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Revolution Drill
Gear Blanks: Revolution Drill® 
Code:
6003
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The Challenge
The customer machines gear blanks made from 4140 (40 Rc) using an OKUMA OSP 5000 horizontal mill with flood coolant.

 Tool used:  Mitsubishi high feed mill
  • Hole diameter = 2.47" (62.74mm)
  • Hole depth = 1.60" (40.6mm)
  • 1000 RPM
  • 0.060 IPR (15.2 mm/rev)
  • 60 IPM (1524 mm/min)
  • Cycle time = 3.5 minutes
  • Tool life = 16 holes (per edge)
The customer needed to improve cycle time and asked Allied for a more effective solution.
The Solution
Allied recommended the Revolution Drill.

Tool used:  Revolution Drill holder (R42X22-CV50) with insert (item OP-05T308-H)
  • 395 RPM
  • 0.006 IPR (0.15 mm/rev)
  • 2.3 IPM (58.40 mm/min)
  • Cycle time = 50 seconds
  • Tool life = 48 holes (per edge)
The Advantages
The Revolution Drill significantly improved the customer’s process. The cycle time decreased while the tool life increased, providing a lower cost-per-hole for the customer.
  • Decreased cycle time from 3.5 minutes to 50 seconds (76%)
  • Increased tool life by 20%
  • Lowered the cost-per-hole from $5.39 to $1.24
  • Overall cost savings = 77%