KOMET has developed a new PCD drilling tool for drilling water and freeze plugs, which, thanks to its innovative chip spoilers, prevents chip build-up in components.

Engine blocks generally contain “water plugs” or “freeze plugs”, which – in the event that the coolant freezes – prevent damage to the engine. The KOMET GROUP has a specific range of tools to create the drill holes for these plugs, including a particularly efficient brand new PCD drilling tool equipped with “chip spoilers”, which are highly effective at preventing chip build-up in components. The key to this is  KOMET’s  use of additive manufacturing, which makes it possible to construct highly intricate chip spoilers with optimised, curved cooling channels.

Although the chip space on a conventional drilling tool is open to the side and the front, the chip spoiler on every cutting edge covers the groove frontally and radially. That leaves only a narrow gap of a few tenths of a millimetre between the spoiler and the cutting edge of the tool, through which any chips produced can run off. The spoiler channel then guides them reliably out of the drill hole. That’s how the new water-plug drilling tool can be used to prevent chips remaining in the drill hole. Furthermore, initial experiences in production have shown that the cost of monitoring chips remaining in components has reduced considerably.

AXIS have the right milling and drilling solutions designed for machining difficult to machine Carbon-Fiber Reinforced Plastic and Metal matrix composites.

Our CFRP cutters are optimally engineered to outperform in this application by minimizing fraying, delamination and increasing tool life AXIS CFRP cutters and drills are available in below geometries:

• Coarse Cut
• Medium Cut
• Fine Cut

AXIS milling and drilling tools available with features:

• Specially designed geometry
• Engineered Hard CVD Diamond coating
• Sharp cutting edges with optimised grinding techniques

This features offer the following benefits:

• Reduce forces, Cut clean without fibres, no delamination of layers
• Enhanced tool life
• Vibration free operation, excellent edge retention of holes and milled surfaces, less job damages

The complete tool range is made out of Tungsten carbide with micro grain which offers high wear resistance suited for edge retention and sharp cutting edges.

Here are a few tips for machining such materials :

• When the material delaminates, normally feed rate need to be reduced. In case of splintering,   use positive geometry and increase speed and feed rate
• In case where layer delaminates sometimes modified geometries are offered. This is based on   machine kinematics and conditions.
• Typical starting values should be cutting speed of 60-120m/min and feed rates of 0.02 –   0.15mm/ rev are used on such materials
•  PolyCrystalline Diamond tools (PCD) are sometimes used for higher feed and sometimes higher speeds. Only straight cutting edges are possible with such tools. CVD diamond tools have harder cutting edges and can be provided with helical and wavy edges. Tools with this type of geometry is called Gama Geometry.

Tungaloy Corporation is pleased to announce the expansion of DrillForce-Meister, a head-changeable drill series.

DrillForce-Meister is a tool series for large-diameter holemaking (drill diameter: ø26.0 – ø41.0 mm) that features two effective cutting edges for high speed and high productivity.

DrillForce-Meister’s clamping system uses a unique error-proof asymmetric seat and a screw setting, which allows easy and swift head replacement by simply loosening and tightening the screw. Since a new drill head can be mounted without removing the drill body from the spindle, a full re-setting and re-indexing process is eliminated, shortening entire tool change time. By replacing the head screw regularly, the drill body can be used for an even longer period, reducing tooling cost and inventory requirements.

The drill head is supported by a wide contact area on the seat so the drill can withstand the high cutting force generated during high-feed drilling. The insert seat is designed with precision, providing excellent repeatability and minimizing run-out.

The cutting edge is prepared to increase the coating adhesion of a highly reliable AH725 grade. The tool life has been prolonged by a smart combination of cutting edge geometry and grade property.

DrillForce-Meister will not only increase productivity but also reduce a total machining cost by shortening tool change time and eliminating regrinding cost.

Main features:

• Tool diameter: ø26.0mm – ø41.0 mm; Drilling depth: L/D = 3 and 5
• Two effective cutting edges for high productivity in a large-diameter holemaking range
• Unique clamping system for simple head replacement with excellent repeatability
• A wide support area on the seat for stable clamping in high-load machining, such as a large-diameter holemaking
• Replaceable clamping screw for extended tool life of the drill body
• Ideal flute design for both excellent chip evacuation and tool rigidity
• Long tool life due to an ideal combination of a cutting edge preparation and the reliable AH725 grade
• Cutter body: 30 items
• Head: 61 items

KOMET has developed a 6xD indexable insert high-performance drill bit that retains its stability even when working without a centring point or guide rails.

5xD is as good as it gets when it comes to the length/diameter ratio of drilling tools. Or at least, that’s what was previously thought, since larger ratios have a considerable adverse effect on stiffness; until now, stable machining operations and adequate feed rates have been mutually exclusive. But the KOMET GROUP has been hard at work, pooling its many years of experience and sophisticated development methods to come up with a new, 6xD drill bit with performance data that will not fail to impress.

The impetus for the project was provided by a customer who enquired about the possibility of a productive 6xD 33-mm drill bit for making large screw holes for bearing rings of the kind used in wind turbines, for example. Tools of this size normally have guide elements, such as a centring point or guide rails, which makes the manufacturing process significantly more complex and drives costs skywards. In the words of Dr. Michel Maes, Head of Development at the KOMET GROUP, “Although you can find cheap 6xD drilling tools on the market that do not feature guide geometries, these are generally only able to work at relatively low feed rates and are therefore not particularly productive.”

The new KOMET KUB Pentron® 6xD indexable insert drill bit has been designed to be a low-cost, high-performance alternative without guide elements, which does not compromise on productivity or process reliability – just like the successful KOMET KUB Pentron® 5xD, which the Besigheim-based drilling specialists used as the gold standard for stiffness in this latest endeavour. Development Engineer Julius Osterried explains, “Our finite element analyses concluded that the stiffness of a 6xD tool was up to 45 per cent less than that of a 5xD tool.” To counteract this, the developers had to make changes to the basic body, since both the substrate from the KOMET® KUB Pentron® and the successful Pentron W80 indexable inserts were to be retained for the new tool design.

Julius Osterried describes the next stage in the development process: “To establish the kinds of loads that would be encountered, machining tests were conducted in which forces were measured, and the results from these were compared with results achieved using simulation tools – both numerical and hybrid.” “We collaborated with other organisations such as universities, who were able to bring the latest scientific expertise to the table.” In a screening, the KOMET® developers then established which geometric characteristics have a significant influence on stiffness. Armed with these findings and their experience, they used the design of experiments (DoE) and finite element (FEM) methods to optimise the geometry of the basic body in order to achieve a stiffness that is sufficient to withstand the specific loads to which it is subjected on the lateral force plane. The development team turned promising design variants into prototypes and validated them by means of drilling tests.

The results of this testing were used to create the final design of the new, 6xD drill bit, which was then taken to the customer for field testing. The drill bit needed to prove itself for roughing operations in 42CrMo4 quenched and tempered steel. At feed rates of up to 0.12 mm/rev and cutting speeds of up to 176 m/min, the new, 6xD drill bit has done just that, achieving positive results in terms of the hole diameters it can drill, which are within the tolerance limits set out in the specifications. In addition to this, the anti-penetration cutting forces of the drill bit, chip evacuation and quality of the drilled hole fulfil the customer’s requirements.

Head of Development Dr. Michel Maes concludes, “With this kind of cutting data and the results it has achieved in testing, the new KOMET®KUB Pentron® 6xD indexable insert drill bit without additional centring point is set to be a highly productive tool for 42CrMo4V machining. It allows us to achieve tool life travel of up to 9.9 m. Not only are these figures considerably higher than comparable drill bits without guide elements, but they also demonstrate that the new tool can hold its own against its guided counterparts. Ultimately, our customers are very pleased with the outcome.”

The new KOMET KUB Pentron® 6xD indexable insert drill bit is now already in use in the field, and developers have wasted no time getting to work on additional 6xD drill bits with other diameters.

Image Credit: KOMET Group

Smart thinking has led to simple solutions for some old problems associated with indexable insert drilling. Difficulties such as chip clogging on deep holes, dissimilar rates of wear on inner and outer inserts due to differing peripheral speeds, plus flexing and wear of the drill body itself have all been resolved with a new and innovative design.

New US chipbreaker for stainless steels

The existing tried and trusted UM chip breaker and range of grades for steels, stainless and cast iron has been complemented with a new chipbreaker that has been specially designed for stainless steel applications. This new US breaker displays a varied cutting edge that features both sharp and strong geometry along its length. This combination provides the well known characteristics needed for successful cutting of stainless steels – namely those of sharpness and strength.

Different grades for inner and outer inserts

The outer insert in this type of drill naturally runs at a higher speed than the inner, thereby leading to higher levels of wear. Consequently the inner insert needs to have a higher level of stability and resistance to fracturing at lower speeds. This anomaly has been negated by using a CVD coated outer insert that has higher abrasion resistance, in tandem with a PVD coated inner insert that can cope better with fracturing forces and resistance to welding. This combination means improved reliability and fewer changes of insert for increased levels of productivity.

Interchangeable inserts with 4 cutting edges

The SOMX type inserts are interchangeable from inner to outer position, have 4 cutting edges and a unique wavy chipbreaker design for improved chip control. The peripheral edge also has a wiper type geometry for excellent hole wall accuracy and surface finishes. The inserts are also positioned in such a way that when cutting, they are both equally in contact with the workpiece, thereby reducing drill body flex to provide a more consistent performance.

Tool body

The tool body is designed with through coolant holes and an optimum sweep of the flutes that provides extra metal thickness behind the direction of the principal cutting force. This controls tool body deflection and helps to achieve reliable deep hole drilling up to 6 x D. Additionally the body surface is heat treated to prevent wear from chip evacuation. The sizes available are Ø17mm-Ø33mm and in L/D=2, 3, 4, 5 and up to L/D=6.

Pramet aims to increase the accuracy of indexable hole-making with the launch of a versatile new chip-breaker. Suitable for machining low carbon and soft stainless steels, the SD geometry supports both Pramet’s SCET and XPET ranges.

The SD (soft drilling) chip breaker has been specifically designed to provide improved stability and productivity when drilling low strength soft and long-chipping material, where the balance of forces between the inserts becomes more difficult to maintain.

Part of a wider launch of new products announced by Dormer Pramet in November 2015, the chip-breaker’s positive geometry with stabilizer provides reliable chip evacuation, minimal vibration and low cutting forces. This results in a quieter and more stable machining process.

The addition means Pramet can offer a greater choice of grades, geometries and designs of inserts for indexable hole-making.

Its existing UD (universal drilling) geometry is suitable for machining most medium and high strength steels, while grades D8345, D8330 and D9335 provide a number of options for Pramet’s 800D line of 2D-5D indexable drills.

Marcel Nunes, product manager for indexable hole-making at Dormer Pramet, said: “A key requirement for any indexable drilling task is accurate hole-tolerance and straightness. This is best achieved when the cutting forces on the inner and outer inserts are balanced.

“However, the cutting conditions for both inserts are typically very different. The outer insert cuts smoothly at maximum speed, while the inner insert has to work closer to zero cutting speed, shearing rather than cutting and enduring higher impact forces.

“When this in-balance gets too large the drill starts to move, deflecting it off course. This results in greater vibration and poor-hole quality, unreliable chip evacuation and reduced tool life.

“When machining low strength soft and long-chipping steel and stainless steel the balance of forces becomes even more difficult to maintain. Our new SD chip breaker has been specifically designed to provide better stability and productivity when drilling these materials.””

An overview of all the new indexable ranges launched by Dormer Pramet in November 2015 is available in its latest product brochure. To order a printed copy or for more information contact your local Dormer Pramet sales office.

The new Supreme tool from Walter, the DC170 Supreme for steel and cast iron workpieces, is more than just another high-performance tool.

Thanks to its revolutionary design and new features, this high-end drill is in a performance class, which has never before been achieved and boasts the very latest high-end technology. It is the characteristic lands in particular which make this tool stand out from the rest, both visually and in terms of technology. The flat grooves guide the coolant that is released at the tip around the drill, ensuring 360-degree cooling. This allows the circulating coolant to control the machining temperature.

The radial lands on the tip are a new feature never before seen on a solid carbide drill. These continuously guide the tool, reduce vibration to a minimum and keep the tool exactly on course. Furthermore, its unique design means that more solid carbide mass confronts the cutting forces than on a normal solid carbide drill. This makes the DC170 Supreme tougher, which is particularly important when drilling inclined hole exits or cross holes. In short: All these new features ensure excellent process reliability and outstanding tool life, even with the highest of cutting data. In addition to the currently available drill lengths of 16xD and 20xD, customers can now also choose from the shorter dimensions of 3xD, 5xD, 8xD and 12xD. Custom-made versions can also be supplied via the Walter Xpress Service for rapidly available special tools.​

Xtra·tec B401x point drills are high-performance tools for drilling applications. They are equipped with Color Select P600x indexable inserts, which are suitable for use with a variety of materials.

The unique range of colours used for their coatings was developed by Walter experts and are based on the colours used to designate ISO material groups. They immediately show users which cutting material grade for which application they have in their hands. The colour also acts as a wear indicator. The red Color Select grade WKK45C will soon be available for cast iron workpieces.

The substrate, its coating and geometry have been developed to suit the typical properties of cast iron: Brittle, irregular structure, inclusions and crusty surfaces. These properties place a great deal of strain on the cutting edges, which means that temperatures also increase very quickly while machining. The new WKK45C cutting tool material has a multilayer PVD coating which counteracts this: It consists of a combination of highly wear-resistant layers and supporting layers that give the material its toughness. ​​

The relationship between hardness and toughness is therefore optimal for working on ISO K materials; cracks are prevented from forming and spreading. The structure of the coating is thicker than that of standard single-layer coatings, which gives it exceptional heat shielding characteristics. The result is a considerably higher level of productivity and process reliability when drilling in ISO K materials.

Tungaloy Corporation is pleased to introduce TungDrillTri, the new series of indexable gundrills.

Deep hole drilling is one of the most difficult operations and tends to be a bottleneck for many manufacturers. In most cases, brazed gundrills and solid drills are used; however, there are some problems to be solved.

Brazed gundrills are difficult to improve its machining efficiency. Those tools are usually made of cemented carbide with no coating, and, thus, not applicable for high-speed cutting. To increase the feed rate is also very much limited as the operation is performed by a single cutting edge.

As for solid drills, although higher feed can be applied compared to gundrills, hole deflection and tool damages due to poor chip evacuation may occur. Plus, both brazed gundrills and solid drills put a huge burden on customers, such as the cost for regrinding and the management of spare tools.

TungDrillTri is the innovative indexable gundrills to solve these problems. The series provides the same circularity, straightness, and surface finish as brazed gundrills because of the optimized positioning of the insert and two guide pads. The insert has the chip splitters. By splitting the chips, the cutting force is reduced, allowing the feed to be increased more than gundrills. The chips created by TungDrillTri are smaller than those by gundrills and solid drills, resulting in more stable chip evacuation. In addition, the coated inserts and guide pads enable high-speed cutting, where the conventional brazed gundrills were not feasible.

TungDrillTri contributes to highly efficient operation while maintaining stability and provides easy tool management due to indexable insert system, which helps increase the productivity and reduce the cost in deep hole drilling.

Productive drilling into solid material now also for drilling depths of 2xD

The extended product range of the high-performance MaxiDrill 900 now also includes tools suited for drilling depths of 2xD to 5xD in the diameter range 14 to 63 mm, thus covering all common specifications.

The CERATIZIT MaxiDrill 900 system is one of the best-performing Systems available in the market when it comes to drilling into solid material. The special design allows for high feed rates, increasing the metal removal rates up to 30 %. Process security in drilling is also guaranteed at higher cutting values and under difficult conditions thanks to the stable construction. Moreover, the asymmetric chip flute design ensures ideal chip evacuation.

The specially optimised grade CTPP430 is ideally suited to a variety of drilling applications and materials, thus making MaxiDrill 900 a specialist for a wide application spectrum.

Furthermore, the drill stands out for its ease of handling. The peripheral and central cutting edge of the insert have the same geometry, size and grade