The end-user is machining valve bodies made from A36 using a Femco horizontal machining center, with semi-synthetic through-tool coolant.
Previously the customer was using a Metcut drill running at the following parameters: 525 RPM, 0.003 IPR, (0,08 mm/rev) which resulted in 1.58 IPM (40,13 mm/min). The tool drilled a through-hole diameter of 3 5/8" (92,08 mm) to a depth of 8.25 inches (209,55 mm). The tool had a cycle time of 5 minutes, 13 seconds and a tool life of 32 holes.
Looking for performance and cycle time improvements, the customer asked about the Revolution Drill® offered by Allied.
Allied recommended testing the Revolution Drill® in this application, using insert item number OP-05T308-H. The tool ran at a speed of 850 RPM, 0.003 IPR (0,08 mm/rev) which resulted in 2.55 IPM (64,77 mm/min). The Revolution Drill® delivered a cycle time of 3 minutes and 13 seconds, and a tool life of 48 holes.
Revolution Drill® helped to reduce the costly machine run time by reducing the cycle time by 38%! This improvement resulted in the cost per hole dropping from $9.62 to $7.51, for a cost savings of 22%.