1/1/2015

Boosting Deep-Hole Drilling Productivity Up To 10 Times(MAN August 1999)

DRILLING/BORING/TAPPING

Boosting Deep-Hole Drilling

Productivity Up To 10 Times
Using conventional twist, spade, or gundrilling methods to drill holes larger than " diameter to
depths of 100 times diameter usually means severely reduced productivity and accuracy.
Like all manufacturers, job shops involved in deep-hole drilling are always looking for ways to
deliver product on time without compromising dimensional, geometric, and surface accuracy
requirements. Traditionally, deep-hole generation has been a slow, cautious process with the
potential for bottlenecks. In response to frequent conflicts between increased throughput and
reduced accuracy, meeting specifications usually won out at the expense of extended processing
cycle times.
A hole is considered to be a "deep hole" when it is five to 10 times, and up to 100 times, its
diameter. Unlike milling and turning, where the work surface is in full view, drilling occurs almost
entirely within the workpiece. What happens at the cutting edge is governed primarily by cutting
speeds and feeds, tool geometry and grades, the material, and the coolant. The deeper the hole,
the more problems with chip disposal, tool overhang, and tool deflection.
In addition, there is the problem of getting cutting oil to the drilling face, with the obvious
consequences of failure. If the drill head does not get enough coolant, there is the risk of improper
chip breaking due to the lack of lubricity on the cutting edges. Friction between the drill support
pads and the hole wall can build up torsional forces and increase the horsepower and feed-force
requirements.
Now, single-tube drilling tools are available that address the deep-hole productivity/accuracy
dilemma. The answer is a robust, rigid tool with strong, effective chipbreakers and a choice of
carbide grades, and a design that delivers lots of cutting fluid for cooling and chip removal.

Single tube drills meet all these requirements.

The single tube system is based on external cutting fluid supply and internal chip transport. That is,
incoming cooling is pumped to the cutting face through the annular space between the outside of
the tube and the wall of the hole itself using an oil pressure head. The fluid exits through the tubular
drill shank, carrying the chips to a chip collection area. With the proper application of coolant,
internal chip evacuation through the hollow drill shaft eliminates all the problems of chip binding and
jamming which often occurs with conventional gundrills. No groove is required in the shank, so the
tube cross section is completely round. As a result, the shaft is more rigid and able to absorb feed
and torque forces.
The single tube drill consists of a drill head, drill tube, collet, and sealing sleeve, or in many cases a
tube driver. The drill head is screwed onto the drill tube and has an arrangement of two or more
carbide inserts, depending on the diameter of the drill. These inserts each operate in different heat
zones, with different chip formation in each zone, as well as differing tool wear patterns. The drill
http://www.modernapplicationsnews.com/articles/m9908san.html

1/3

1/1/2015

Boosting Deep-Hole Drilling Productivity Up To 10 Times(MAN August 1999)

head can be either a brazed disposable type or multi-tip indexable insert. Since cutting forces are
not totally balanced in deep-hole drilling, the drill has two support pads that are located
strategically. These pads "ride" on the hole wall keeping the drill centered and allowing for
increased penetration and straightness.
Brazed drill heads have two or three cemented regrindable carbide tips positioned to overlap and
balance cutting forces. Chipbreakers are form-sintered in each tip to provide the best possible chip
control. Disposable drill heads yield lower cost-per-inch of drilled hole length than regrindable
heads. (For holes less than " diameter, regrindable drills are still the only alternative.) Because of
improved cutting edge geometry, cutting forces are more balanced and chipbreaking is more
uniform. Besides the conventional application areas, disposable single tube drills are very effective
with low-carbon stainless steels and more elastic materials such as high-temperature alloys.

Tips for Successful Single Tube Deep-Hole Drilling

Disposable drill heads eliminate the time and cost associated with regrinding. In a switch from a
regrindable gundrill to a disposable single tube system drill, one manufacturer reduced edgechanging time from 15 minutes to two minutes. To change to new cutting edges, all that is required
is to unscrew the drill and replace it with a new one. Successful single tube deep-hole drilling
depends on starting with the proper machine tool and tooling parameters, and taking some
preventive measures.
Avoid excessively long, large chips to prevent binding and frequent maintenance; chips
should be as long as they are wide. Increasing feed and reducing cutting speed have proved
helpful.
The machine tool must have adequate horsepower and rigidity. A good rule is to use
horsepower that is 10 times the drill diameter: a 1" tool at recommended feeds and speeds
needs a 10hp spindle.
When using a water-soluble coolant (emulsion) or straight oil containing sulfur, at
temperatures above 135 F, the sulfur or lubricant burns and lubricating effect is reduced.
Loss of lubrication results in premature tool failure, guide pad wear, and loss of chip control.
Premature built-up edge, flank wear, frittering, or thermal cracking indicate a problem with
tool and pad wear, possibly due to excessively high coolant temperature or improper
machine settings. Worn pads mean that the tool is unbalanced, and losing tool diameter will
result in reduced tool life.
Pump pressure requirements decrease and volume requirements increase for proper coolant
delivery with larger hole diameters. The tank must be large enough for adequate filtering and
cooling.
The best straightness tolerances are produced with counter rotation, where the drill and the
workpiece rotate in opposite directions.
When working with asymmetrical workpieces with holes that are not too deep, high
http://www.modernapplicationsnews.com/articles/m9908san.html

2/3

1/1/2015

Boosting Deep-Hole Drilling Productivity Up To 10 Times(MAN August 1999)

accuracy can be achieved with a rotating tool and a stationary workpiece. However, as the
hole aspect ratio increases, hole straightness degrades since the risk of deflection is
increased.
The acceptable deviation from straightness is: for counter rotation, 0.0005" - 0.002" per
foot of drilling length; for a stationary drill, 0.001" - 0.003" per foot; and for a rotating drill,
0.003" - 0.006" per foot.
To ensure hole straightness, the machine tool must be aligned. Misalignment causes
deflection or deviation from the centerline, making it impossible to meet tolerances and
unbalancing cutting forces.
Drill bushings should not be oversized, worn, or positioned incorrectly. These conditions can
lead to misalignment and early tool wear. Cemented carbide bushings are preferred for
maximum wear resistance.
A mechanical feed mechanism, such as a ball screw, will hold up best to resultant feed
forces.
A 40 micron or less cutting fluid filter should be used to ensure good life for the drill and
associated pumps and oil pressure heads.
Single tube deep-hole drilling is a unique metal removal method, requiring some skill and systematic
preventive maintenance. Once mastered, it will provide rewards of about 10 times higher
productivity than conventional gundrilling methods, with greater accuracy and process control.
Sandvik Coromant
- August 1999

http://www.modernapplicationsnews.com/articles/m9908san.html

3/3