The customer manufactures turrets made from A36 structural steel using a Giddings & Lewis horizontal machining center MC60 with high pressure flood coolant.
Tools used:
- HSS twist drill
- Komet twin bore tool
Process:
- Hole diameter =2.1" (53.34mm)
- Hole depth = 2.5" (63.5mm)
- 100 RPM
- .010 IPR (0.25 mm/rev)
- 1.0 IPM ( 25.4 mm/min)
- Tool life = 15 holes
- Cycle time = 5 minutes
- Cost per part = $10.71
To improve production, the customer needed to reduce the cost of this drilling operation.
Allied recommended the Revolution Drill.
Tool used: Revolution Drill holder (R36X22-150L) with insert (item OP-05T308-H)
- 825 RPM
- .003 IPR (0.076mm/rev)
- 2.475 IPM (62.87 mm/min)
- Tool life = 22 holes
- Cycle time = 1 minute
- Cost per part = $4.54
The Revolution Drill accomplished the cusomer's needs by reducing cycle time and increasing tool life.
- Reduced cost per hole from $10.71 to $4.54
- Decreased cycle time by 80%
- Total cost savings = 57.6%