The customer is machining aerospace landing gear made from 4340 alloy steel using a LeBlond Heavy Duty Lathe with 60 GPM of oil.
Tools used: A special Sandvik ejector drill to rough a form at the bottom of the hole, followed by another BTA head to finish the form (priced at $5,000 per head)
- Hole diameter = 2.050" (52.07mm)
- Hole depth = 11.00" (279.4mm)
- 500 RPM
- 0.003 IPR (0.08 mm/rev)
- 1.5 IPM (38.1 mm/min)
- Cycle time = 15 minutes
- Tool life = 2 holes
The customer needed to improve the process and reduce cost. They asked Allied for a durable solution at a lower price.
Allied recommended the BT-A Drill.
Tool used: BT-A Drill head with #4 series special Super Cobalt T-A® form insert
- 125 RPM
- 0.006 IPR (0.15 mm/rev)
- 0.75 IPM (19.05 mm/min)
- Cycle time = 1 minute 20 seconds
- Tool life = 43 holes (per insert)
The BT-A Drill completed 43 pieces against Sandvik’s disappointing 2 pieces. The BT-A Drill cost was justified after only 15 parts.
- Eliminated 2 hours of set-up time
- Eliminated 30 minutes of deburring time
- Combined the rough & finish process into one tool
- Decreased finish by 125 Ra
- Achieved a tighter tolerance on the 2.050" diameter
- Decreased cost per hole from $5136.00 to $7.89
- Total cost savings = 99.85%