XT Pro dropped the cycle time from 23 seconds to just 4 seconds, allowing the customer to increase production significantly while maintaining the necessary surface finish.
GEN3SYS XT Pro line of high-penetration drilling products features inserts and holders designed for three specific geometries. This line also introduces several unique coatings. Combining specific geometries, substrates and coatings creates the optimal solution for drilling challenging materials, such as the ductile iron mentioned above.
The GEN3SYS XT Pro line of replaceable inserts is available for steels, cast irons, non-ferrous materials, and most recently, structural steel.
The drill inserts are available in diameters ranging from 11mm to 35mm. The steel materials geometry (ISO class P) is ideal for low and medium carbon and alloy steels. The ISO class K geometry, according to Allied Machine, is engineered for cast and nodular iron applications and the blade’s geometry includes a corner radius for improved hole finish and heat dispersion. The addition of their multi-layer AM440 coating offers increased abrasion resistance and tool life. The ISO class N geometry excels in softer materials including aluminum, brass, and copper applications and yields excellent chip control. Its TiN coating provides the versatility to run in a variety of materials while reducing buildup.
Holders for the GEN3SYS XT Pro line feature an enhanced flute design that improves chip evacuation and an updated coolant configuration that increases coolant flow and directs coolant to the cutting zone. The holders are offered in 3xD, 5xD, 7xD, and 10xD depth-to-diameter ratios.