Increased Holemkaing Productivity

Product catalog summary

Introduction
Recent advancements in materials, geometries, and coatings are significantly enhancing the efficiency of holemaking processes, particularly in aerospace and automotive manufacturing. These improvements are essential for achieving cost-effective and precise drilling operations.

Materials and Technologies

Carbide Drills: Kennametal's DynaPoint drills feature a low-thrust cutting geometry, reducing stress and improving chip flow in hard-to-machine metals like Inconel and titanium alloys. These drills offer a 20% lower thrust, minimizing thermal reactions and enhancing accuracy.
PCD-Tipped Drills: Designed for high-silicon aluminums, Kennametal's PCD-tipped DynaPoint drills provide full production capabilities and reduce wear.
Indexable Drills: Carboloy's CrownLoc drills offer precision with replaceable crowns, ensuring rigidity and repeatability.

Productivity Enhancements

Coolant-Through Drills: Iscar's ChamDrill Jet introduces coolant through the drill insert, improving tool life and sidewall finishes by effectively managing heat.
Shrink-Fit Toolholders: Bilz's ThermoGrip toolholders provide precise toolholding, enhancing accuracy and tool life, particularly in high-speed aerospace and automotive applications.

Advanced Boring and Tapping

Precision Boring: KPT Kaiser's Full Bore boring head toolkit offers precision and rigidity for high-precision boring without extensive tooling investments.
Automated Bore-Size Control: Komet's KomTronic systems automate bore-size adjustments, reducing scrap and enhancing precision in automotive applications.
Threaded Holes: Accurate drilling is critical for quality threading, especially in aerospace applications where precision is paramount.

Conclusion
Advancements in holemaking technologies are driving productivity and precision in manufacturing, with significant implications for aerospace and automotive industries. These innovations are reducing costs, improving accuracy, and enhancing overall manufacturing efficiency.

Introduction to Threadmills
Emuge has introduced a new generation of solid carbide Aero threadmills designed for aerospace manufacturers. These tools are capable of producing internal 'J' series threads in challenging aerospace materials such as Inconel 718, titanium, and stainless steels, meeting the MIL-S-8879 specification requirements.

Specifications
The threadmills are made from select micrograin carbide with multiple spiral flutes and a profile-corrected micro-geometry. They feature an axial internal coolant supply for efficient chip removal and a PVD TiCN coating for enhanced edge wear and thermal stability. These tools can machine materials up to RC58.

Challenges in Aerospace Manufacturing
Aerospace materials often present machining challenges due to their squeezing characteristics, leading to tool breakage and reduced tool life. Companies like Boeing, Pratt & Whitney, Rolls-Royce, and General Electric are increasingly outsourcing chip capabilities, placing subcontractors under pressure to maintain high-quality standards while managing tight margins.

Importance of J-Series Threads
J-series threads are critical in aerospace applications, particularly in engine components that must withstand fatigue and heat stress. These threads are essential for safety in aircraft engines, airframes, and space vehicles.

Additional Information
For more details on holemaking equipment, readers are directed to specific companies such as Bilz Tool Co. Inc., Carboloy Inc., Emuge Corp., and others listed with their respective service card numbers.

Catalog excerpts

www.sme.org/ manufacturingengineering ? March 2003 >

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Holemaking cy, adds Chet Parzick, Kennametal product manager, inorder to avoid damaging the part when drilling work-pieces that can cost between $35,000$200,000. ֓In this industry, youre talking about jet engines spinning at high speed, and itҒs been pretty well accepted that componentfailure starts at a hole, notes Parzick. ԓA hole is consid-ered abusive machining in this industry, so the drill has tobe able to cut the material away very freely. Consistency in tool life means drill suppliers get a high-ly predictable number of holes for any particular applica-tion. ԓIf youre trying to get 18...

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Holemaking PCD going all the way across, you have full production.You dont experience the usual wear, and you can run thedrill longer.ҔKennametal also plans to introduce at WESTEC anenhancement to its KSEM modular drills, which will add achamfering collar or ring to the replaceable carbide-tippeddrills. The chamfer collar will slide over the drill's steelbody, enabling users to save cycle time. Coolant-through drills helpreduce the tremendous heat gener-ated in drilling operations. Lastyear at IMTS, Iscar Metals Inc.(Arlington, TX) introduced a new ChamDrill Jet coolant-throughdrill that passes...

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Holemaking insert which, to the best of my knowl-edge, is the first time anybodys donethat on a drilling insert.ғDue to the fact that the coolantscoming right into the end of the car-bide itself, all indications are that itҒsgiving us much better tool life, headds. ԓIts getting coolant right down to the cutting edge, and weҒre also seeing much better sidewall finishes because were able to flush chips outmuch more effectively. It also appearsto be produce something like a refrig- erating effect as the coolant goes through the carbide, so it keeps the carbide cooler when drilling materials that...

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After drilling, many other common holemaking opera-tions require boring and tapping of threaded holes, partic- ularly in aerospace and automotive. KPT Kaiser Precision Tooling Inc. (Elk Grove Village, IL) recently updated its line of boring systems with the new 112.118 Full Bore boring head toolkit for high-precision boring. Aimed at companies ranging from small shops through larger manu-facturers, the boring-head toolkits include two boringheads, two KAB shanks, insert holders, reduction bush- ings, and accessories. They offer shops precision and rigid-ity without the need to buy a large number...

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Holemaking line of smart toolingӔ mechatronicsystems, automakers can createholes that require recessing, groov- ing, or facing operations similar toturning-type operations done on amachining center, notes Bob Bied, Komet of Americas OEM product manager. KometҒs M042 boring sys- tem and P70 drive unit can helpautomakers with connecting rodboring applications.WeӒre at the point right nowwhere weve had some good break-throughs with this,Ҕ Bied says ofKomets projects on boring operationsfor flexible production with Ford Motor Co.Ғs (Dearborn, MI) Premier Automotive Group (PAG) engine pro- gram, and...

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Holemaking Coolant-through inserts on Iscars ChamDrill Jetdrills cool workpiece while enabling efficient chip evacuation. > WANT MORE INFORMATION? For more information on the holemaking equip-ment mentioned in this article, circle the numberson the reader service card. CompanyCircle Bilz Tool Co. Inc. 360 Carboloy Inc. 361 Emuge Corp. 362 Kennametal Inc. 363 Iscar Metals Inc. 364 Komet of America Inc. 365 KPT Kaiser Precision Tooling Inc. 366 Sandvik Coromant 367 > March 2003? www.sme.org/ manufacturingengineering

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Increased Holemkaing Productivity

Increased Holemkaing Productivity

Catalog excerpts

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