The customer manufactures weldments from A36 steel plates. Initially, the process involved flame cutting the roughed hole. The parts were then machined on a SuperMAX Machining Center utilizing flood coolant. Previously, the customer flame burned a rough hole and then experimented with the following selection of tooling.
The results and the time it took to complete the operation were unacceptable. The best results they could achieve provided a 35 minute cycle time.
The combination of the Revolution Drill® and Opening Drill® decreased the cycle time by 94%, providing the ideal solution for this application.
| Product: |
Opening Drill and Revolution Drill |
| Objective: |
Decrease cycle time |
| Industry: |
Heavy Equipment |
| Part: |
Weldments |
| Material: |
A36 steel plates |
| Hole Ø: |
4.02" (102.108mm) |
| Hole Depth: |
4" (101.6mm) thru-hole |
The Revolution Drill and the Opening Drill
- Revolution Drill holder: R42x22-150L
- Opening Drill holder: OP3-1S-1.5
| Measure |
Competitor |
Revolution Drill |
Opening Drill |
| Speed |
Previously tried:
- Twist drills
- Spade drills
- Indexable end mills
- Finish bore tools |
700 SFM (213.360 M/min) |
800 SFM (243.84 M/min) |
| Feed Rate |
0.004 IPR (0.102 mm/rev) |
0.005 IPPR (0.127 mm/rev) |
| Penetration Rate |
4.3 IPM (109.22 mm/min) |
3.8 IPM (96.520 mm/min) |
| Cycle Time |
35 min |
2 min |
| The Opening Drill offered 94.29% cost per hole savings over the competitor tooling. |
The combination of the Revolution Drill and Opening Drill provided:
- 94% cycle time decrease
- Decreased cost per hole