The customer manufactures aerospace gears made from 4340 (28 Rc) using a Mazak Lathe with oil-based water soluble coolant.
Tool used: Sandvik boring bar
- Pre-existing diameter = 2.125" (53.9mm)
- Enlarged diameter = 3.75" (95.3mm)
- Hole depth = 7.00" ( 177.8mm)
- 400 RPM
- 0.012 IPR (0.30 mm/rev)
- 4.8 IPM (122 mm/min)
- Passes required = 13
- Tool life = 30 parts
- Cycle time = 19 minutes
The customer realized this process was not optimal, and they contacted Allied for a solution.
Allied recommended the Opening Drill.
Tool used: Opening Drill (item OP3-1L-SS1.5)
- 509 RPM
- 0.004 IPR (0.10 mm/rev)
- 2.037 IPM (51.7 mm/min)
- Tool life = 30 parts (using four inserts)
- Cycle time = 3.5 minutes
The Opening Drill paid for itself after only 60 parts. The customer also makes a number of aerospace gears from of 15-5 stainless and 4340 (ranging from 1.00" ID to 4.50" ID), and they plan to utilize the Opening Drill in these additional applications.
- Completed the process in 1 pass
- Eliminated 13 boring passes
- Decreased the cost per hole from $29.62 to $7.75