The end-user is manufacturing valve actuator bodies for the Aerospace industry made out of 316 stainless steel using a low thrust Mori Seiki machining center, with 20 Horse Power, using water soluble coolant.
Previously the customer was using a series of spade drills, which failed due to Z axis overload. They then tried an Iscar plunge mill which worked, but was very slow and costly. This drill ran at the following parameters: 800 RPM, .001 IPR, down (0.025 mm/rev), and .005 IPR, circular (0.13 mm/rev), which resulted in 0.8 IPM (20,32 mm/min). The tool drilled a 2.5" (63,5 mm) diameter hole to a 12" (304,8 mm) depth. Eight of the holes were blind, four were through. The tool had a cycle time of 15 minutes and a tool life of 8 holes. Looking for improvements, the customer wanted to reduce the high cost of hole-making caused by
Allied recommended using the Revolution Drill with insert item OP-05T308-H and holder R42X35-150L. The tooling ran at a speed of 1000 RPM, .005 IPR (0,13 mm/rev), which resulted in 5 IPM (127 mm/min). With the Revolution Drill, the cycle time dropped sharply from 15 minutes to only 2.4 minutes, plus the tool life almost quadrupled from 8 to 30 holes. The outcome was quite favorable as the Revolution Drill met thThe the customer’s goals of speeding up the process and reducing the overall cost of drilling.
The cost per hole was reduced from $21.21 to $3.71, which, when extended out over a 500 piece run, saved the customer $8,747.96, or a very impressive dollar savings of 82.49%.