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Opening Drill
Gear Blank: Opening Drill® 
Code:
6503
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The Challenge
The customer manufactures automotive gear blanks made from free machining steel using a Puma 40HP lathe with water soluble thru-tool coolant.

Tool used:  OTM core drill (2.00″ diameter)
  • Drilling the 1.50″ diameter hole
    • Hole depth = 6.0″
    • 764 RPM
    • 400 SFM
    • 0.004 IPR
    • 3.056 IPM
    • Cycle time = 2 minutes
  • Followed by several boring passes to size the hole
    • 492 RPM
    • 400 SFM
    • 0.004 IPR
    • 1.96 IPM
    • Cycle time = 3 minutes 4 seconds (per boring pass)
    • 10 passes = 31 minutes
  • Total process cycle time = 33 minutes
The customer was not pleased with this process. They needed a solution that would increase productivity, reduce cycle time, and lower their overall cost of production.
The Solution
Allied recommended the Opening Drill

Tool used:  Opening Drill (item OP2-1L-SS-1.5) set to 0.100″ smaller than the desired diameter
  • Drilling the 1.50″ diameter hole
    • 635 RPM
    • 500 SFM
    • 0.005 IPR
    • 3.18 IPM
    • Cycle time = 1 minute 53 seconds
  • Followed by ONE boring pass
    • 492 RPM
    • 400 SFM
    • 0.005 IPR
    • 2.46 IPM
    • Cycle time = 2 minute 26 seconds
  • Total cycle time = 4 minutes 19 seconds
The Advantages
The Opening Drill drastically improved the customer’s process and achieved the requested results.
  • Decreased cycle time from 33 minutes to 4 minutes
  • Increased productivity and decreased downtime
  • Significantly lowered the customer’s cost of production