polytool application

POLYTOOL APPLICATION
APPLICATION
Machining of an alternator – Automotive market
Machining conditions before
our intervention
Material:
Cast steel
Competitor: SECO
Tool:
Interchangeable head with left
hand helix (to push chips) Ø17H7
Cost:
75€ per tool
N = 900 rpm ! Vc = 50 m/min
Vf = 850 mm/min ! f = 0.95 mm/rev
Reaming allowance = 0.10 mm (on Ø)
Reaming depth = 12 mm
Dry machining
Tool life = 400 holes (average)
Customer’s troubles:
•A lot of pieces are wrong due to the run-out
generated by the head replacement.
•The customer would like to improve the tool life.
•The chips are pushed to the front due to the left
hand helix, and they stay blocked in the part.
Advices from DIXI
Tool:
Cost:
Solid reamer with 10° right hand
helix (to pull chips backwards)
+ air blown into the flutes
120€ per tool + 25€ for 1 resharpening
! 72.50 € per tool
N = 900 rpm ! Vc = 50 m/min
Vf = 850 mm/min ! f = 0.95 mm/rev
Reaming allowance = 0.10 mm (on Ø)
Reaming depth = 12 mm
Tool life = 700 holes
"Almost twice the previous tool life
with our solution
Technical and economical results
Further than doubling tool life, DIXI
Polytool’s reamers :
•increased the chip removal
•decreased the machining time off.
Technical and economical results
! The cost per hole has been divided by two.
! The customer produces 6’000 pieces per
day in 3 shifts, which means cost reduction
is 500€ per production day
" DIXI Polytool supplies now 300 reamers
per month since June 2011 for that
customer
Thank you for your attention !