The end-user is machining gear blanks made from 4140, 40 Rc, using an OKUMA OSP 5000 Horizontal Mill, with flood coolant
Previously the customer was using a Mitsubishi High Feed Mill, running at the following parameters: 1000 RPM, 0.060 IPR, (15,2 mm/rev) which resulted in 60 IPM (1524 mm/min). The tool helically interpolated a 2.47" (62,74 mm) diameter thru hole to a thickness of 1.60" inches (40,6 mm). The tool had a cycle time of 3.5 minutes and a tool life of 16 holes per edge.
Looking for improvements in cycle time, the customer asked if Allied could provide the solution.
Allied recommended the Revolution Drill® using insert item OP-05T308-H in holder R42X22-CV50. The tooling ran at a speed of 395 RPM, 0.006 IPR (0,15 mm/rev) which resulted in 2.3 IPM (58,40 mm/min). The tool had a cycle time of 50 seconds and a tool life of 48 holes per edge. The outcome met the customer’s goals of tool performance improvements.
Revolution Drill® made a significant difference for the customer as the cycle time was reduced from 3.5 minutes to just 50 seconds. This significant time savings reduced the cost per hole from $5.39 to $1.24, for a considerable cost savings of 77%.