Chip Control Solution Provides Increase In Tool Life

General Automotive (Franklin, Wisconsin), an automotive component manufacturer, faced a chip control problem on an ID turning operation. As a producer of high-precision components for engines, fuel systems, hydraulics, air systems, brake systems and transmissions, quality is essential to its business. Therefore, it was crucial that the company found a solution to the chip control problem.

On this job, injector bodies were being machined out of AISI/SAE 1055 steel, and the ISO inserts being used had problems with chip breaking and chip buildup. This chip buildup would periodically lead to poor quality parts, which would then need to be scrapped. As a result, constant monitoring was necessary to ensure that quality parts were being produced.

In order to find a reliable tool that could run without the need for constant monitoring, the company first contacted its Iscar Metals (Arlington, Texas) representative. After analyzing the situation, he suggested replacing the traditional ISO-style inserts with Iscar’s Bayo T-Ream reaming system and suggested running it with Iscar’s Gyro toolholder. He believed this combination would provide a more reliable setup compared to the current tooling being used.

The reaming system features interchangeable heads for quick tool changes and high-speed reaming and allows for minimal setup time while indexing. It consists of an interchangeable carbide reaming head with a quick-change bayonet mechanism mounted on a Hard Touch-coated steel shank using a bayonet screw and special key to clamp and release the interchangeable head. The shank and head combination makes it possible to use one shank for a variety of hole diameters and types of cutting edges. This combination of carbide head and steel shank provides for a durable system for machining on a variety of materials, the company says. In addition, the reamer is designed with internal coolant holes for head lubrication and chip evacuation.

For this project, the Bayo T-Ream was mounted onto a Gyro toolholder, which is an adjustable toolholder designed to eliminate problems from radial or angular misalignment. Its design also allows for a smooth and easy adjustment of alignment between the chuck and turret on drilling, tapping and reaming operations. This toolholder makes it possible to completely machine a hole with only one setup while still achieving tolerances as close as 0.0004 inch. By automatically making alignment adjustments, cutting tool life is increased by as much as tenfold while also increasing speeds and feeds by as much as 300 percent.

With this new system in place, General Automotive was able to increase the pieces per edge from 550 to 5,800. This 1,000-percent increase in tool life was accomplished by running at 3,257 rpm at 0.024 ipr while taking a 0.012-inch depth of cut. In addition, not one part was scrapped because of chip buildup.