With engine bays getting smaller, transmissions adding more gears, and every
1) Is a pre-hole necessary when drilling greater than 5xD?
Traditionally, when drilling more than 5xD, you’re required to make a pre-hole with the same size drill and matching point geometry and at least half the depth of the diameter – 1xD is better. Iscar’s HCP insert point geometry is self-centering and self-starting, eliminating the pre-hole and drill 8xD to 12xD, going straight into the full depth of the hole, penetrating the material at 100% feed rate and rpm.
2) Can you drill on angled surfaces without a pre-hole or spot face?
3) You mentioned High Feed tooling. What is a High Feed tool and how does it differ from the typical milling tool?
High Feed tooling uses an extremely shallow depth of cut when compared to conventional milling techniques/tooling. The main idea is to achieve high material removal rates at, you guessed it, high feed rates. This is made possible by the extreme lead-angle design, which creates a much thinner chip; we must compensate for this by increasing the feed rate. High Feed tooling functions at feed rates 10x to 12x higher than typical milling tools running at conventional cutting parameters.
4) How can machinists increase drill penetration rates?
The limiting factor is how quickly you can evacuate chips. We have twisted coolant throughout the tool, allowing us to have a strong center core while maintaining a deep chip gullet.
With minimum quantity lubrication (MQL), which we’re seeing a lot more of in automotive, especially in Europe, you’re often using air pressure. It does affect your drilling parameters. You’re going to have to drill at a lower penetration rate because you’ve got to get those chips out. If you change the speeds and feeds, you can evacuate the chips if you have as much air pressure as possible.
5) Can replaceable tip drills increase productivity?
In most cases, a customer can live with 0.001" difference in lengths. By having an indexed tip, you’re replacing the cutting tool on the machine instantly without going to pre-setting.