Challenge Details
- Tight Bore tolerance - Ø47mm (+/-.0125)
- Long tooling gage line- +600mm
- Low initial boring cost
- High part volume - EAU 30K/Year
- High Scrap Rate
Objective
Propose a consistent and robust process that would replace the current single point boring system. The system should be easy for an operator to use and require minimal intervention. Overall cost per part must be comparable or better than the current system. Scrap costs due to bore inconsistency must be reduced, preferably eliminated.
The Solution
Monaghan proposed a high performance reamer from Diatool. A multi-bladed reamer utilizing eight cermet cutting blades allowed for fast cutting speeds and high feed-rates. To account for wear and to maintain the cutting size of the bore an expandable option was also specified. This expandability allows for micro-expansions to maintain the correct size of the reamer and extend the useable life of the reamer many times more than a traditional solid or fixed tool.
Overall Results
- Yearly Savings - $36,000
- Cycle time reduced 54 Seconds
- No Operator Intervention
- First part good for size and finish
- ROI- Less than 2 Months
- Total CPU cost less than $.06 cents/part
Benefits Realized
Cycle time reduced
With 8 effective cutting blades, the Diatool monoblock reamer was able to feed faster than a single effective cutting tool resulting in a 54 second per part cycle time savings.
Predictable Size Control
The multi-bladed reamer arrives on size and creates a stable process that requires no operator adjustment to maintain bore size.
Consistent Bore Finish
With a surface finish of 6.3 Rz and a 0.025mm tolerance held, the customer was able to maintain excellent bore quality for both size and finish.