4TEX Drill
Air Cooled Heat Exchangers: 4TEX Drill 
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The Challenge

“Going to all costs” doesn’t always mean you have to spend more.

We can all agree scrapping parts is always a bad thing, but scrapping extremely expensive parts is even worse. Our customer was machining air-cooled heat exchangers that cost $15,000 each. Needless to say, they were going to all costs to make sure the parts were right the first time.

But going to all costs doesn’t mean you can’t find other ways to decrease your costs.

The high penetration drill they were using worked well, but with a $130 price tag on the replaceable insert, they wanted to reduce their drilling costs. The customer decided to test the 4TEX Indexable Carbide Drill with inserts that only cost $12 each. Using the 4TEX “M” geometry inserts - designed to produce excellent chips in ductile materials and improve tool life in heat resistant materials - our customer was thrilled with the small chips and equal hole quality.

With the previous drill, our customer achieved 30 holes of tool life before needing to replace the insert, which gave them a cost of $4.33 per hole. Utilizing the 4TEX four-sided insert design, they achieved 100 holes of tool life before replacing the inserts. This feature, along with the “M” geometry’s heat-resistant coating, gave them a cost of just $0.24 per hole.

With insert cost savings of $4 per hole (94.5%), the switch to the 4TEX Drill was a no-brainer for our customer. Just because a part is expensive doesn’t mean it also needs to cost more to machine.

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Product 4TEX Drill
Objective Decrease tooling costs
Industry Heat exchangers/tube sheets
Part Air cooled heat exchanger
Material Inconel 825 plate
Hole Ø 0.964"
Hole Depth 1.750"

The Solution
4TEX Indexable Carbide Insert Drill
  • Drill holder, 3xD length:  D3072450M-100F
  • Drill inserts, M geometry (stainless steel & high temp):  4T-070305-M
Measure Replaceable Insert Drill 4TEX Drill
RPM 396 991
Speed Rate 100 SFM 250 SFM
Feed Rate 0.010 IPR 0.003 IPR
Penetration Rate 3.96 IPM 2.97 IPM
Cycle Time 26 sec 35 sec
Tool Life 30 holes 100 holes
Insert Cost Per Hole $4.33 $0.24

The Advantages
The 4-sided indexable inserts with heat-resistant coating provided:
  • 94.5% cost per hole savings
  • Decreased tooling costs
  • Increased tool life
  • Worry-free machining