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Revolution Drill
Die Slide: Revolution Drill® 
Code:
6002
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The Challenge
The customer produces die slides made from 4130 Forging (390-450 Bhn) using a 30 HP CAT50 horizontal boring mill with 1000 PSI water soluble coolant.

Tool used:  Komet Kub drill
  • Hole diameter = 2.56" (65.02mm)
  • Hole depth = 11.00" (279.40mm)
  • 525 RPM
  • 0.002 IPR (0.05 mm/rev)
  • 1.05 IPM (26.67 mm/min
  • Cycle time = 10 minutes 29 seconds
  • Tool life = 2 holes
The customer needed to improve this process. They specifically requested the Revolution Drill because they liked the diameter adjustability and the fact that every drill utilizes the same inserts.
The Solution
Allied provided the Revolution Drill.

Tool used:  Revolution Drill (item R42X35-150L)
  • 900 RPM
  • 0.003 IPR (0.08 mm/rev)
  • 3 IPM (76.2 mm/min)
  • Cycle time = 3 minutes 40 seconds
  • Tool life = 8 holes
The Advantages
The Revolution Drill provided excellent chip control, and the surface finish was within a 32 RMS with a hole tolerance of .002". This was exactly what the customer needed from this process.
  • Reduced cycle time by 65%
  • Decreased cost per hole from $31.50 to $5.25
  • Total cost savings = 84%