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Revolution Drill
Valve Actuator Bodies: Revolution Drill® 
Code:
6013
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The Challenge
The customer manufactures valve actuator bodies for the aerospace industry. The parts are made from 316 stainless steel. They use a low thrust Mori Seiki machining center with 20 HP using water soluble coolant. Previously, the customer used a series of spade drills that failed due to Z axis overload. They then tried an Iscar plunge mill.

Tool used: Iscar plunge mill
  • Hole diameter = 2.5" (63.5mm)
  • Hole depth = 12" (304.8mm)
  • 800 RPM
  • .001 IPR down (0.025 mm/rev)
  • .005 IPR circular (0.13 mm/rev)
  • 0.8 IPM (20.32 mm/min)
  • Cycle time = 15 minutes
  • Tool life = 8 holes
  • Cost per hole = $21.21
Looking for improvements, the customer needed to reduce the plunge mill's high cost per hole.
The Solution
Allied recommended using the Revolution Drill.

Tool used: Revolution Drill holder (R42X35-150L) and inserts (item OP-05T308-H)
  • 1000 RPM
  • .005 IPR (0.13 mm/rev)
  • 5 IPM (127 mm/min)
  • Cycle time = 2.4 minutes
  • Tool life = 30 holes
  • Cost per hole = $3.71
The Advantages
The Revolution Drill accomplished the customer’s needs by speeding up the process and reducing the overall cost of drilling.
  • Reduced cycle time by 84%
  • Reduced cost per hole from $21.21 to $3.71
  • Total cost savings (per 500 parts) = $8,747.96 or 82.49%