All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopy, recording or any information storage and retrieval system, without permission in writing from the publisher.This handbook has been carefully prepared and translated.Flowdrill does not accept any responsibility for errors in the handbook and any consequences resultant therefrom. No guarantee can be given that the details are free from patent rights assigned to third parties. All data and comparative details should be understood as being indicative...

The Flowdrill > System > 3 Toolholder with Nut, Spanner and "C" Spanner-FDMC2 -FDMC3Collets-Fd 430e 6 up till 14 -Fd 470e 12 up till 20 -Rubber flex colletsFlowdrills and Flowtaps -Standard (see cover at the back) -SpecialsLubricants and Miscellaneous size="-3">

(a)No swarf(b)Long tool life (c)Accurate hole formMuch experience has been gained in theautomobile, gas-heating, metal furniture, lighting and household appliance indus-tries, etc.Although the process itself has beenapplied for some time, it is necessary for the user to understand the nature of the Flowdrill process, the various types of Flowdrills and the physical requirements of the drilling machine for best results. for any column drilling machineAutomatic Turret drilling Head suitable >

The standard Flowdrill design is shown in figure 3. Its working portion consists of a pointed end, a cone and a parallel body. Both the cone and the body are polygon shaped. This specially designed shape plays an essential part in the Flowdrill process. The Flowdrill also has a collar and a straight shank. Flowdrills are made of a carbide grade developed to satisfy the unique charac- teristics of the Flowdrill operation. > -Develops heat rapidly in Flowdrill creating thermal stress.-Increases feed rate - reduces drillingtime.-May alter the physical properties ofworkpiece material. Relatively...

Material thickness (h)Flowdrill dia. Speed (n) Drilling time1. 5 sec. 2.0 sec. FlowdrillTemperature 2.0 mm1750 min-12.0 mm3 000 min- 1 700 C600 ں C7.3mm 7.3mm >

Maximum material thickness (h.Max) isproportional to the Flowdrill diameter. Minimum thickness follows the general rule: h Min = approx. 0.2 x D 1 up to 2mm, which rule is suitable for most of the bigger sizes. D1 is the Flowdrill diameter.Flowdrill life is reduced if used on heavier gauge material or materials with high tensile strength.Notes: Fig. 6 indicates maximum materialthickness that can be Flowdrilled with standard long or short Flowdrills. See also table in chapter 16.0 Special Flowdrills can be supplied to meet unusual needs. For greater thickness an extra long L 5 may be necessary....

The long Flowdrill has a long parallel body (L5)(fig.7) designed to produce a hole that is cylindrical for the entire bush length. Material that is backward extruded is rolled into a rim by the Flowdrill collar (fig. 8e). > Short Flowdrills have a shorter parallel body. This design produces a bush that is conical and provides great strength when formed into a thread (fig. 8a). > Special L 4 & L 5 dimensions are avai- lable for use when Flowdrill penetration length is restricted for example in small diameter tube. fig. 7 fig. 7b fig. 7c fig. 7a >

The following optional features can be supplied on any Flowdrill: > The Flowdrill collar is ground into a cutter (fig. 8c,g). This removes the rim formed around the top surface of a Flowdrilled hole, leaving the surface flat. fig . 7d fig. 7e fig. 7f > Fluted point: all Flowdrills can besupplied with two small cutting flutes at the tip (fig. 8b,f). This style is useful for coated materials such as paint, anodised and some galvanised steel, depending on thickness of layer. The axial force is also reduced, permitting use in portable hand drills, or when a work-piece has insufficient support in...

8a. short8b. short rem8c. short flat8d. short flat rem >

8e. long8f. long rem8g. long flat8h. long flat rem >

7.1 Flowtapping 7.1.2 Example > The most common use of Flowdrills is to provide a high strength threaded fast- ener in thin sheet metal or tube. A Flowdrilled hole may be tapped with conventional cutting taps or preferably, with cold form Flowtaps. Flowtapping resembles Flowdrill except the opera- ting temperature is much lower; instead of cutting, Flowtaps cold-form the thread(no swarf). The diameter of the Flowdrill determines the final thread form,-depth and -strength. Tables in chap- ter 18.0 (back cover) show the recom-mended Flowdrill diameters for various thread sizes. M6 in 2 mm Fe 360Use...

Soldered connection ( fig. 2f)Bearing support ( fig. 2e) fig. 2e fig. 2f >

Non-ferrous metals (with the excep- tion of brittle material, like CuZn40Pb2). > Aluminium with less than 5% Si. > Stainless steel, acid resistant steel.In some cases it is desirable to test the suitability of the Flowdrill system. In particular in case of zinc coated mate- rials. >

9.1Flowdrills are made of speciallydeveloped carbide. This will maintain its strength at high temperatures but is sensitive to thermal stress. Local cooling should be avoided.9.2Flowdrills cannot withstand highmechanical shock. They should not be dropped and hard impact onto the surface of the workpiece, as well as welded spots should be avoided.9.3Avoid radial forces on the Flowdrill 9.4Torsional stability of the Flowdrill is important. Too rapid release of torsional load caused by fast break through (very high feed rate) can cause fatigue.9.5A similar condition can occur due towind up if start...

Flowdrill results depend on the mate-rial's physical properties, such as tensile strength, hardness, chemical content and conductivity. Generally all malle- able materials can be Flowdrilled. Lubrication of the Flowdrill can work against the need to generate heat but is required in small amounts to prevent pick-up or adhesion on the carbide surface, particularly when Flowdrilling aluminium. Flowdrill lubricants are spe-directly after Flowdrill operation. cially developed to meet this criterion. > Lubricate while Flowdrill is still running, > FDKS paste and FDKS fluid to use fordrilling in steel,...