The end-user is machining sub-sea petroleum manifolds using a Giddings & Lewis Boring mill, with 250 PSI water soluble coolant.
Previously the customer was using a series of boring bars and boring heads, running at the following parameters: 125 RPM, 0.003 IPR, (0,08 mm/rev) which resulted in 0.375 IPM (9,53 mm/min). The need was to bore to 3.80" (96,52 mm) diameter with finish bore bars.
Starting with a hole measuring 2.8" (71,12 mm) in diameter, the tool cut through a cross hole to a depth of 9" (228,60 mm). The tool had a cycle time of 4 hours as it had to complete 20 passes. Half the work day was consumed by this operation. Looking for performance improvements, the customer asked if Allied could provide a better solution. He recalled seeing a tool at the Allied booth while visiting IMTS: a new tool appropriately named the Opening Drill®.
Allied recommended the Opening Drill® using insert item OP05T308-1H
and holder OP3-IL-CV50. The tool ran at a speed of 150 RPM, 0. 004 IPR (0,102 mm/rev) which resulted in 0.6 IPM (15,24 mm/min). The outcome was amazing, as the cycle time was only 15 minutes as compared to the 4 hours consumed by the boring bars.
Opening Drill® helped to drastically reduce the costly machine run time resulting in the cost per hole dropping from $600.00 to $37.50, for an incredible cost savings of $562.50, or 93.7%.