Gear Blank: Opening Drill®

Code:

6503

The Challenge

The customer manufactures automotive gear blanks made from free machining steel using a Puma 40HP lathe with water soluble thru-tool coolant.

The customer was not pleased with this process. They needed a solution that would increase productivity, reduce cycle time, and lower their overall cost of production.

The Opening Drill® drastically improved the customer’s process and achieved the requested results with only one boring pass.

Product:	Opening Drill
Objective:	Decrease cycle time
Industry:	Automotive
Part:	Gear blank
Material:	Free machining steel
Hole Ø:	1.50" (38.1mm)
Hole Depth:	6.00" (152.4mm)

The Solution

The Opening Drill

Drill holder: OP2-1L-SS-1.5

Measure	Competitor Drill	Competitor 10 Boring Passes	Opening Drill with 1 Boring Pass
RPM	764	492	635
Speed	400 SFM (121.92 M/min)	400 SFM (121.92 M/min)	500 SFM (152.4 M/min)
Feed Rate	0.004 IPR (0.102 mm/rev)	0.004 IPR (0.102 mm/rev)	0.005 IPR (0.127 mm/rev)
Penetration Rate	3.056 IPM (77.622 mm/min)	1.96 IPM (49.784 mm/min)	3.18 IPM (80.772 mm/min)
Cycle Time	33 min		4 min 19 sec

The Advantages

The Opening Drill provided:

87% cycle time decrease
Decreased downtime
Decreased costs