Vibration drilling[edit]

Titanium chips – conventional drilling vs vibration drilling

Vibration drilling of an aluminum-CFRP multi-material stack with MITIS technology

The first studies into vibration drilling began in the 1950s (Pr. V.N. Poduraev, Moscow Bauman
University). The main principle consists in generating axial vibrations or oscillations in addition to the
feed movement of the drill so that the chips break up and are then easily removed from the cutting
zone.
There are two main technologies of vibration drilling: self-maintained vibration systems and forced
vibration systems. Most vibration drilling technologies are still at a research stage. In the case of
self-maintained vibration drilling, the eigenfrequency of the tool is used in order to make it naturally
vibrate while cutting; vibrations are self-maintained by a mass-spring system included in the tool
holder.[6] Other works use a piezoelectric system to generate and control the vibrations. These
systems allow high vibration frequencies (up to 2 kHz) for small magnitude (about a few
micrometers); they are particularly suitable for drilling small holes. Finally, vibrations can be
generated by mechanical systems:[7] the frequency is given by the combination of the rotation speed
and the number of oscillation per rotation (a few oscillations per rotation), with magnitude about
0.1 mm.
This last technology is a fully industrial one (example: SineHoling® technology of MITIS). Vibration
drilling is a preferred solution in situations like deep hole drilling, multi-material stack drilling
(aeronautics) and dry drilling (without lubrication). Generally it provides improved reliability and
greater control of the drilling operation.

Circle interpolating[edit]

The orbital drilling principle

Circle interpolating, also known as orbital drilling, is a process for creating holes using machine
cutters.
Orbital drilling is based on rotating a cutting tool around its own axis and simultaneously about a
centre axis which is off-set from the axis of the cutting tool. The cutting tool can then be moved
simultaneously in an axial direction to drill or machine a hole – and/or combined with an arbitrary
sidewards motion to machine an opening or cavity.
By adjusting the offset, a cutting tool of a specific diameter can be used to drill holes of different
diameters as illustrated. This implies that the cutting tool inventory can be substantially reduced.
The term orbital drilling comes from that the cutting tool “orbits” around the hole center. The
mechanically forced, dynamic offset in orbital drilling has several advantages compared to
conventional drilling that drastically increases the hole precision. The lower thrust force results in
a burr-less hole when drilling in metals. When drilling in composite materials the problem
with delamination is eliminated.[8]

Material[edit]
Drilling in metal[edit]
High speed steel twist bit drilling into aluminium with methylated spirits lubricant

Under normal usage, swarf is carried up and away from the tip of the drill bit by the fluting of the drill
bit. The cutting edges produce more chips which continue the movement of the chips outwards from
the hole. This is successful until the chips pack too tightly, either because of deeper than normal
holes or insufficient backing off (removing the drill slightly or totally from the hole while drilling).
Cutting fluid is sometimes used to ease this problem and to prolong the tool's life by cooling and
lubricating the tip and chip flow. Coolant may be introduced via holes through the drill shank, which
is common when using a gun drill. When cutting aluminum in particular, cutting fluid helps ensure a
smooth and accurate hole while preventing the metal from grabbing the drill bit in the process of
drilling the hole. When cutting brass, and other soft metals that can grab the drill bit and causes
"chatter", a face of approx. 1-2 millimeters can be ground on the cutting edge to create an obtuse
angle of 91 to 93 degrees. This prevents "chatter" during which the drill tears rather than cuts the
metal. However, with that shape of bit cutting edge, the drill is pushing the metal away, rather than
grabbing the metal. This creates high friction and very hot swarf.

Magnetic Drilling Machine (manufactured by BDS Maschinen GmbH, Germany)

For heavy feeds and comparatively deep holes oil-hole drills are used in the drill bit, with a lubricant
pumped to the drill head through a small hole in the bit and flowing out along the fluting. A
conventional drill press arrangement can be used in oil-hole drilling, but it is more commonly seen in
automatic drilling machinery in which it is the workpiece that rotates rather than the drill bit.
In computer numerical control (CNC) machine tools a process called peck drilling, or interrupted cut
drilling, is used to keep swarf from detrimentally building up when drilling deep holes (approximately
when the depth of the hole is three times greater than the drill diameter). Peck drilling involves
plunging the drill part way through the workpiece, no more than five times the diameter of the drill,
and then retracting it to the surface. This is repeated until the hole is finished. A modified form of this
process, called high speed peck drilling or chip breaking, only retracts the drill slightly. This process
is faster, but is only used in moderately long holes, otherwise it will overheat the drill bit. It is also
used when drilling stringy material to break the chips.[9][10][11]
When it is not possible to bring material to the СNС machine, a Magnetic Base Drilling Machine may
be used. The base allows drilling in a horizontal position and even on a ceiling. Usually for these
machines it is better to use cutters because they can drill much faster with less speed. Cutter sizes
vary from 12mm to 200mm DIA and from 30mm to 200mm DOC(depth of cut). These machines are
widely used in construction, fabrication, marine, and oil & gas industries. In the oil and gas industry,
pneumatic magnetic drilling machines are used to avoid sparks, as well as special tube magnetic
drilling machines that can be fixed on pipes of different sizes, even inside.

Drilling in wood[edit]
Wood being softer than most metals, drilling in wood is considerably easier and faster than drilling in
metal. Cutting fluids are not used or needed. The main issue in drilling wood is ensuring clean entry
and exit holes and preventing burning. Avoiding burning is a question of using sharp bits and the
appropriate cutting speed. Drill bits can tear out chips of wood around the top and bottom of the hole
and this is undesirable in fine woodworking applications.
The ubiquitous twist drill bits used in metalworking also work well in wood, but they tend to chip
wood out at the entry and exit of the hole. In some cases, as in rough holes for carpentry, the quality
of the hole does not matter, and a number of bits for fast cutting in wood exist, including spade bits
and self-feeding auger bits. Many types of specialised drill bits for boring clean holes in wood have
been developed, including brad-point bits, Forstner bits and hole saws. Chipping on exit can be
minimized by using a piece of wood as backing behind the work piece, and the same technique is
sometimes used to keep the hole entry neat.
Holes are easier to start in wood as the drill bit can be accurately positioned by pushing it into the
wood and creating a dimple. The bit will thus have little tendency to wander.