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Opening Drill
Aerospace Gears: Opening Drill® 
Code:
6501
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The Challenge
The customer manufactures aerospace gears made from 4340 (28 Rc) using a Mazak Lathe with oil-based water soluble coolant.

Tool used:  Sandvik boring bar
  • Pre-existing diameter = 2.125" (53.9mm)
  • Enlarged diameter = 3.75" (95.3mm)
  • Hole depth = 7.00" ( 177.8mm)
  • 400 RPM
  • 0.012 IPR (0.30 mm/rev)
  • 4.8 IPM (122 mm/min)
  • Passes required = 13
  • Tool life = 30 parts
  • Cycle time = 19 minutes
The customer realized this process was not optimal, and they contacted Allied for a solution.
The Solution
Allied recommended the Opening Drill.

Tool used:  Opening Drill (item OP3-1L-SS1.5)
  • 509 RPM
  • 0.004 IPR (0.10 mm/rev)
  • 2.037 IPM (51.7 mm/min)
  • Tool life = 30 parts (using four inserts)
  • Cycle time = 3.5 minutes
The Advantages
The Opening Drill paid for itself after only 60 parts. The customer also makes a number of aerospace gears from of 15-5 stainless and 4340 (ranging from 1.00" ID to 4.50" ID), and they plan to utilize the Opening Drill in these additional applications.
  • Completed the process in 1 pass
  • Eliminated 13 boring passes
  • Decreased the cost per hole from $29.62 to $7.75