Valve Actuator Bodies: Revolution Drill®

Code:

6013

The Challenge

The customer manufactures valve actuator bodies for the aerospace industry. The parts are made from 316 stainless steel. They use a low thrust Mori Seiki machining center with 20 HP using water soluble coolant. Previously, the customer used a series of spade drills that failed due to Z axis overload. They then tried an Iscar plunge mill.

Looking for improvements, the customer needed to reduce the plunge mill’s high cost per hole.

The Revolution Drill® accomplished the customer’s needs by speeding up the process and reducing the overall cost of drilling.

Product:	Revolution Drill
Objective:	Decrease cost per hole
Industry:	Aerospace
Part:	Valve acuator bodies
Material:	316 Stainless steel
Hole Ø:	2.5" (63.5 mm)
Hole Depth:	12" (304.8 mm)

The Solution

The Revolution Drill

Drill holder: R42X35-150L
Drill inserts: Op-05T308-H

Measure	Competitor Plunge Mill	Revolution Drill
RPM	800	1000
Feed Rate	0.001 IPR (0.025 mm/rev) down 0.005 (0.127 mm/rev) circular	0.005 IPR (0.127 mm/rev)
Penetration Rate	0.8 IPM (20.32 mm/min)	5.0 IPM (127 mm/min)
Cycle Time	15 min	2 min 24 sec
Tool Life	8 holes	30 holes
*The Revolution Drill offered 82.51%* cost per hole savings over the competitor tooling.**

The Advantages

The Revolution Drill provided:

Reduced cycle time by 84%
Reduced cost per hole
Increased tool life