The end-user is manufacturing turbine components made out of chrome moly alloy steel using a Super 8 Vertical Machining Center, with water soluble coolant.
Previously the customer was using a series of Kennametal Boring Bars running at the following parameters: 500 RPM, 0.005 IPR (0,127 mm/rev), which resulted in 2.5 IPM (63,5 mm/min). The tool drilled a 3.5" (88,9 mm) diameter thru hole to an 8" (203.2 mm) depth. The tools had a cycle time of 2 hours, 59 minutes and a life of 14 holes. The boring bar machining process was just moving too slowly. Looking for improvements, the customer wanted to reduce cycle time on a part that was scheduled for quick delivery.
Allied recommended the Opening Drill, using insert item OP-05T308-H and holder OP3-1L-BT50. The tooling ran the same speed of 500 RPM, 0.005 IPR (0,127 mm/rev), which resulted in 2.5 IPM (63,5 mm/min). The outcome was excellent as an equal number of 14 holes were machined, but in half the time, lowering the cost to the customer.
In addition to allowing for fast completion of the turbine components, the Opening Drill factored in at a lower cost per hole as the cost was reduced from $30.89 to $18.25 per hole, for a savings of 41%. The Opening Drill met the customer’s requirements by reducing the cycle time from almost three hours to 1 hour and 29.6 minutes, for a significant and impressive time savings of 50%.