Deep Drilling Tools OUTILTEC Single Flute Gundrill

Size: px

Start display at page:

Download "Deep Drilling Tools OUTILTEC Single Flute Gundrill"

Antony Shelton
6 years ago
Views:

1 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 1 eep rilling Tools OUTITEC Single Flute Gundrill Outilec Gundrill Outiltec's gundrill consists of a single piece carbide head, a streamlined shank and a driver through which coolant flows to the working end where it is most needed. Chips are evacuated along the v -shaped external flute. The rilling Head The carbide head is tapered on its length to reduce friction. The taper angle depends on the type of material to be drilled. For high precision drilling, the taper should be reduced to a minimum (see page 3). Note that when the head is resharpened, the diameter of the drill changes, effecting the hole tolerance. Outiltec Carbide Tipped Gundrill Range rill iameter Max Flute ength 2.50 to mm 3.10 to mm 6.00 to mm to mm to mm to mm to mm Overall length=flute length+driver length The Shank The cross-section of the shank is V-shaped with coolant holes. It is made of hardened steel that is highly resistant to twisting (for information on carbide shanks, see next page). This crosssection provides the optimal conditions for twist resistance, coolant flow and chip evacuation. The river The driver ensures the connection between the gundrill and the machine tool, (see pages 6-7 for detailed driver information). Outiltec s advanced Gundrill technology provides superior geometric and dimensional quality for both deep and shallow drilling. The drills are available in the range of 2.5 to 32 mm in 0.1 mm increment diameters. arger diameters, between 32 and 40 mm, are available upon request. In addition, any other drilling head configuration or coated drilling head can be produced upon request. river Advantages rilling precision of IT7 to IT9 tolerances can be reached. Excellent straightness and concentricity. Maintains high precision hole center alignment. Surface roughness of R0.4 - R1.6 is easily obtained. Reboring operations are often unnecessary. Shank rilling Head 1

ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 2 OUTITEC Single Flute Solid Carbide Gundrills Another type of gundrill is made with integral tip and shank, made of solid carbide with either a steel or

2 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 2 OUTITEC Single Flute Solid Carbide Gundrills Another type of gundrill is made with integral tip and shank, made of solid carbide with either a steel or a carbide driver. These drills are designed for conventional machines, machining centers and lathes. This style of gundrill is available from mm and can be used on various types of materials. It provides superior rigidity and optimal coolant flow rates. As a result of its rigidity, up to 100% higher feeds and speeds can be reached. When using the small diameter drills, it is crucial to adhere closely to recommended drilling parameters. Outiltec Solid Carbide Gundrill Range (with or without brazed steel driver) rill iameter Max Flute ength 1.4 to mm 4.51 to 8.85 up to 35 x drill diameter 8.86 to mm 2

3 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 3 eep rilling Tools OUTITEC Standard Gundrill Head Sharpening Angles Subject to the required tolerance, cutting performance and desired chip shape, the following standard sharpening angles are recommended (shown in figures 1 and 2). Fig x Standard sharpening for 2.5 to 4 mm drill diameters Fig x Standard sharpening for 4 to 32 mm drill diameters Remark: For special or semistandard gundrills, special geometries will be offered to match the application. 3

4 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 4 OUTITEC Standard Gundrill Head Profiles rilling capacity and finish of the drilled hole are dependent on the geometrical shape of the drill head. Both the profile and the sharpening must be matched to the workpiece material. The profile is defined when the tool is manufactured. Although regrinding may change the cutting geometry, the profile should remain the same. All cross section profile parameters such as: P, a and α must be precisely matched to the workpiece material properties. P Ø a Standard shape for every kind of material. Recommended for materials that have a tendency to shrink and for high precision bore hole tolerances Standard shape for cast iron and aluminum alloys. It can also be used for drilling crossholes and for angular entry and exit. α General Sketch Profile G (Universal) Profile A Suggested for high precision bore hole tolerances. Standard shape for every kind of material, especially for drilling crossholes, very deep holes and for angular entry and exit. Suitable for grey cast iron, malleable iron, hydraulic castings and similar materials. Profile B Profile C Profile For general use and plastics. Recommended for steel and aluminum. Can be used for drilling cross-holes and for interrupted cuts. Suggest for steel, cast iron and other soft materials. Profile E Profile H Profile I 4

5 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 5 eep rilling Tools Standard Gundrill Carbide Head ength 120 iameter Range Head ength Note: regrindable length=- 5

6 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 6 Standard Gundrill rivers for Machining Centers, athes etc... river Carbide Tipped Solid Carbide river Type rawing ø x Code Gundrills Gundrills 4x x x x x x45 06 Cylindrical 14x45 07 IN1835A 16x48 08 IN6535HA 18x x x x x x x x x36 17 Weldon 10x40 18 IN1835B 12x x x x x56 23 IN6535HB 32x x x x x x x40 30 Whistle Notch 12x45 31 IN1835E 16x x x x x x x x x40 40 Whistle Notch 12x45 41 IN6535HE 16x x x50 44 CM1 45 IN228AK CM2 46 CM3 47 CM4 48 CM1 49 IN228BK CM2 50 CM3 51 CM4 52 Recommended style 6

7 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 7 eep rilling Tools Standard rivers for Gundrill Machines river Carbide Tipped Solid Carbide river Type rawing ø x Code Gundrills Gundrills 6x x x45 55 Central Clamping 19.05x Surface 15 25x70 57 Frontal Clamping Surface x x x x x50 M6X x60 M6X M 12.7x50 M6x Cylindrical 16x80 M10X1 65 with Thread 25x100 M16x x120 M24x x68 M6x VI esign M 16x90 M10x x112 M16x x135 M24x Central Clamping 25x70 72 Hexagonal 32x x Central Clamping 16x70 75 Tapered 19.05x x x x x Frontal Clamping 25.4x Surface x x x x x112 Tr 16x Trapezoidal 20x126 Tr 20x2 87 Thread Tr 28x126 Tr 28x x162 Tr 36x x40 90 Spraymist river 25x x60 92 Recommended style 7

8 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 8 Standard Gundrill ength Calculation H N W B F A s = Cutting diameter H = Carbide length (page 5) N = Regrinding area = H- W = Hole depth B = Chip evacuation area = For typical gundrill machines, 250 mm = For machining centers, 2x (minimum 15 mm) F = 10 mm A = river ength S = Flute ength = Overall ength Example 1: rilling of a ø10x500 depth hole on a gundrill machine with ø25x70 mm driver code No. 57 (See page 7) =10 W=500 A=70 B=250 (or per experience) =N+W+B+F+A =(35-10) =850 (OA) s=n+w+b=770 (flute length) Ordering Code For example 1: and s are available as standard STG IC08 Example 2: 8 mm diameter Gundrill 1550 mm overall length with a ø25x70 mm driver on a gundrill machine =8 =1550 A=70 B=250 (or as per experience) s = -A-F = =1470 Ordering Code For example 2: s is not available in standard. For an 8 mm diameter, the maximum length of a standard tool is 1455 mm (see table on next page). This is a semi-standard tool. Note: The same tool 15mm shorter could be available in the standard range with a shorter delivery time. Note for Example 2: The same tool diameter, but 15 mm shorter, is available in the standard range with a shorter delivery time (see table on next page). 8

9 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 9 elivery Schedule Based on rill imension for Carbide Tipped Gundrills Standard drills diameters are available in 0.1mm increments on standard cutting edge geometry and G profile. All drills are made only from sub-micron IC08 grade. elivery for standard tools: 1-2 weeks from order. (Shipment not included) elivery for semi-standard tools: 2-4 weeks from order. (Shipment not included) Gundrills with a longer flute length than specified in the table will be considered as specials. elivery for special tools: 8-10 weeks from order. Note: for gundrill length calculations see page 8. rill iameter Maximum rill Flute ength Maximum rill Flute ength Range for Standard elivery for Semi-Standard elivery eep rilling Tools 9

10 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 10 Single Flute Carbide Tipped Gundrill esignations New Tools Standard (1) Brazed rill (Carbide Tipped): Ordering Example: STG IC08 (The Only Available Carbide Grade) rill Overall river iameter ength Type Semi-Standard (1) Brazed rill (Carbide Tipped): Ordering Example: G ER IC908 (Carbide Grade) (2) rill Overall river E=Head Profile iameter ength Type R=Rough (P-Polished) Special (1) Gundrill Carbide Tipped: Ordering Example: SPG rill Overall Offer No. Version iameter ength or rawing No. No. Repairing (Replacement of the Carbide Tip) Repairing of Standard (1) rills Ordering Example: RSTG IC08 (The Only Available Carbide Grade) rill Overall iameter ength Repairing of Semi-Standard (1) Ordering Example: RG GR - IC508 (Carbide Grade) (2) rill Overall G=rill Profile iameter ength R=Rough (P=Polished) Repairing of Special (1) rills Ordering Example: RSPG rill Overall Offer No. Version No. iameter ength or rawing No. (1) Standard gundrills: elivery within 1-2 weeks from order (shipment not included). Semi-standard gundrills: elivery within 2-4 weeks from order (shipment not included). Spacial gundrills: elivery within 8-10 weeks from order (shipment not included). (2) Available Carbide Grades: IC08 uncoated grade used as a substrate for the following coated grades: IC908 (TIAlN); IC508 (TiCN+TiN); IC308 (TiCN); IC208 (TiN). 10

11 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 11 eep rilling Tools Single Flute Solid Carbide Gundrill esignation New Tools Stansdard (1) Solid Carbide rills: Ordering Example: STCG rill Overall river iameter ength Type Semi-Standard (1) Solid Carbide rills: Ordering Example: CG CPIC08 rill Overall river C=rill Profile iameter ength Type P=Polished (R=Rough) IC08=Carbide Grade (2) Special (1) Solid Carbide Gundrills: Ordering Example: SPCG ril Overall Offer No. Version No. iameter ength or rawing No. Repairing of a solid carbide drill is not possible Special (1) Two Flute Carbide Tipped Gundrill esignations Ordering Example: G rill Overall Offer No. Version No. iameter ength or rawing No. (1) Standard gundrills: elivery within 1-2 weeks from order (shipment not included). Semi-standard gundrills: elivery within 2-4 weeks from order (shipment not included). Spacial gundrills: elivery within 8-10 weeks from order (shipment not included). (2) Available Carbide Grades: IC08 uncoated grade used as a substrate for the following coated grades: IC908 (TIAlN); IC508 (TiCN+TiN); IC308 (TiCN); IC208 (TiN). 11

ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 12 Resharpening esignations Standard Geometry Resharpening of Carbide Tipped or Solid Gundrills (See page 3) Ordering Example: STGRIN - 05520 rill

12 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 12 Resharpening esignations Standard Geometry Resharpening of Carbide Tipped or Solid Gundrills (See page 3) Ordering Example: STGRIN rill iameter Special Geometry Resharpening Ordering Example: SPGRIN rill Offer Version iameter No. No. General Notes Standard Head Geometry Standard means: G style, not polished with standard cutting edge grinding and standard back taper, uncoated grade. Semi-Standard Head Geometry Other than G style, polished or coated grade. Special and 2 Flute Gundrills Any specification other than the standard solid carbide (STCG), semi standard solid carbide (CG), standard tipped drill (STG) or semi-standard tipped gundrills (G) is considered as a special. The offer number specified is accompanied by a version number. For example: SPG FP SPG FP SPG FP

13 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 13 eep rilling Tools Gundrill Inquiry Form 1. Tool Quantity Nominal diameter and tolerance Please fill in dimensions on the sketch. s A 2. Workpiece (If possible, please attach a drawing) 2.1 Material Material description (IN material number or any other standard): Hardness and Properties: Ø Ød : Short Chips : ong Chips river river: for standard drivers please use codes from pages 6, 7 : Code No. : Special, please attach sketch and specifications. Grind: : Special (fill in the dimensions and angles below). 2.2 Hole Type : Blind Hole : rilling into Prehole : Angled Entry : rilling into Solid : Boring : Angled Exit rilling epth mm Hole Tolerance 2.3 Application: Workpiece: : Stationary : Rotating Tool : Stationary : Rotating γ α2 α1 αf1 bf1 3. Machine 3.1 Technical ata Machine Type: Power: kw Internal Cuttnig Edge ψ2 as ψ1 α3 external Cuttnig Edge 3.2 Cutting ata: Cutting Speed Vc m/min Revolutions Nmin RPM, Nmax RPM Feed Fmin mm/rev, Fmax mm/rev Feed Rate VF mm/min α1= αf1= ψ1= α2= bf1= ψ2= α3= as= γ= Coolant: : Oil : Soluble Oil : Other Coolant Pressure: Bar Sketch of drilling application : Standard (see page 3) Coating: : TiN : TiCN : TiN+TiCN : TiAIN : Other : IC208 (TiN) : IC308 (TiCN) : IC508 (TiCN+TiN) : IC908 (TiAN) Type: Please circle the required type. A B C E G H I 13

14 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 14 Typical Gundrill Applications User Guide The gundrill is not a self-centering tool. Therefore an external means must be used to guide it to the point of entry into the workpiece It is recommended that the machine tool be equipped with a means for guiding the gundrill, preferably during the entire drilling process. An alternative method is a pre-drilled guide hole (figure 2), which is common for machining centers. Once the drill has been fully engaged into this hole, it continues being self-guided. The guiding pads contribute to the high degree of calibration and provide burnishing of the drilled hole. Main rilling Methods Figure 1 Guiding Barrel Figure 2 Pre-rilled Guide Hole 14

ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 15 eep rilling Tools Typical Gundrill Applications - Chip Evacuation and Coolant Flow Figure 3 Figure 4 Boring with chip evacuation and coolant flowing

15 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 15 eep rilling Tools Typical Gundrill Applications - Chip Evacuation and Coolant Flow Figure 3 Figure 4 Boring with chip evacuation and coolant flowing opposite the boring direction rilling of solid material with chips evacuation and coolant flow opposite the drilling direction. Figure 5 Figure 6 Boring with chip evacuation in the boring direction. Boring with a staged tool. Chip evacuation and coolant flow in the boring direction. 15

16 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 16 eep Hole Machine Accessories rill Bushing Sealed Housing Sealing isk Bushing Guide Support Bushing river Adjustment Adapter Bushing Based on modified IN 179 specify the d diameter of the drill. Carbide barrel is delivered only on request. Sealing isk Supplied with a single sealing disk or a protection sheet. Indicate the dimensions needed for your requirements. rill iameter Support Bushing Indicate the d diameter of the drill. d(rill iameter) d d Sealed Housing Indicate the d diameter of the drill. Bushing Guide Indicate the d diameter of the drill. Adjustment Adapter (on request) d Other accessories are available on request 16

17 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 17 eep rilling Tools The Grinding Wheel The gundrill should be re-sharpened with a special diamond grinding wheel. The doublefunction wheel is divided into two areas. The external area is for rough grinding - during this operation the temperature of the drill does not rise significantly. The internal, fine-grained diamond is for finishing and it ensures high surface quality. The Grinding Machine A standard grinding machine (adjustable on three planes) for the gundrill range of mm must be equipped with a special support for long gundrills. The Grinding Wheel Ø150 Ø100 Ø20 Finishing grinding zone Rough grinding zone Warning: It is absolutely essential that the operator wears the proper protective glasses and a mask. Carbide dust can be hazardous! 17

18 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 18 rilling Tolerances Obtainable In eep Hole rilling eep rilling Tolerances Outiltec gundrill configurations when used under recommended conditions, can produce holes with tolerances of IT8-IT9. Even better tolerances can be achieved when operating under optimal conditions. Non ferrous materials Aluminum Tool steel Cast iron High alloyed steel>800n/mm 2 Hardened steel ow alloyed steel<800n/mm 2 Carbon steel Sintered steel rilling quality machinability of metals IT Tolerance range under normal conditions. Tolerance range under optimal conditions. Surface Quality Surface quality of 0.2 Ra can be achieved when using gundrills under recommended conditions. Indexable rills Reaming Honing eep drilling egree of roughness (Ra roughness index) µ m µ in N12 N11 N10 N9 N8 N7 N6 N5 N4 N3 N2 N Tolerance range under normal conditions. Tolerance range under optimal conditions. Concentricity and Straightness The resulting quality depends on different factors such as: rilling depth and diameter Type of machining and cutting parameters Quality and uniformity of the workpiece material Machine tool conditions Gundrill support. Concentricity mm , Circularity The geometric quality of bores obtained from deep hole drill bits is clearly higher than that obtained with the use of twist drills. It is possible to obtain precision with deviations of less than 4µm. Straightness mm Stationary workpiece rotating tool Rotating workpiece rotating tool mm rilling epth mm rilling epth 18

19 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 19 eep rilling Tools Cutting Parameters The most effective machining depends on the workpiece material and its structure. The shape of the chip produced during machining operation determines their ease of evacuation from the cutting area. The chip shape is influenced by the feed, speed and cutting head geometry. The ideal chip shape for materials with normal machinability is a short helix, cork screw shape. Gundrill Cutting Speeds iameter Range Carbon and 2-5 free cutting steel 5-13 Rm<700 N/mm ow alloyed steel Rm<800 N/mm Tempered steel 5-13 Rm<1100 N/mm Hardened steel Rm<700 N/mm High alloy steel Rm<1100 N/mm Stainless 2-5 steel GGG, GG, GTW 2-5 and GTS cast iron 5-13 Rm<2400 N/mm Brass and bronze 5-13 Rm<500 N/mm Aluminum alloys Up to 160 Up to 180 Up to 300 Up to 300 Feed per Turn for Gundrills (Approximate values) V (m/min) mm/rev Curve 1: Curve 2: Curve 3: Curve 4: Curve 5: Curve 6: Curve 7: Aluminum alloys Alloyed cast iron Grey casting and low carbon steel ow alloyed Steel High alloy steel Hardened steel Ferritic and austenitic stainless steels Ø mm Pressure and Coolant Flow Rate for Gundrills Bar P /<100 />100 />100 /<100 Q rilling iameter /min P bar Q l/min Ø mm rilling iameter 19

20 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 20 Gundrill ubrication and Cooling The best performance is obtained by using oil. On Equipment that uses watersoluble fluids (i.e., on machining centers and CNC machines) a concentration between 10% and 15% is recommended. Guidelines for Optimal Gundrill Performance: Coolant pressure and flow: It is recommended to use a strong coolant flow for efficient chip flushing and cooling of the cutting edge. Filtration: It is suggested that a filter under 20 µm be used. Note: Improper filtration may result in interrupted flow of the lubricating oil. This creates a sticky surface on the bearing pads and leads to premature wear of the tool and overloading coolant pump and spindle seals. Temperature of the coolant: The coolant temperature should be between 20 and 22ºC. Note: Above 50ºC the viscosity of the coolant is reduced by 50% and becomes ineffective. Choice of coolant: OUTITEC, in cooperation with JP INUSTRIE, recommends the following oils and water-soluble fluids to obtain the finest performance from your gundrills. Copper and Aluminum and Alloys Cast Iron and Steel High-Speed Steel Copper Alloys Titanium and Inconel Top Performance SITAA 601 High Performance SITAA A401 SITAA A401 Good Performance SITAA B1230 Soluble Cutting Oil Soft metal, and/or Hard metal (steel, stainless Steel, tempered aluminum, copper alloys steel, high-speed, titanium) SOFT-UCTIE META HAR Top performance GARIA 604S15-GARIA 1660S15/22 High performance MACRON 402M5 GARIA 604M8/15-GARIA M15 Good performance GARIA 402F15 20

21 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 21 OUTITEC 2, rue ouis Armand Zone industrielle BP Soufflenheim, France Tel. +33 (0) Fax. +33 (0) info@outiltec.fr Internet: ISCAR T. All rights reserved Printed in Israel /2003

22 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 22

23 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 23 for eep rilling

24 ENGISH GUNRI - Outiltec 17/12/02 2:00 PM Page 24 for eep rilling

APRIL 2009 / NEW-100 / PAGE 1 OF 13

APRIL 2009 / NEW-100 / PAGE 1 OF 13 The standard UNIDEX line covers reaming applications from 5/16 to 1 1/4 diameter. The single indexable blade and high wear resistant carbide or cermet pads provide a