HOLEMAKING

SELECTION & APPLICATION -

DRILLING

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,10mm

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 DRILL
40%
BORE REAM
10% 5%

MILL
COUNTERSINK 9% TAP
21% 13%

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 Chisel Effects

The chisel edge deforms material; cutting does not usually

start until “lips” engage.

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 Chip Formation
Mid cutting lip

End of
chisel edge
start of
cutting lip

Mid chisel
edge

Drill center

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6
Accuracy for Drilling on Turning Machines
> 0.008”
Vertical Adjustment Clamping
Chuck
± 0 mm

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 Rules for Spot Drilling
•3XD No spot needed
• 5 X D May need to spot
• 7, 8 & 10 X D Must spot

140o 140o

Spot = 30-50% of drill Spot = 100% of drill Center Cutting Endmill

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Rules for Spot Drilling
Use same size blade to Metric Spot Blades
spot and drill
inch or metric

140o
☺ 150o
☺
Spot = 70% of drill O Spot = 70% of drill O

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Options in Drill Selection

• Geometry
Point Design: Chisel, “S” Point, Gun Drill, Point Angles,
Direction of forces, Multi Angles
Web Design
Flute Design
Helix Angles
• Categories
Twist Drill
Replaceable Tipped
Indexable Carbide
Gun Drill

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 economic solutions for hole making

2,00

1,80 costs per hole

machine mach. center
time for tool change (s) 10 seconds 1,60
machine cost per hour (DM/h) 200dm
holes per workpiece 6 1,40
workpiece material C45
1,20

1,00

0,80

0,60

HSSE+TiN
6*18 = Diameter / Depth 0,40
SC-Drill
0,20
indexable

0,00
6*18 12*36 16*48 20*60 24*72

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Features of Conventional
HSS Drilling
☺Low Cost
☺Easy Set-up
☺Easily Maintained

Longest Cycle Time

Pecking Cycle Required
Poor Chip Control

• Basic Quality Holes

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Features of High Performance
Carbide Drilling
Advantages:
☺Reduces cycle times

☺Good chip control

☺High quality parts

☺Eliminates operations

• Specialist regrind

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You buy high performance drills.
So …….
What can you expect?

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 Cost per a hole !!!!!
For eg.: Dia 10 SE drill (High Performance Drill)
Material: Steel

Normal Solid Carbide Drill

500 - 600 HOLES with Rs.1800 - Rs.2000 DRILL = 3.6 PER HOLE

High Performance Drill

1500 HOLES with Rs.3800 DRILL = 2.5 PER HOLE

less 3 tool changes = ?

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Characteristics

• With / With-Out coolant

• Carbide substrate is
matched to material being
cut
• Margin design
• Lightly Honed
• Corner chamfer reduces
exit burr

chamfer
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 Chamfer
Material cross
section (20
degree) at
exit is too thin
to be cut. 90° point or a 130 ° point with
Material is a 90° corner- chamfer
pushed out
forming an decreases exit break out / burring
exit burr.

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Four Margin Design
The four margins help the drill stay straight
through interrupted cuts, cross holes, deep
holes, and irregular (angles, radii) surface on
exit.

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What are your surface finish
requirements?

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 Drill Hole Quality
HSS Twist Drill Solid Carbide SE Drill

.020mm .004mm

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 The Straight Flute Drill
Four Margins

• Ultra Precision
Applications
• Two Cutting Edges
• Two Guide Margins
• Excellent Surface Finish
• Complex Forms
• PCD Diamond
• Aluminum & Gray Iron Ø range 3 - 25 mm
• All custom made Ø range 1/8” - 1”

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 Point Style

TX SE TF

Centering Ability +

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 Flute Profile
OLD
KSEC
Patented High
Performance SE KSE

New:
•Flute Design
•TiAlN Coating
•Flute Polish

+ Chip Evacuation

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 Core Thickness
Short & Regular Long All TX, and
Length SE Length SE 4-Margin SE(SE256)

Tapered to Parallel Constant Parallel

to Tapered Taper
+ + Strength
Point Bulk Strength +
Chip Evacuation

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Troubleshooting
Excess wear on corners
1. Cutting speed too high
2. Material too abrasive for carbide grade
3. Coolant too weak
4. Drill run out
Excess wear on cutting edge
1. Cutting speed too high
2. Feed too low
3. Carbide grade too soft
4. Insufficient coolant

Build up on cutting edge

1. Cutting speed too low
2. Coating not smooth enough
3. Negative land on cutting edge
4. Not enough heat in cut 25
Chipping on corners
1.Workpiece movement at entry
2. Clamping chuck not rigid
3. Carbide grade too hard
4. Insufficient coolant
5. Drill run out

Chipping on margin lands

Workpiece movement at exit;

☺
Chipping on cutting edge
1. Cutting conditions
2. Maximum allowed wear exceeded
3. Wrong drill
4. Clamping chuck not rigid
5. Carbide grade too hard 26
WHY?

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 The Right Combination
Point
Style
Point
Angle

Margins

Edge
prep

Flute

HOLDER
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 Features of Insert Drilling

Advantages:
☺Low maintenance

☺Good chip control

☺Can reduce overall cycle times

☺High metal removal rates

☺Change in cutting edge possible

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Action!

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 The “SSF” or
round shank
w/ EZ entry
Drill dia.
Margins for marked
Rear pipe
chip evacuation
thread for
Coolant

Five geometries
Four grades Complete part
number

Side access
for
Large face ground
No Coolant
flange for
exposed stability
hardware
7, 8 10 X D
Polished flutes

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Web Gashed Web Swept

Stepped Edge Smooth Edge

Chips Flow Chips Flow Easy
Hindered
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KSEM in AISI 1045 Steel

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 Exit Disk

1400
1045 RPM
steel
231
SFM
.013 IPR

16 MM

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 Chip Breaking Action =
Savings
OLD TECHNOLOGY NEW

• EMPTY LESS FREQUENTLY

• LESS OPERATOR LACERATIONS

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Drills With Carbide Inserts

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 Features of Indexable
Carbide Insert Drilling

Advantages:
☺ Low maintenance
☺ High metal removal rates
☺ Can reduce overall cycle times
☺ Change in cutting edge possible
☺ Good chip control
☺ Can off-set and bore the hole on a lathe

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Geometries for Drilling Inserts

" HD " " GD " " MD " " -LD "

short chipping long chipping

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Engineered for peak performance

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Carbide Insert Drilling

Two different grades!

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X-Offset Capability

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 X-Offset Capability

X Adjustment Tapered hole

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 Setup check

A B

Look for
center nib ☺ C D
“A” width = “B” width
“C” width = “D” width
☺
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Carbide Insert Drilling

DEEP HOLE DRILLING

Deep Holes
Big, Deep Holes
.750” to 1.750” / 5x LTD
1.77” to10.63” / 8x LTD
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 HTS-C / HTS
• HTS-C is a complete
assembly

• HTS is made up of

HTS
components
– Outer Cartridge can be
shortened to effect a change in
the overall hole diameter.
– Extensions and reducers allow
for customizing the drill.

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Application Hints

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 Application Hints
Through Hole Drilling
Drill can become unstable once
pilot breaks through Use sacrificial piece of material

Be sure to program feed stop just before the

disk breaks off the work to prevent damage to
the inserts and drill body

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 Application Hints

☺
As pilot drill breaks through, reduce feed by 50%

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 Application hints

☺
Specials can be designed with wear
strips for cross hole drilling
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 Multi Operation Tools
• Saves tool positions in the tool changer
• Insures true position between C’bore and
hole.

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 KSEM Chamfering Ring

Advantages:
* 2 cutting edges per insert
* drilling feed = chamfering feed
* cartridges are applicable on different Ø
* cartridges are exchangeable in case of defect
* clamping of the ring via. clamping shoes protect drill
body and transmit the radial cutting forces properly
* for deburring (<0,5x45mm°) use of just 1 cartridge possible

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 KSEM Chamfering Ring:
Design & Components
Ring Body
Clamping shoe
Screw on Insert

Clamping Screw
Cartridge
Wedge

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 “Ken-Tip” Modular Drill

KenTIP Step-Drills

For application with limited

space in machining room.

KenTIP and SEFAS

SEFAS Tools allow drilling and chamfering

in one operation

Special insert geometry for this combination is available

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 Multi - Operation Tools
Fixed

Advantages:
☺Reduces cycle time
☺Reduces set - up time
☺Increases tool changer capacity

Higher tool cost

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Step Drills

• One shot drill and

chamfer
– Sized for both inch and
metric threads
– 45 degree chamfer

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 Combination Tools
Adjustable
Extend Application Range of Standard Carbide Drills

• Lower machining cycle times

• Replace special drills

• Increase production capacity

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Standard Chamfer Inserts

45° Chamfer

45° Full Chamfer

30° Chamfer

Semi Finished Insert

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 KSEM drill 1xD & 45° Chamfer
FAS

Advantages:

* 3 cutting edges per insert 45°

* drilling feed = chamfering feed
* First choice application for holes =/> 7xD
and will substitute KSEM 1xD stub drills
* Standard tool for short through holes+chamfer
* Short design provides good surface quality
* Fast Lane capability for specific length requirements
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Tubular Exchanger Manufacturing Association

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 The Tubesheet
• Average thickness: 2-3”
• 2000-3000 holes with + .002 tolerance
• Materials: 516-70, aluminum, brass, 300 series SS
and low carbon steel w / hastalloy overlay

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 The Baffles
• Usually stacked, welded and drilled as one
unit
• .010-.020” larger than tube sheet holes
• Relatively loose tolerance
• Difficult to drill due to gaps between plates

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