The end-user is manufacturing fittings for Fluid Transfer Lines made out of 304 Stainless Steel, using an Okuma Lathe, with Synthetic Coolant, at 75 PSI.
Previously the customer was using a Kennametal IC drill running at the following parameters: 1400 RPM, .003 IPR (0.08 mm/rev), which resulted in 4.2 IPM (106.7 mm/min). The tool drilled a 5.0" diameter hole to a depth of 9.5". The tools had a cycle time of 43 minutes and a life of 5 holes. Looking for improvements, the customer wanted to speed up the hole-making process. After the drilling was done, the customer used several boring bars to complete the job. The cost of the finished hole using the Kennametal tooling netted to an enormous $936.13 per hole.
Allied recommended the Revolution Drill to make the hole, and the Opening Drill to enlarge it to the proper size. Using an OP4-1L-SS2.0 and R46X35-150L, the tooling ran at a speed of 306 RPM, .0045 IPR (0.11 mm/rev) which resulted in 1.377 IPM (35 mm/min). The outcome was excellent and met the customer’s goals of speeding up the hole-making process. The combination of the Revolution and Opening drills were able to produce 8 quality holes, 3 more than Kennametal, but the real success was the cycle time. What previously took 43 minutes was now reduced to just 14 minutes, the significant time savings that the customer was looking for. The cost per hole provided by Allied’s Rev and OP drills netted down to $130.02, far below the $936.13 per hole offered by the competitor’s drills.
By reducing the cycle time, Allied also greatly reduced the cost per hole. The end-user saved over $800 per hole, for an astounding cost savings of 86%.