Opening Drill
Opening Drill
Weldments: Opening Drill® / Revolution Drill® 
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The Challenge

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 Solution
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 Advantages
The combination of the Revolution Drill and Opening Drill provided: 
  • 94% cycle time decrease
  • Decreased cost per hole