Custom carbide step drill consolidates machining process and increases tool life in swivel housing production
Yasmin Natacha Nunes da Silva | OSG Sulamericana
Founded in 1982, Fundimig Indústria De Peças e Componentes LTDA. (Fundimig) is a company that specializes in the casting and machining of parts and components for the agricultural, automotive and industrial parts markets. Employing 1,120 staff, Fundimig is headquartered in the center-west of Minas Gerais in southeastern Brazil, with an estimated production area of 38,300-square-meter. As a specialist in the production and machining of gray and nodular iron castings, Fundimig has been operating for more than 30 years in the national and international markets with a production capacity of over 3,000 tons of parts per month, distributed across three manufacturing units, all of which are ISO 9001-2008 and IATF 16949 certified.
Recently, Fundimig was looking to enhance its drilling process on a CNH swivel housing production, minimize costs and decrease machine setup time. Fundimig has been making these parts since 2017 and has an annual estimate production volume of 4,200 pieces. The swivel housing is made of ductile cast iron GGG50. Each part requires the processing of 14 M14 x 1.5 6H holes. The pre-drilled holes are 12.5 mm in diameter with a depth of 26 mm (through holes). The parts are machined using a Heller H 4000 4-axis horizontal machining center. A shrink fit tool holder is used for the fixation. Soluble oil is used for the coolant during machining.
Fundimig has been manufacturing CNH swivel housings since 2017 with an annual estimate production volume of 4,200 pieces. The parts are machined using a Heller H 4000 4-axis horizontal machining center.
Fundimig was originally using a competitor 2-flute coolant-through carbide drill for the application. After drilling, a 45-degree carbide chamfer is used. The competitor carbide drill was used at a cutting speed of 90 m/min (2,300 rpm) and a feed rate of 690 mm/min (0.3 mm/rev). The competitor drill averaged 250 parts (3,500 holes) per tool.
During a visit to Fundimig’s facility, OSG Sulamericana Sales Engineer José Eisenhower Galdino Vieira learned of the company’s challenge. Upon a detail evaluation of the application, Vieira recommended a custom tool.
To maximize performance, the engineering team at OSG Sulamericana tailored a 12.5 mm diameter 2-flute carbide step drill based on its High-Tech tool series. The custom drill features a unique cutting edge geometry and is coated with OSG’s original EgiAs coating for long tool life and excellent performance in cast iron applications.
A custom 12.5 mm diameter 2-flute carbide step drill tailored by OSG Sulamericana’s engineering team.
Under identical cutting condition as the competitor drill, OSG’s custom step drill is able to complete 950 parts (13,300 holes) before wearing out, which is nearly four times the durability. Moreover, with OSG’s tooling proposal, Fundimig has eliminated the chamfering tool, which reduced tooling cost, setup time, and enhanced the entire production process.
OSG’s custom 2-flute carbide step drill is being presetted on a Zoller tool presetter.
With an aim for continuous improvement, Fundimig always seeks to exceed market expectations in all aspects. As a valuable partner, Fundimig has consistently counted on OSG for processing improvement.
From left, Fundimig Engineer Tiago Nazareno, OSG Sales Engineer José Eisenhower Galdino Vieira, and Fundimig Engineering Manager Paulo Andres pose for a photograph at Fundimig’s manufacturing facility in Cláudio, Minas Gerais, Brazil.
“We trust the quality of OSG’s products and in the technical capacity of its group,” said Fundimig Engineering Manager Paulo Andres. “This time it was no different. We are very satisfied with the results by achieving our objectives in reducing costs and improving product quality,” said Andres.
For more information on OSG Sulamericana and Fundimig
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