Revolution Drill
Die Slide: Revolution Drill® 
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The Challenge

The customer produces die slides made from 4130 Forging (390-450 Bhn) using a 30 HP CAT50 horizontal boring mill with 1000 PSI (68.948 bar) water soluble coolant.

The customer needed to improve this process. They specifically requested the Revolution Drill because they liked the diameter adjustability and the fact that every drill utilizes the same inserts.

The Revolution Drill® provided excellent chip control, and the surface finish was within a 32 RMS with a hole tolerance of .002” (0.051 mm). This was exactly what the customer needed from this process.

Product: Revolution Drill
Objective: Improve process
Industry: Aerospace
Part: Die slide
Material: 4130 forging, 390-450 Bhn
Hole Ø: 2.56" (65.025 mm)
Hole Depth: 11.00" (279.4 mm)

The Solution
The Revolution Drill
  • Drill holder: R42X35-150L
Measure Competitor Drill Revolution Drill
RPM 252 900
Feed Rate 0.002 IPR (0.051 mm/rev) 0.003 IPR (0.076 mm/rev)
Penetration Rate 1.05 IPM (26.67 mm/min) 3 IPM (76.2 mm/min)
Cycle Time 10 min 29 sec 3 min 40 sec
Tool Life 2 holes 8 holes
The Revolution Drill offered 83.33% cost per hole savings over the competitor tooling.

The Advantages
The Revolution Drill provided:
  • Reduced cycle time by 65%
  • Decreased cost per hole
  • Increased tool life
  • Excellent chip control