SOL-GENMACH_EU-EN

general machining

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MACHINE A HOLE maximise performance with reliable solutions in difficult applications LOT BETTER

Improve processes Gain better chip control Increase penetration rates

T-A Pro ® DRILLING SYSTEM The best just got better.

Allied Machine offers a wide range of drilling, boring, reaming, burnishing, and threading tools to lower your cost per hole .

general machining

CONTENTS Valve Flaps Valve Bodies Fittings

Valves and Fittings Automotive Fittings Fuel Nozzles Hardened Bevel Gears Steel Gears ..................................2 ................................3 ....................................4 .............................5 .............................6 .................................7 ...........................8 ..................................8 .................................9 .................................10 .......................11 ................................12 .............................13 ..............................14 ...............................14 ....................15 ORDERING The solutions listed in this guide represent general standard products and/or special product designs. To order items specific to your application, please contact your local Allied Field Sales Engineer or a member of Allied’s Application Engineering Team. Application Engineering Department enquiries.eu@alliedmachine.com Gear Blanks Gearboxes Hydraulic Manifold Blocks Tube Sheets Hot Rolled Plates Barbell Sleeves Bearing Cups Hydraulic Cylinder Component

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VALVE FLAPS

Adjustable torx screw pins allow for 0.006" total adjustment on diameter.

Multiple coolant outlets provide a hydro bearing for stability in deeper holes.

GUIDED T-A ® DRILL REPLACEABLE INSERT DRILLS X Diameter range: 12.98 mm - 114.48 mm X Specialised coolant configuration improves chip evacuation at high penetration rates X Diameter-specific holders maximise performance and rigidity X Coolant-fed carbide bearing area provides long-lasting support to ensure hole accuracy and tolerance

Guided wear pads provide improved hole straightness.

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22% c o st psear vhionlges

VALVE BODIES

38% CYCLE TIME DECREASE Revolution Drill® CUSTOMER’S OBJECTIVE: DECREASE CYCLE TIME PREVIOUS CYCLE TIME NEW CYCLE TIME 5 MIN 13 SEC 3 MIN 13 SEC

Revolutionise your process. The customer is manufacturing valve bodies for the general machining industry using a Femco horizontal machining center with semi-synthetic through-tool coolant. The parts are made from A36 steel. Previously, the customer was achieving a cycle time of 5 minutes and 13 seconds. The customer needs to decrease cycle time and improve performance overall. Allied’s Revolution Drill with indexable inserts achieved a 3 minute and 13 second cycle time, a 38% decrease over the competition along with an increased tool life from 32 holes to 48 for an overall improved process. The Revolution Drill met the customer’s request and successfully reduced costly machining time.

Product:

Revolution Drill

Measure

Competitor

Revolution Drill

Objectives:

Decrease cycle time General machining

RPM

525

850

Industry:

Part:

Valve bodies

Feed Rate

0.076 mm/rev

0.076 mm/rev

Material: Hole Ø:

A36

Penetration Rate

40.132 mm/min

64.77 mm/min

3.625" (92.075 mm) Hole Depth: 8.250" (209.55 mm)

Tool Life

32 holes

48 holes

Increased tool life The Revolution Drill provided: Decreased cycle time Decreased cost per hole

Revolution Drill Inserts Item No. OP-05T308-H

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FITTINGS

COMBI-LINE WOHLHAUPTER ® ROUGH AND FINISH BORING HEADS X Diameter range: 24.50 mm - 201.00 mm X Completes rough and finish boring in one operation X Available in semi-standard same level or height-displaced insert holders

4TEX ® DRILL X Diameter range: 2 mm - 47 mm X Robust design allows for reliability in interrupted cuts even when the material is difficult to machine X Single-effective cutting on light-duty machines increases penetration rates X Strengthened core and increased coolant volume improve the hole size and chip evacuation INDEXABLE CARBIDE DRILLS

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VALVES AND FITTINGS

78.18% cycle time decrease

110% TOOL LIFE INCREASE ACCUTHREAD® 856 CUSTOMER’S OBJECTIVE: IMPROVE THREAD QUALITY PREVIOUS TOOL LIFE NEW TOOL LIFE 475 HOLES 1000 HOLES

Measure

Competitor

AccuThread

RPM

1300

1800

Product:

AccuThread 856 Indexable Improve thread quality

Objectives:

Feed Rate

0.102 mm/rev

0.152 mm/rev

Industry:

General machining Valves & fittings

Part:

Penetration Rate

66.04 mm/min

151.892 mm/min

Material: Hole Ø:

4140

Cycle Time

6 min 2 sec

1 min 19 sec

2.00" (50.8 mm)

Tool Life

475 holes

1000 holes

The AccuThread indexable thread mill provided:

AccuThread 856 Item No. TN150K-UN14I Item No. THP-1116-3F150

Decreased cycle time

Increased tool life

Improved thread quality

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AUTOMOTIVE FITTINGS

REDESIGNED HOLDERS

NEW flute design for increased chip evacuation

NEW coolant configuration

NEW inserts and point geometry

T-A PRO ® DRILLING SYSTEM REPLACEABLE INSERT DRILLS X Diameter range: 11.1 mm - 47.8 mm X Proprietary coolant outlet configuration provides superior performance even in low-coolant applications X Optimised flute design for increased chip evacuation X ISO-specific geometries with a new point design to simplify your insert choices

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FUEL NOZZLES

Longer tool life When the cutting edge on the periphery insert wears down, just rotate and move it to the center insert position.

Improved tool holder rigidity and increased reliability provided by the stronger core. This design helps you produce the best holes every time. Stable & efficient

4TEX ® DRILL X Diameter range: 12 mm - 47 mm X ISO-specific insert options for optimal cutting conditions for any material class X High positive outboard edge allows for lighter tool pressure and better chip control X Substrate and coating combination promotes faster speeds while maintaining impressive tool life in the most challenging applications INDEXABLE CARBIDE DRILLS

Double Coolant Hole

Center Insert Flute

Periphery Insert Flute

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HARDENED BEVEL GEARS

NOTE: Adjustment accuracy of 0.0001" or 0.002 mm on diameter NOTE : Imperial item pictured

DIGIBORE BORING HEAD WOHLHAUPTER ® FINE BORING HEADS X Diameter range: 3 mm - 208 mm X Digital display allows for quick and accurate diameter corrections at the machine X Internal balancing improves tool life and surface finish X Bore multiple hole sizes using one boring head with a broad range of compatible components

STEEL GEARS

THREADMILLS USA ™ X Thread mills drastically reduce the occurrences of scrap when compared to taps, and this advantage makes them desirable when manufacturing large and/or costly components X Produces threads in difficult-to-machine materials including those that are post-heat treated X Available with coolant through capabilities SOLID CARBIDE THREAD MILLS

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GEAR BLANKS

GEN2 T-A ® DRILL X Diameter range: 9.5 mm - 114.48 mm X Notch Point® geometry on the GEN2 T-A insert improves stability and hole straightness X Large assortment of geometries available with the T-A® drilling system allows for a consistent drilling process you can rely on regardless of material X Utilising replaceable inserts increases your productivity by reducing setups and downtimes REPLACEABLE INSERT DRILLS

VARIOBORE X VarioBore diameter range: 4 mm - 114 mm X VarioBore head offers precision and versatility with one boring head capable of the full diameter range X 3E TECH docking port for precise external digital diameter adjustments WOHLHAUPTER ® FINE BORING HEADS

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GEARBOXES

NOTE: Adjustment accuracy of 0.0001" or 0.002mm on diameter NOTE : Imperial item pictured

Absorber mass

565 (564) BORING HEAD & NOVI TECH ® X Machining diameter range: 50 mm - 205 mm X The 565 (564) boring head with easy-to-read digital display is specifically engineered to minimise the residual imbalance produced by insert holder displacement X The NOVI TECH system is a viscoelastically mounted damping module, which reduces vibrations during machining WOHLHAUPTER ® MULTIBORE ® SYSTEM TOOLS

Damper module with viscoelastic bearing

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HYDRAULIC MANIFOLD BLOCKS

Time is money. A contract machine shop is manufacturing specialised hydraulic manifold blocks made out of low carbon steel. They are using a KIWA HMC with 69 bar coolant through the spindle. They are mounting 16 blocks on one tombstone at a time. Turning to Allied for improvement, the customer wanted to reduce the costs of machining the manifold blocks. With the AccuPort 432 drill and finish port forms completed in one operation, pre-drilling was no longer required. Furthermore, the replaceable insert design eliminated regrinding. CUSTOMER’S OBJECTIVE: REDUCE COSTS PREVIOUS CYCLE TIME NEW CYCLE TIME 24 MIN 16 MIN 33% CYCLE TIME DECREASE ACCUPORT 432 ®

ACCUPORT 432 ® X Port Range: size 4 - size 32 X Asymmetrical cutting edges provide excellent hole roundness PORT CONTOUR CUTTERS

Port kits incorporate an AccuThread ® solid carbide thread mill allowing hydraulic ports to be produced in just two operations.

X Replaceable inserts eliminate the need for regrinds X Uses a variety of geometries for precision finishes

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TUBE SHEETS

BT-A DRILL BTA (STS) DEEP HOLE MACHINING X Diameter range: 12.98 mm - 47.80 mm X Double-effective cutting allows up to 2x penetration rates over conventional BTA heads X Utilises the standard BTA-STS tube connection X Improves performance in cross holes X Versatility of available T-A® geometries and substrates allows for increased penetration rates and excellent chip control in any application

T-A ® DRILLING SYSTEM X Diameter range: 9.5 mm - 114.30 mm X Large variety of geometries and coatings optimises chip formation in various materials X Replaceable insert reduces setup and downtime, increasing productivity X Effectively dissipates heat from the cutting edge, which increases tool life and reduces overall costs REPLACEABLE INSERT DRILLS

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HOT ROLLED PLATES

T-A ® (-IN) GEOMETRY X Diameter range: 9.5 mm - 114.48 mm X Combination of high impact and Notch Point® geometries X Increases stability in deep hole applications X Enhances chip formation in materials with high elasticity/ ductility and poor chip forming characteristics REPLACEABLE INSERT DRILLS

T-A PRO ® STEEL (-P) GEOMETRY REPLACEABLE INSERT DRILLS X Diameter range: 11.1 mm - 47.80 mm X Designed to provide increased penetration rates and tool life in steel applications X Superior geometry and edge provides excellent chip control X Allied’s multilayer AM300® coating increases heat resistance and improves tool life

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BARBELL SLEEVES

GEN3SYS ® XT PRO DRILL REPLACEABLE INSERT DRILLS X Diameter range:11 mm - 35 mm X With increased coolant at the cutting zone, the XT Pro dissipates heat, which is critical in extending tool life X The increased coolant flow also allows the tool to achieve maximum penetration rates, which can help increase your throughput X The XT Pro holder has additional flute volume that improves chip evacuation

BEARING CUPS

SPECIAL T-A ® INSERTS REPLACEABLE INSERT DRILLS

X Diameter range: 9.5 mm - 114.48 mm X Special form insert designed to reduce or eliminate additional operations X Allows for ease of replaceability due to utilising the T-A drilling system X Available in a variety of coating and substrates to optimise tool life

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HYDRAULIC CYLINDER COMPONENT

Adjustable Ø

REVOLUTION DRILL ® INDEXABLE CARBIDE DRILLS X Diameter range: 47.6 mm - 101.0 mm X Provides ideal performance and high penetration rates on low horsepower machines X Robust geometry allows the tool to drill through uneven surfaces and interrupted cuts X Drills from solid with no pilot hole required

Replaceable cartridges and inserts reduce machine down time and protect your investment.

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NOTES

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NOTES

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ONLINE TOOLS

Increase the production and success of your applications today. • Direct access to 2D drawings and 3D models • Assemble and view tool images in your browser • Download drawings for use in most machining software programs • Browse products, search item numbers, and save assemblies for future use

toolmd.com

Allied Tool Academy

Whether it is online or on-site, get the product knowledge you need.

• Online training to level up your tooling IQ through a series of product overviews, demos, and short quizzes • Allied LIVE broadcasting lets you watch live demos and ask our trainers questions • On-site Technical Education Seminar (TES) puts the attendees in front of the machines to gain first-hand experience in real-life application situations

alliedtoolacademy.com

Boring Insert Selector

Find the best insert for your application.

• Generate the correct boring insert for your job in just six easy steps • Choose type, shape, substrate, insert form, nose radius, and material • Order easily by adding the item to your cart

alliedmachine.com/bis

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ONLINE TOOLS

Insta-Code ®

Eliminate the wait. Get your program now.

• Choose the best thread mill for your application • Create program code for your machine • Available as a PC download app (that can be used offline) • Website app available 24/7

Insta-Code also has a Cycle Time Calculator

alliedmachine.com/InstaCode

®

Design your custom tooling and receive a drawing and quote...all within minutes. • Design and quote your own tooling • Generate the solution you need in just a few steps • Features the following products

- T-A® Inserts - T-A® Holders - GEN3SYS® XT Holders - ALVAN® Reamers

iq.alliedmachine.com

Machinist Tool App

Solution Hub App

Quickly convert cutting tool parameters for the machine inputs you need. • Input data to calculate the RPM and speed and feed rates • Use the Boring Insert Selector • Access product literature right at your fingertips

All Allied all the time. • Quickly look up product information • Links to our free online tools • Locate distributors • Stay up to date on news and events

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WE HAVE THE ANSWERS

No matter the type of holemaking, Allied is here to help you. Whether you’re a production facility producing thousands of parts for one customer or a job shop making a handful of parts for a thousand customers, we’re here to make sure the job gets done. Our precision holemaking and finishing solutions are backed by our experienced staff of knowledgeable engineers who are standing by. Don’t hesitate to call us. Let us know what problems you’re having, and we’ll find the solution. Machining is what we do, and we don’t mind showing off what we know. After all, we are the holemaking experts. All you have to do is ask.

+44 (0) 1384 400 900

For more general machining case studies, visit www.alliedmachine.com/CaseStudies

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Warranty Information

Allied Machine & Engineering (“Allied Machine”) warrants to original equipment manufacturers, distributors, industrial and commercial users of its products for one year from the original date of sale that each new product manufactured or supplied by Allied Machine shall be free from defects in material and workmanship. Allied Machine’s sole and exclusive obligation under this warranty is limited to, at its option, without additional charge, replacing or repairing this product or issuing a credit. For this warranty to be applied, the product must be returned freight prepaid to the plant designated by an Allied Machine representative and which, upon inspection, is determined by Allied Machine to be defective in material and workmanship. Complete information as to operating conditions, machine, setup, and the application of cutting fluid should accompany any product returned for inspection. This warranty shall not apply to any Allied Machine products which have been subjected to misuse, abuse, improper operating conditions, improper machine setup or improper application of cutting fluid or which have been repaired or altered if such repair or alteration, in the judgement of Allied Machine, would adversely affect the performance of the product. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Allied Machine shall have no liability or responsibility for any claim, whether in contract, tort or otherwise, for any loss or damage arising out of, connected with, or resulting from the manufacture, sale, delivery or use of any product sold hereunder, in excess of the cost of replacement or repair as provided herein. Allied Machine shall not be liable in contract or in tort (including, without limitation, negligence, strict liability or otherwise) for economic losses of any kind or for any special, incidental, indirect, consequential, punitive or exemplary damages arising in any way out of the performance of, or failure to perform this agreement. ALL PRICES, DELIVERIES, DESIGNS, AND MATERIALS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

Allied Machine & Engineering Co. Europe Ltd. is registered to ISO 9001:2015 by bsi.

Allied Machine & Engineering is registered to ISO 9001:2015 by DQS

Wohlhaupter GmbH is registered to ISO 9001:2015 by QA TECHNIC

Europe Allied Machine & Engineering Co. (Europe) Ltd. 93 Vantage Point Pensnett Estate Kingswinford West Midlands DY6 7FR England

Phone: +44 (0) 1384.400900

Wohlhaupter GmbH Maybachstrasse 4 Postfach 1264 72636 Frickenhausen Germany

Phone: +49 (0) 7022.408.0

Fax: +49 (0) 7022.408.212

United States Allied Machine & Engineering

Phone: +1.330.343.4283 Fax: +1.330.602.3400

Toll Free USA and Canada: 800.321.5537 Toll Free USA and Canada: 800.223.5140

120 Deeds Drive Dover OH 44622 United States

Allied Machine & Engineering 485 W Third Street Dover OH 44622 United States Asia Wohlhaupter India Pvt. Ltd. B-23, 3rd Floor B Block Community Centre Janakpuri, New Delhi - 110058 India

Phone: +1.330.343.4283 Fax: +1.330.364.7666 (Engineering Dept.)

Toll Free USA and Canada: 800.321.5537

Phone: +91 (0) 11.41827044

Your local Allied Machine representative:

www.alliedmachine.com Allied Machine & Engineering Co. (Europe) Ltd is registered to ISO 9001:2015 by bsi.

Wohlhaupter GmbH is registered to ISO 9001:2015 by QTA TECHNIC Allied Machine & Engineering is registered to ISO 9001:2015 by DQS

Copyright © 2023 Allied Machine & Engineering Corp. All rights reserved. All trademarks designated with the ® symbol are registered in the United States and other countries. Available online only. Publish Date: August 2023