Keeping the Customer First. Tungaloy Report No. 409-US. Indexable drill NEW. TDS type TUNGALOY. The most economical solution for drilling!

Keeping the Customer First Tungaloy Report No. 409-US Indexable drill NEW TDS type TUNGALOY The most economical solution for drilling!

Features Double-sided insert with 6-cutting edges TungSix-Drill is the first indexable drill in the world to adapt double-sided inserts with 6-cutting edges. The 6-cutting edges reduce the number of inserts consumed. Central side 1 2 Peripheral side 4 5 3 Optimal distance between each cutting edge 6 This prevents the overlapping of damaged edges One insert type can be used on both the central and peripheral edge Customers only require one type of insert. This simplifies inventory control. Optimized cutting balance Optimized cutting balance of TungSix-Drill provides excellent hole accuracy. (in) Hole diameter 1.131 1.129 1.127 1.125 Entrance f =.002 ipr f =.004 ipr f =.006 ipr Middle Bottom (in) 1.131 1.129 1.127 1.125 Entrance Competitors f =.002 ipr f =.004 ipr f =.006 ipr Middle Bottom ødc = ø1.125" Vc = 460 sfm ødc = ø1.125" Vc = 460 sfm 2

New revolutionary grade AH9030 PVD coated grade Special Surface Technology TUNGALOY Smooth insert surface prevents chip adhesion and provides smooth chip flow. New generation PVD coating Advanced wear and oxidation resistance. Adhesion reinforcement technology This specialized treatment enhances the adhesion between the coating and the substrate. Drastically improves chipping and fracture resistance. Enhanced corner of central insert The corner of the central cutting edge on the TungSix- Drill improves performance by adapting a negative angle relief. This enhanced corner prevents fracture. Cutting force Negative angle relief Competitors Cutting force Positive angle relief Fracture Twisted coolant holes Twisted coolant holes improve coolant flow. This improves chip evacuation, cooling and lubrication of the cutting edges. 3

Chipbreakers DJ type General purpose chipbreaker for almost all applications. Features low cutting forces and allows stable drilling. Central insert Identification for central edge side Chipbreaker for central edge The chipbreaker has thick width and gentle curves. This prevents chips from packing. Low cutting forces and long tool life Bumps and grooves formed on the rake face reduce cutting forces and deliver longer tool life. Peripheral insert Identification for peripheral edge side Chipbreaker for peripheral edge The high rake angle and high breaker wall reduce cutting forces and improve chipbreaking. Wiper design Can improve surface finish System to avoid wrong insert clamping TungSix-Drill has been adapted to ensure the new system prevents incorrect insert clamping. Incorrect clamping of central and peripheral insert does not happen. Note: The drill is designed to avoid wrong insert clamping. Please check the central and peripheral insert faces before setting the insert. OK Correct clamping Central insert Central insert seat Insert hole fits screw hole Correctly clamped! Central insert Central insert seat Incorrect clamping Pheripheral insert Central insert seat Peripheral insert Central insert seat Insert hole doesn't fit screw hole Screw can t enter screw hole Grades Application Grade Substrate Coating layer Application code AH9030 14.5 90.8 2.8 (Ti, Al)N 5 P20 - P35 AH9030 14.5 90.8 2.8 (Ti, Al)N 5 M20 - M35 Specific gravity Hardness (HRA) T.R.S. (GPa) Main Composition Thickness (μm) Features For steels and stainless steels Excellent wear and oxidation resistance in medium to high cutting speed conditions. "PremiumTec" prevents edge welding. 4

Cutting performance TungSix-Drill adapts its positive land, this enables the drill to reduce the cutting forces even when using double-sided inserts. The cutting forces are almost equal to competitors with single sided inserts. Spindle power consumption Power consumption (kw) Reduction of cutting force 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 Tool life.016.012.008.004 Competitors f =.002 f =.004 f =.006 0 Feed: f (ipr) ødc = ø1.125" Vc = 460 sfm Work material: 1055 Excellent wear resistance of AH9030 Corner wear width on peripheral edge Vc (in) Competitor A Competitor B 20 40 60 Machining length (ft) Chip control Feed: f (ipr).004.006.008 Chips are stably controlled in this range. The chips created are the ideal shape. Cutting speed: Vc (sfm) 330 500 660 Drill Insert Grade Work material Cutting speed Feed Hole diameter Hole depth Machine Coolant Drill Insert Grade Work material Machine Hool diameter Hole depth Coolant.100" : TDSU1125-03 : WWMU08X408R-DJ : AH9030 : 1045 : NC lathe : ø1.125" : H = 2.8" : Wet : TDSU1125-03 : WWMU08X408R-DJ : AH9030 : 1055 : Vc = 460 sfm : f =.004 ipr : ø1.125" : H = 2.8" : Horizontal M/C, BT40 : Wet (Internal supply) AH9030 offers superior wear resistance against competitors. Maximum flank wear width on central edge VBmax (in) Thougness of central insert.014.012.010.008.006.004.002 Competitor A 0 2 4 Machining length (ft) Fracture Drill Insert Grade Work material Cutting speed Feed Hole diameter Hole depth Machine Coolant : TDSU1125-03 : WWMU08X408R-DJ : AH9030 : Pre-hardened steel (40HRC) : Vc = 330 sfm : f =.003 ipr : ø1.125" : H = 1.125" : Vertical M/C, BT50 : Wet (Internal supply) Enhanced corner of central cutting edge prevents fracture even in prehardened steel machining. 5

Inserts DJ chipbreaker r ød T ød1 Stocked grades Dimensions (in) Applicable drill Cat. No. diameters TUNGALOY ød T ød1 rε NEW AH9030 ødc (in) WWMU08X408R-DJ.315.154.134.031 ø1.125 ~ ø1.250 WWMU09X510R-DJ.382.193.173.039 ø1.312 ~ ø1.500 WWMU11X512R-DJ.445.224.217.047 ø1.562 ~ ø1.812 WWMU13X512R-DJ.512.224.217.047 ø1.875 ~ ø2.000 Drills L/D = 2 ø c ø ø s h6 R R Cat. No Stock Dimensions (in) Max Clamping Weight Offset Applicable inserts screw ødc øds ød r rs L (Radius) (lb) Torx driver TDSU1125-02 1.125 2.250 5.892.043 1.5 TDSU1187-02 1.187 1.250 1.575 2.374 2.280 6.079.019 1.6 WWMU08X408R-DJ CSTB-3 T-9D TDSU1250-02 1.250 2.500 6.267.008 1.7 TDSU1312-02 1.312 2.624 6.862.055 2.5 TDSU1375-02 1.375 2.750 7.049.047 2.6 TDSU1437-02 1.437 1.969 2.874 7.237.027 2.8 TDSU1500-02 1.500 3.000 7.424.015 2.9 TDSU1562-02 1.562 3.124 7.612.074 3.0 TDSU1625-02 1.625 3.250 7.799.059 3.3 1.500 2.688 TDSU1687-02 1.687 3.374 7.987.051 3.5 TDSU1750-02 1.750 3.500 8.174.027 3.7 TDSU1812-02 1.812 2.165 3.624 8.362.015 3.9 TDSU1875-02 1.875 3.750 8.549.094 4.2 TDSU1937-02 1.937 3.874 8.737.078 4.3 TDSU2000-02 2.000 4.000 8.924.067 4.6 WWMU09X510R-DJ CSTB-4 T-15D WWMU11X512R-DJ WWMU13X512R-DJ CSTB-5 T-20D : 3rd Quarter, 2012 6

L/D = 3 ødc ød øds h6 R L Rs Dimensions (in) Max Weight Cat. No Stock Offset ødc øds ød r rs L (Radius) (lb) TDSU1125-03 1.125 3.375 7.017.043 1.7 TDSU1187-03 1.187 1.250 1.575 3.561 2.280 7.267.019 1.8 TDSU1250-03 1.250 3.750 7.517.008 1.9 TDSU1312-03 1.312 3.936 8.174.055 2.8 TDSU1375-03 1.375 4.125 8.424.047 2.9 TDSU1437-03 1.437 1.969 4.311 8.674.027 3.1 TDSU1500-03 1.500 4.500 8.924.015 3.3 TDSU1562-03 1.562 4.686 9.174.074 3.4 TDSU1625-03 1.625 4.875 9.424.059 3.8 1.500 2.688 TDSU1687-03 1.687 5.061 9.674.051 4.1 TDSU1750-03 1.750 5.250 9.924.027 4.3 TDSU1812-03 1.812 2.165 5.436 10.174.015 4.6 TDSU1875-03 1.875 5.625 10.424.094 4.9 TDSU1937-03 1.937 5.811 10.674.078 5.1 TDSU2000-03 2.000 6.000 10.924.067 5.5 Applicable inserts WWMU08X408R-DJ CSTB-3 T-9D WWMU09X510R-DJ CSTB-4 T-15D WWMU11X512R-DJ WWMU13X512R-DJ Clamping screw CSTB-5 Torx driver T-20D : 2nd Quarter, 2012 : 3rd Quarter, 2012 7

Standard cutting conditions Work materials Low carbon steels (C < 0.3) 1010,1025, etc. Carbon steels (C > 0.3) 1045,1055, etc. Low alloy steels 5120, etc. Alloy steels 4137,4140, etc. Stainless steels (Austenitic) 304,316, etc. Stainless steels (Martensitic and ferritic) 430,416, etc. Stainless steels (Precipitation hardening) S17400, etc. Gray cast irons No.250B, etc. Ductile cast irons 100-70-03, etc. Cutting Speed Vc (sfm) Feed: f (ipr) ødc (in) ø1.125 ~ ø1.500 ø1.562 ~ø2.000 500-1000.0015 -.004.0015 -.004 250-800.002-.006.003 -.007 500-800.002 -.005.002 -.006 250-650.002 -.006.003 -.007 300-650.0015 -.005.0015 -.005 300-650.0015 -.005.0015 -.005 250-380.0015 -.004.0015 -.004 250-800.002 -.007.003 -.008 250-650.002 -.007.003 -.008 Application range In case of Interrupted cutting, feed should be decreased. Feed f (ipr) OK Upper table.002.002.002 OK OK OK Plane surface Slant surface Cross hole Plunging Application Feed f (ipr) OK.004.002 Disapprove Disapprove OK Boring Round surface Stacked plate Back boring Application 8

New chamfering tool "TDXCF Series" The TDXCF Series with the TungSix-Drill completes both drilling and chamfering at the same time. This reduces machining processes by chamfering and drilling simultaneously. Features High productivity with two inserts Optimum space between the drill body and chamfering inserts prevents cutting edges from fracture Chamfering tool Max. chamfering width: C.098" Chamfering angle: 45º Two inserts type Optimum clearance prevents chipping on edge Insert Flute for chip evacuation Space for drill body Clamping screw of chamfering tool Insert grade is GH130 which has TiCNO coating for steels Suitable for machining steel, stainless steels and cast irons Cutting edge of chamfer insert 9

Cutting performance Surface finish Tool TDS280W25-3 (L/D = 3) TDXCF Cutting force Feed: f (ipr).004.005 Sharp cutting edge decreases cutting forces by 50%!!! Tool Work material Machine Coolant Cutting speed Chamfering width TDXCF : TDXCF280L30 : Carbon steel 1055 (245HB) : Vertical M/C, BT40 : Wet : Vc = 460 sfm : C =.08" New chamfering tools TDXCF provides stable surface finish Conventional Tool Work material Machine Coolant Cutting speed Feed Chamfering width : TDXCF280L30 : Carbon steel 1055 (245HB) : Vertical M/C, BT40 : Wet : Vc = 460 sfm : f =.004 ipr : C =.08" Thrust force (kn) Drilling time (min) Thrust force (kn) Drilling time (min) Chip control TDXCF Conventional Tool Work material Machine Coolant Cutting speed Chamfering width : TDXCF280L30 : Carbon steel 1055 (245HB) : Vertical M/C, BT40 : Wet : Vc = 460 sfm : C =.08" Continuous spiral chips prevent them from wrapping around the drill body or work piece Chamfering tool insert & part list Cat. No. TDXCF280L30 ~ TDXCF540L30 Insert Grade, Stock GH130 Insert clamping screw Torque (ft-lb) Ring clamping screw Torque (ft-lb) Wrench for insert Wrench for ring XHGX090700R-45A CSPB-4S 2.58 CM8 x 20 5.90 T-15D P-5 : Stocked items 10

Chamfering ring (TDXCF Series) Max. drilling depth ø c ø s Dimensions (in) Max. drilling depth (in) Cat. No. Stock Application drill øds ødc L Drill dia. ødc L/D = 2 L/D = 3 TDXCF280L30 1.059 2.520 1.181 TDXCF290L30 1.098 2.520 1.181 1.125 TDSU-1125-* 1.338 2.463 TDXCF300L30 1.138 2.520 1.181 1.187 TDSU-1187-* 1.456 2.643 TDXCF310L30 1.177 2.520 1.181 TDXCF320L30 1.217 2.520 1.181 1.250 TDSU-1250-* 1.614 2.864 TDXCF330L30 1.252 2.520 1.181 TDXCF340L30 1.291 2.520 1.181 1.312 TDSU-1312-* 1.732 3.044 TDXCF350L30 1.331 2.520 1.181 1.375 TDSU-1375-* 1.889 3.264 TDXCF360L30 1.370 3.346 1.181 TDXCF370L30 1.409 3.346 1.181 1.437 TDSU-1437-* 2.007 3.444 TDXCF380L30 1.449 3.346 1.181 1.500 TDSU-1500-* 2.164 3.664 TDXCF390L30 1.488 3.346 1.181 TDXCF400L30 1.528 3.346 1.181 1.562 TDSU-1562-* 2.322 3.884 TDXCF410L30 1.567 3.346 1.181 1.625 TDSU-1625-* 2.440 4.065 TDXCF420L30 1.598 3.346 1.181 TDXCF430L30 1.638 3.346 1.181 1.687 TDSU-1687-* 2.598 4.285 TDXCF440L30 1.677 3.346 1.181 TDXCF450L30 1.717 3.346 1.181 1.750 TDSU-1750-* 2.755 4.505 TDXCF460L30 1.756 3.346 1.181 1.812 TDSU-1812-* 2.873 4.685 TDXCF470L30 1.795 3.346 1.181 TDXCF480L30 1.835 3.346 1.181 1.875 TDSU-1875-* 3.031 4.906 TDXCF490L30 1.874 3.346 1.181 TDXCF500L30 1.913 3.346 1.181 1.937 TDSU-1937-* 3.188 5.125 TDXCF510L30 1.953 3.346 1.181 2.000 TDSU-2000-* 3.306 5.306 TDXCF520L30 1.992 3.346 1.181 TDXCF530L30 2.031 3.346 1.181 TDXCF540L30 2.071 3.346 1.181 : Stocked items 11

Points of caution when mounting the chamfering ring on drill body Place the ring on the drill body and match the ring flute with the drill flute. Temporarily clamp the ring on the body by lightly tightening the ring screw. Place the inserts on the ring and lightly tighten the insert screws. Adjust the ring to the right position with a Presetter, height gauge or Vernier caliper. Securely tighten the ring screw and then the insert screw. OK Match the ring flute with the drill flute (Insert will be automatically set to the right position) The ring flute does not match the drill flute Insert is in the wrong position due to incorrectly placed ring Adjustable drilling diameter holder Enables diameter of TungSix-Drill to adjust easily Specification L S.s. ød ød G J L2 12 Cat. No. Stock S.s. Dimensions (inch) ød ød L L2 J G TUNGBORE CAT40 EM3/4 40.750 2.835 5.337 2.795 M10 5/8-11 TUNGBORE CAT40 EM3/4 B 40.750 2.835 5.337 2.795 M10 5/8-11 TUNGBORE CAT40 EM1 40 1.000 2.835 5.337 2.795 M10 5/8-11 TUNGBORE CAT40 EM1 B 40 1.000 2.835 5.337 2.795 M10 5/8-11 TUNGBORE CAT40 EM1-1/4 40 1.250 2.835 5.337 2.795 M10 5/8-11 TUNGBORE CAT40 EM1-1/4 B 40 1.250 2.835 5.337 2.795 M10 5/8-11 TUNGBORE CAT40 EM1-1/2 40 1.500 2.835 5.337 2.795 M10 5/8-11 TUNGBORE CAT40 EM1-1/2 B 40 1.500 2.835 5.337 2.795 M10 5/8-11 TUNGBORE CAT50 EM3/4 50.750 2.835 5.179 2.795 M10 1-8 TUNGBORE CAT50 EM1 50 1.000 2.835 5.179 2.795 M10 1-8 TUNGBORE CAT50 EM1 B 50 1.000 2.835 5.179 2.795 M10 1-8 TUNGBORE CAT50 EM1-1/4 50 1.250 2.835 5.179 2.795 M10 1-8 TUNGBORE CAT50 EM1-1/4 B 50 1.250 2.835 5.179 2.795 M10 1-8 TUNGBORE CAT50 EM1-1/2 50 1.500 2.835 5.179 2.795 M10 1-8 TUNGBORE CAT50 EM1-1/2 B 50 1.500 2.835 5.179 2.795 M10 1-8 Min. ødc -0.3 Max. ødc +1.3 Drill shank Constraint surface : Stocked items The bore section is actually made from two shifted circular sections. The clamping screw pushes the drill shank through a narrow opening, forcing elastic deformation of the holder. Contact is made around more than 180, providing a high clamping force.

Tool diameter ødc (in) Adjustable range (in) Min. dia. ø Max. dia. ø Adjustable range of TungSix-Drill combined with TungBore Tool diameter ødc (in) 1.125 1.125 1.168 1.625 1.625 1.675 1.187 1.187 1.207 1.687 1.687 1.737 1.250 1.250 1.258 1.750 1.750 1.778 1.312 1.312 1.362 1.812 1.812 1.828 1.375 1.375 1.422 1.875 1.875 1.925 1.437 1.437 1.465 1.937 1.937 1.987 1.500 1.500 1.516 2.000 2.000 2.050 1.562 1.562 1.637 Regarding adjustment, please refer to the operating instructions in the TungBore leaflet for the TungHold (No. 389-E) Adjustable range (in) Min. dia. ø Max. dia. ø EZ sleeve (Eccentric sleeves for TungSix-Drill) The function of EZ sleeves Adjusting the hole diameter when drilling Adjusting the hole diameter in toolrotating applications. Adjusting cutting edge height on lathe Adjusting the cutting edge height in rotating work applications. By using EZ sleeve, the hole diameter can be adjusted in the range from +.024" to -.008". By using EZ sleeve, the cutting edge height can be adjusted in the range from +.012" to -.008". That reduces troubles caused by improper cutting-edge height. Scale for adjusting the hole diameter in milling machine (Periphery of sleeve) Scale for adjusting cutting edge height in turning (Front face of sleeve) 13

Setting of EZ sleeve Adjusting the hole diameter on M/C Adjusting cutting edge height on lathe Set the EZ sleeve between the drill shank and the holder. Align the scale on the periphery of EZ sleeve with the center of the flat on drill flange. Flat Flange EZ sleeve Set the EZ sleeve between the drill shank and the toolblock. Align the scale on the front face of the EZ sleeve with the center of the flat on drill flange. Fixing bolt A Flat Flange Fixing bolt B EZ sleeve In the figure shown on right, the sleeve is set and the hole diameter will be increased by.016". +0.4 +0.2 Fixing bolt A Fixing bolt B In the figure shown on right, the sleeve is set and the center of the drill will shift by.004" to the plus (+) direction. X-axis of machine When rotating EZ sleeve, fixing bolts A and B have to be loosened. After setting the hole diameter, fix the drill body with bolt A. Then lightly tighten the bolt B to fix EZ sleeve. If the bolt B is over tightened, EZ sleeve may be damaged. Cautious points Cannot be used for collet chuck holders For adjustments over L/D 4, please reduce feed rate For smaller adjustment, the drill itself will interfere with the hole diameter. (It is recommended that hole diameter should be adjusted to a larger diameter than the drill diameter) Specifications ød1 ød2 ød3 Cautious points L2 L4 L3 L1 Sleeve Cat. No. Stock ød1 ød2 ød3 L1 L2 L3 L4 Adjusting range of finishing diameter Adjusting range of cutting edge height EZ0.75-1.25.750 1.25 1.75 2.00.197 1.575.375 +.016 ~ -.008 +.008 ~ -.006 EZ1.00-1.50 1.00 1.50 2.00 2.50.197 1.965.375 +.016 ~ -.008 +.008 ~ -.006 EZ1.25-2.00 1.25 2.00 2.50 2.70.197 1.965.375 +.016 ~ -.008 +.008 ~ -.006 EZ1.50-2.00 1.50 2.00 2.75 2.90.197 1.965.375 +.022 ~ -.008 +.012 ~ -.008 Note: Select the sleeve so that the D1 of the sleeve will be same as the diameter of the drill shank. Using TungSix-Drill Ensure that the drilling machine to be used has sufficient rigidity and motor output Not recommended for drilling stacked plates Be sure to carry out proper alignment when drilling is to be performed on a rotating workpiece Cutting fluid Be sure to supply cutting fluid through the tool A water soluble emulsifiable type cutting fluid should be used Fluid pressure of 1 MPa or higher and fluid quantity of 7 l/min or more are essential. (For 4D and 5D type, a fluid pressure of 1.5 MPa or higher and fluid quantity of 10 l/min or more is recommended) Cautionary points for setting inserts Before installing the insert in the drill body, remove all foreign matter from the insert pocket When clamping and unclamping the insert, the center-line of the wrench should be aligned with the center-line of the screw. (Misalignment may result in deformation of the socket of the screw head or the tip of the wrench) When installing the insert, eliminate all play between the insert pocket and the bottom face of the insert Replace the screw before it is excessively deformed or worn out by long term use Proper handling of wrench 14

Use of TungSix-Drill on lathes Setting of drill body is an important issue for stable machining Mounting the drill on turret (tool post) When mounting drill body, the cutting edges should be parallel to the X-axis of the machine Usually, the drill body is mounted with the direction that the peripheral insert can be seen by the operator As the cotter on shank is parallel to the cutting edges, by tightening the flat with the fixing screw, the cutting edges are guaranteed to be parallel to the X-axis of the machine Turret Cutting edges should be parallel to the X-axis of the machine Direction of fixing bolt on tool block X-axis of machine Central edge Peripheral edge Checking of cutting edge height Usually, the drill body is mounted with the direction that the peripheral insert can be seen from the operator The cutting edge height is an important factor for stable machining The cutting edge of central insert should be.008" lower than the rotating axis of machine For checking the difference between rotating center and the tool block, please use a reference bar that is from ground solid bar In this case, the checking of the center height should be measured at the same position as the overhang length of the drill required When there isn t a reference bar, the ground part of a boring bar can be used as a substitute Difference: should be about.008" Turret of the lathe Dial gauge X-axis of machine Central edge Peripheral edge Overhang length of drill Reference bar If the condition of cutting edge height is not good, the height should be set by adjusting the turret. A simple method is shown in page 16. Main spindle Boring bar as a substitution Same length as the overhang of drill 15

Checking of setting conditions by trial cutting After mounting the drill body, the tool center should be checked by trial cutting before production When the drill body is properly set, a core with about ø.020" diameter is left on the bottom of hole If there is no core, the drill is above center If the core diameter is larger than ø.040", it is excessively below center (In these cases, the cutting edge height has to be checked again) When trial cutting, the feed should be.004 ipr or less, drilling depth should be up to.400" About.020" diameter Core on the center Drilling depth: Up to.400" Adjusting of cutting edge height When the condition of the cutting edge height is incorrect, the height should be adjusted with the following methods. 1 In the case of above-center When machining with such condition, the central cutting edge may be easily chipped. So this condition has to be rectified. Solution #1: Change the mounting direction. Solution #2: Rotate drill body 180 In #2, additional cotter is required on the opposite side. Mounting direction X-axis of machine Center of drill Central edge Peripheral edge Rotate 180 Center of drill Peripheral edge Central edge X-axis of mach Mounting direction In the case of slightly above-center (about.002") 2 3 In this case, shifting the mounting position to another position may improve the condition. In the case of excessive belowcenter (.008" or more) When this occurs, the large diameter of the core remains and heavy vibration may occur. To improve this situation: Use EZ sleeve (the eccentric sleeve) and adjust the cutting edge height to correct value. Information on EZ sleeve, is on page 13. 16

Machining with offset on the lathe A larger hole than the drill diameter can be machined! Drilling with offset When drilling on the lathe, the hole diameter can be adjusted by offsetting the drill body along the X- axis of machine When drilling with offset, the drill body must be correctly mounted with cutting edges parallel to the X- axis of the machine ( Mounting the drill on the turret can be viewed on page 15) X-axis of machine Interferences Offsetting to the direction of decreased diameters Central edge Peripheral edge Offset value must be less than.004". Direction of decreased diam- eters Central edge Peripheral edge Direction of increased diameters Hole diameter machined with offset are roughly calculated as following. Drilled diameter = Drill diameter + offset value x 2 Example: Drill diameter: ø1.125" Offset value:.020" Drilled hole diameter = 1.125 +.020 x 2 = ø1.165" Offset value (+) is depend on the each drill body. Central edge Peripheral edge Offsetting to the direction of increased diameters Shapes of hole bottom Unevenness of the hole-bottom face when machined with TungSix-Drill is smaller than with HSS drills! The shape of the hole bottom machined with TungSix-Drill is closer to flat compared with those machined with HSS drills. Drill diameter ødc (in) ø1.125 ~1.25 ø1.312 ~1.50 ø1.562 ~ 1.812 ø1.875 ~ 2.00 Hmax (in).069.083.096.105 Hole bottom shape obtained with TungSix-Drill Drill diameter ødc Maximum unevenness Hmax Hmax 17

Troubleshooting Type and place of trouble Cause Countemeasures Central cutting edge Peripheral cutting edge Relief surface Relief surface Inappropriate cutting conditions Inappropriate cutting conditions Increase the cutting speed by 10% within standard conditions. Lower the feed rate by 10%. Decrease the cutting speed by 10% within standard conditions. When the feed rate is extremely low or high, set to standard conditions. Abnormal wear of insert Common Relief surface Crater wear Coolant types and supply method Vibration during machining Looseness of insert clamping Excessive heat occurrence Confirm that the cutting fluid flow is higher than 7 liter/min. The concentration of coolant must be higher than 5%. Use the coolant superior in lubricity. Change to internal coolant supply from external one. Change to the machine with higher torque. Change to the clamp method with rigidity. Change the drill holding method. Tighten the screw. Change to internal cutting fluid supply from external one. Increase the supply rate of the cutting fluid. (Higher than 10 liter/min.) Lower the feed rate by 20% within standard conditions. Lower the cutting speed by 20% within standard conditions. Remarkable chip rubbing Lower the feed rate by 20% within standard conditions. Lower the cutting speed by 20% within standard conditions. Chipbreaker Improper chip control, chip packing Increase the cutting speed by 20% and lower the feed rate by 20% within standard conditions. Raise the coolant pressure (for higher than 1.5 MPa). Misalignment in work rotating Set the misalignment to 0 ~.008". Machining with large offset Check the manual and use the tool in the allowable offset range. Central cutting edge Rotating center of drill Drilling into non flat surface Too high a feed rate Flatten the entry surface in pre-machining. Set the feed rate for lower than.002 ipr in rough surface area. Lower the feed rate by 20 ~ 50% within standard conditions. Reuse of chipped corner Confirm the corner when exchanging inserts. Use of insert in excess of tool life Exchange the corner or the peripheral insert before the corner wear reaches.012". Chipping and fracture of insert Peripheral cutting edge Peripheral corner area Unused corner and cutting edge Drilling into non flat surface Presence of interrupted portion on the way of machining Reuse of chipped corner Improper chip control, chip packing Chip recutting Mechanical impact Flatten the entry surface in pre-machining. Set the feed rate for lower than.002 ipr at rough surface area. Set the feed rate for lower than.002 ipr in interrupted area. Confirm the corner when exchanging inserts. Increase the cutting speed by 20% and lower the feed rate by 20% within standard conditions. Raise the fluid pressure (for higher than 1.5 MPa). Lower the feed rate by 20% within standard conditions. Change to continuous feed in case of pick feeding. Common Contact boundary Use of insert in excess of tool life Vibration during machining Exchange the corner or the insert before the notch wear reaches.012". Change to the machine with higher rigidity. Change to the clamp method with rigidity. Change the drill setting method. Flaking Common Work hardness is too high Thermal impact Looseness in insert clamping Set the feed rate for lower than.002 ipr. Change to internal cutting fluid supply from external one. Lower the feed rate by 20% within standard conditions. Tighten the screw. 18

Type and place of trouble Cause Countemeasures Misalignment in work-rotating Set the misalignment to 0 ~.008". Offset-machining in excess of allowable value Use the tool in the allowable offset range. Offsetting toward decreasing diameter Set offset direction extended diameter of workpiece Rubbing scratch on drill body Inferior hole accuracy Periphery of drill body Hole diameter Surface finish Common Drilling into or through non flat surface Fracturing of peripheral insert Workpiece deflection Chip packing Misalignment in work-rotating Improper offsetting. Drilling into or through non flat surface Workpiece deflection Coolant types and supply method Flatten the entry surface in pre-machining. Set the feed rate for lower than.002 ipr in rough surface area. Exchange the insert. Change to the clamp method with rigidity. Increase the cutting speed by 20% and lower the feed rate by 20% within standard conditions. Raise the fluid pressure (for higher than 1.5 MPa). Set the misalignment to 0 ~.008". Adjust offset contents. Flatten the entry surface in pre-machining. Set the feed rate for lower than.002 ipr at rough surface area. Change to the clamp method with rigidity. The concentration of coolant must be higher than 5%. Use the coolant superior in lubricity. Change to internal coolant supply from external one. Improper cutting conditions Increase the cutting speed by 20% within standard conditions. Lower the feed rate by 20% within standard conditions. Insert failure Exchange the insert. Increase the cutting speed by 20% and lower the feed rate by 20% Chip packing within standard conditions. Raise the coolant pressure (for higher than 1.5 MPa). Looseness of insert clamping screw Tighten the screw. Improper cutting conditions Work within standard conditions. Increase the cutting speed by 10% within standard conditions. Increase the feed rate by 10% within standard conditions. Chip control Entangling Chip packing Common Insert failure External coolant supplying Chips produced by central edge Improper coolant supply Improper cutting conditions Exchange inserts. Change to internal coolant supply from external one. Work by step feed. Use dwell function for 0.1 sec approximately. Use of excessively damaged drill body Exchange the drill holder. Looseness of insert clamping screw Tighten the screw. There is a tendency to shorten the chips when shifting to higher speed and feed. Change to internal coolant supply from external one. Raise the coolant pressure (for higher than 1.5 MPa). Increase the cutting speed by 20% and lower the feed rate by 20% within standard conditions. Raise the coolant pressure (for higher than 1.5 MPa). Other trouble Chatter Machine stop Large burr Improper cutting conditions Lower the cutting speed by 20% within standard conditions. Increase the feed rate by 10% within standard conditions. Excessively worn insert Exchange the insert. Change to the machine with higher torque rigidity. Vibration during machining Change to the clamp method with rigidity. Change the drill holding method. Looseness of insert clamping screw Tighten the screw. Insufficient machine power and torque Use the range of number of revolutions suited machine spec. Lower the feed rate by 20 ~ 50%. Exchange inserts before the failure becomes larger. Galling Check that the coolant flows powerfully from the drill. Lower the cutting speed and the feed rate by 20% within standard conditions. Insert failure Exchange the insert. Improper cutting conditions Lower the feed rate by 20 ~ 50% just before leaving from the workpiece. 19

3726 N Ventura Drive, Arlington Heights, IL 60004, U.S.A. Inside Sales: +1-888-554-8394 Technical Support: +1-888-554-8391 Fax: +1-888-554-8392 Tungaloy Canada 432 Elgin St. Unit 3, Brantford, Ontario N3S 7P7, Canada Phone: +1-519-758-5779 Fax: +1-519-758-5791 Tungaloy de Mexico S.A. C Los Arellano 113, Parque Industrial Siglo XXI Aguascalientes, AGS, Mexico 20290 Phone:+52-449-929-5410 Fax:+52-449-929-5411 www.tungaloyamerica.com Become a fan on facebook Follow us on Twitter @tungaloy Watch our videos on You Tube Scan for instant web access Distributed by: June. 2012 (TA)