Sandvik Coromant Holemaking Part4

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Part 4 - Application examples

Introduction and general guidelines ......................................................................................... 158

Hole quality - tools .................................................................................................................... 160

How to make precision holes ................................................................................................... 162

Workpiece material - tools ....................................................................................................... 164

Hole making in different industrial segments

Hole making in the Die and Mould industry ......................................................................... 166

Hole making in the Automotive industry ............................................................................... 172

Hole making in the Aerospace industry .................................................................................. 178

Hole making in the Small Part Machining industry ............................................................... 186

Hole making generally in industries ........................................................................................ 190

Application examples with different tools

CoroDrill 880 ............................................................................................................................ 194

CoroDrill Delta-C 840, 842, 844 .............................................................................................. 200

CoroDrill 850 ............................................................................................................................ 204

CoroBore 820 ............................................................................................................................ 208

CoroBore 825 ............................................................................................................................ 211

Reamer 830 ................................................................................................................................ 212

CoroMill 390 and CoroMill Plura vs CoroBore 820 and 825 ............................................... 213

Large through hole D 80 mm ................................................................................................... 214

CoroTurn XS .............................................................................................................................. 215

Contents

158

Introduction and general guidelinesAs mentioned in the first chapter it is impor-tant to consider all different parameters involved in the hole making operation to achieve the best possible productivity, quality and economy.

The first pages in this chapter give some general guidelines of what type of tools to consider depending on batch size, machine conditions, hole tolerance demands and workpiece materials.

The next part describes common compo-nents in different industry segments from a hole making perspective.

In the last part in this chapter a number of different application examples are pre-sented with the aim to give ideas how to produce holes in the most efficient way, with reliability and consistency maintained.

159

Drilling & Boring Step drilling Milling, helical interpolation

Advantages• Simple standard tools • Relatively flexible

Disadvantages• Two tools, adaptors and

basic holders • Requires two tool positions

Advantages• Simple Tailor Made tools • Fast way to make a hole

Disadvantages• Requires more power and

stability • Less flexibility

Advantages• Simple standard tools • Very flexible• Low cutting forces

Disadvantages• Longer cycle times.

The standard option Productivity.Long series production

Flexibility. Short series production

Below you see a common type of hole that can be produced in at least three different ways. Which method is the best? As always it depends on the circumstances:

Different ways to make a hole

160

CoroDrill® Delta-C Coromant Delta CoroDrill® 880

R844

R840 R842R850

The hole tolerance demands are the most basic parameter to consider. According to ISO the tolerance width is defined as IT, see chapter 5.

Below some different tool options are shown in relation to hole tolerance and surface finish.

Hole quality - tools

Short precision holes IT6-7

Close tolerance holes IT8-10

Ra 0.5-1 μm Ra 1-2 μm

Close tolerance holesIT10-11

Eccentrico sleeve

Adjustable holder

Ra 0.5-5 μm

Medium tolerance holes IT12-13


Ra 1-4 μm

161

CoroMill® Plura R216.34

CoroMill®390 CoroMill®300

• Shorter drills and stable set-up (spindle-holder-workpiece) improves the hole tolerance.

• The obtained surface finish is very much dependant on the stability (vibration tendency), the workpiece material and the feed per revolution.

• By presetting the CoroDrill 880, in a late or in a rotating tool application with help from an eccentric sleeve or an adjustable holder, the hole tolerance can be improved.

Medium tolerance holes IT12-13

Open tolerance holes >13

Ra 2-5 μm Ra >5 μmRa 0.5-5 μm


See page 226, Part 5

162

CoroDrill® Delta-C CoroMill® 390Coromant Delta CoroDrill® 880 CoroMill® Plura R216.34

R844 R840 R842R850

CoroBore® 825 CoroMill® Plura R216.34

Operation 1

Different possibilities to reach IT6-7 tolerance class

Reamer 830

How to make precision holes

Operation 2

16�

If straightness or hole position of the drilled (or pre-formed) hole is a problem an inter-mediate boring operation needs to be per-formed. Suitable tools are CoroBore 820, DuoBore, CoroMill Plura, CoroDrill Delta-C 850 etc.

To achieve tolerances of IT 6-7 normally a second and in some cases a third operation has to be considered.

However,one exception is the CoroDrill Delta-C drill type 844 that was originally developed for drilling of carbide button holes in rock drill heads. This drill can produce short holes to IT 6 in one hit.

But normally two operations are needed to reach IT 6-7. The most common tools to perform the finsihing operation are a fine boring tool (CoroBore 825 etc.) or a reaming tool (Reamer 830). But a solid carbide end mill (CoroMill Plura) can also be a good option, not as productive as the multi-edge reamer, but in comparison with a single-edge boring tool it can be competitive.

164

CoroDrill®Delta-C Coromant Delta CoroDrill®880

CoroDrill®805

★★★ ★★★ ★★★

★★★ ★★*) ★★★

★★★(842) ★★★ ★★★

★★★(850) ★ ★★★

★★ ★ ★★★

★★★ ★ ★★★

★★★ ★★★ ★★

**) ★★ -

★★★ ★★★ ★★★

**) ★★★ ★

**) ★★ -

**) ★ -

Workpiece material - toolsExample different drill types

★★★ Means that the drill type is very well adapted for that workpiece material*) Optimized grade recommended (see page 49, part 2)**) Under evaluation, contact your Sandvik Coromant representative

Gun drill

Single-lip Twin-lip

★★★ Means that the drill type is very well adapted for that workpiece material*) Optimized grade recommended (see page 49, part 2)**) Under evaluation, contact your Sandvik Coromant representative

165

CoroBore®820 CoroBore®825

★★★ ★★★ ★★★

★★★ ★★★ -

★★★ ★★★ ★★★*)

★★★ ★★★ -

★★★ ★★★ -

★★★ ★★★ -

CoroMill® 300 CoroMill® 390 CoroMill® Plura R216.34

★★★ ★★★ ★★★

★★★ ★★★ ★★★

★★★ ★★★ ★★★

★★★ ★★★ ★★★

★★★ ★★★ ★★★

★★★ - ★★★

Example different boring/reaming tools

Example different boring/reaming tools

★★★ Means that the drill type is very well adapted for that workpiece material

*) Recommendation for grey cast iron (CMC 08), grade M10C, geometry W

★★★ Means that the tool is very well adapted for that workpiece material

Reamer 830

167

Hole making in the Die and Mould industry

Hole making in the die and mould industry covers a lot of very different requirements, from round bolt-holes to polished profile-cavities. Manufacturing in this industry involve that varied demands from both machining and workpiece material have to be tackled. Material removal rates need to be very high in roughing operations and surface quality very high in finishing operations. With half of the machining in die and mould being some sort of hole making, the cutting tool and method side of manufacturing cavities and holes is well worth optimizing.

Throughput time stands to be gained both on the roughing side and on the finishing side. When large amounts of material can be removed in a shorter time during cavity roughing, it will directly reduce the time the job is on a machine. The most suitable type of operation – milling or drilling – should always be considered. Is helical interpolation with a round insert cutter best or is it a com-bination of solid drilling and plunge drilling?

How are cavity corners machined in moulds – these are often the most demanding for the tool and machine but can be made more effi-cient and reliable. For example, by plunging corners, large radial engagements of milling cutters can be avoided.

On the construction side, the various types and sizes of round holes in base plates can be improved by the use of a suitable indexable drill or solid cemented carbide drill. Most holes are well suited to these very efficient

drills and where a close tolerance is required, can be combined with a cemented carbide reamer – often replacing three or four diffe-rent slower tools. A modern drill will make holes in cast-iron or steel in a fraction of the time taken with out dated tools and step drills will complete multi-diameter/chamfer holes in one pass.

The two examples presented on the following pages are both from the manufacturing of stamping dies for sheet metal forming.

One common hole making operation in the production of moulds is drilling of coolant holes.

One example with the CoroDrill 805 drill can be found on page 207.

168

C

A

D

B

E

CoroBore® 820 CoroBore® 825 CoroDrill® 880CoroMill® 300 CoroMill® 390

CoroBore® 820

CoroBore® 825

CoroMill® 300

CoroDrill® 880CoroDrill® Delta-C R840CoroDrill® 880

CoroDrill® Delta-C R840

Hole making in the Tool & Die industry - Progressive die

Stripper plate

Insert/detail

Die shoe

Guide pin

Spool/Shoulder pad/Keeper

Bolster

<=2×D

M6-M24

Ø80-180 mm

<=

2×

D

~1.5×D

3×D

Ø6-20 mm

Ø5

0-1

50

mm

Ø1

2-2

2 m

m

Ø4

0-8

0 m

m

Reamer 830

169

Feature A

Feature Name: Guide pin holeTypical materials: CMC 01.1, CMC 01.4, CMC 08.2Typical hole diameters: 50, 60, 80, 100, 125, 150 mmTypical hole depth: up to 2 X diameterTypical hole tolerance: 0 - 0.02 mmTypical pre conditions: preformed holes, ~ 50 mm, in casting, when final dia is >80 mm

Cutting tool:CoroMill 300 + CoroBore 820 + CoroBore 825

Feature BFeature Name: Seats for Spools, Shoulder bolts and KeepersTypical materials: CMC 01.1, CMC 01.4Typical hole diameters: Large dia: 40-80 mm, small dia 12-22 mmTypical hole depth big diameter: 1,5 X DTypical tolerance: flat bottom with a position tolerance +-0.05 mmTypical pre conditions: solid material

Cutting tool:Large hole: CoroDrill 880 alt. U-drill + CoroMill 390 alt. CoroMill Plura end millSmall hole: CoroDrill Delta-C R840 alt. CoroDrill 880

Feature CFeature Name: Hole for guide pin bushingsTypical materials: CMC 01.1, CMC 01.4, CMC 08.2Typical hole diameters: Pin diameter +30 mmTypical hole depth: up to 2 X diameterTypical tolerances: 0 + 0.02 mmTypical pre conditions: often a precasted hole ~ 50 mm


Feature D

Feature Name: Bolt holes and threaded holesTypical materials: CMC 01.1, CMC 01.4, CMC 03.21, CMC 08.2, CMC 09.2Typical hole diameters: M6 to M24Typical hole depth big diameter: up to 3 X DTypical tolerance: IT 11-12Typical pre conditions: solid material

Cutting tool:1. Clearance hole: CoroDrill Delta-C R840 alt. CoroDrill 8802. Threaded hole: CoroDrill Delta-C R840 alt. CoroDrill 880Complementary: CoroDrill Delta-C stepdrill R840

Feature E

Feature Name: dowel pin holeTypical materials: CMC 01.1, CMC 01.4, CMC 08.2, CMC 03.21Typical hole diameters: 6 mm to 20 mmTypical hole depth: up to 3 X diameterTypical tolerance: H7Typical pre conditions: solid material

Cutting tool:Small holes: CoroDrill Delta-C R840Larger holes: CoroDrill 880 + Reamer 830

Note: Large machines in the tool & die industry often misses coolant and/or compressed air through the spindle. This has to be considered for chip evacuation in drilling applications.See page 84 for recommendations.

170

B

C A

E

D

CoroBore® 820 CoroBore® 825CoroBore® 820 CoroBore® 825CoroMill® 300 CoroMill® 300

CoroDrill® 880

CoroDrill® 880 CoroDrill® 880CoroDrill® Delta-C R840

CoroMill® 390

Hole making in the Tool & Die industry - Line die

Guide pin

Upper Die shoe

Lower Die shoeWear plate

Punch

Spring (e.g.Coil, Gas, Urethane)

Ø80-180 mm

M20 M24 M30 M6- M24

Ø30-100 mm

Ø50-150 mm

0.5

-3×D

<=

2×

D

<=

2×

D

171

Feature A

Feature Name: Guide pin holeTypical materials: CMC 01.1, CMC 01.4, CMC 08.2Typical hole diameters: 50, 60, 80, 100, 125, 150 mmTypical hole depth: up to 2 X diameterTypical hole tolerance: 0 - 0.02 mmTypical pre conditions: preformed holes, ~ 50 mm, in casting when final dia is >80 mm


Feature B

Feature Name: Eyelet hole (threaded hole)Typical materials: CMC 01.1, CMC 01.4, CMC 08.2Typical hole diameters: M20, M24, M30Typical tolerance: IT 11-12Typical pre conditions: solid material

Cutting tool: CoroDrill 880

Feature C

Feature Name: Hole for guide pin bushingsTypical materials: CMC 01.1, CMC 01.4, CMC 08.2Typical hole diameters: Pin diameter +30 mmTypical hole depth: up to 2 X diameterTypical tolerances: 0 + 0.02 mmTypical pre conditions: often a precasted hole ~ 50 mm


Feature D

Feature Name: Hole/Bolt hole and threaded holesTypical materials: CMC 01.1, CMC 01.4, CMC 03.21, CMC 08.2, CMC 09.2Typical hole diameters: M6 to M24Typical hole depth big diameter: up to 3 X DTypical tolerance: IT 11-12Typical pre conditions: solid material

Cutting tool:1. Clearance hole: CoroDrill Delta-C R840 alt. CoroDrill 8802. Thread hole: CoroDrill Delta-C R840 alt. CoroDrill 880Complementary: CoroDrill Delta-C R840 step drill

Feature E

Feature Name: Seat for springTypical materials: CMC 01.1, CMC 01.4, CMC 08.2Typical seat diameters: 30 mm to 100 mmTypical seat depth: 0,5 - 3 X diameterTypical tolerance: flat bottom with a position tolerance +-0.05 mmTypical pre conditions: solid material

Cutting tool:First choice: CoroDrill 880 alt. U-drill + CoroMill 390 alt. CoroMill PluraComplementary: CoroDrill 880 alt. U-drill + CoroBore 820

Note: Large machines in the tool & die industry often misses coolant and/or compressed air through the spindle. This has to be considered for chip evacuation in drilling applications.

See page 84 for recommendations.

17�

Holemaking in the automotive industry …… involves many hole sizes and designs because of the numerous parts requiring different purpose holes. Machining solutions have in common that they are for large volume production and that cycle times and manufacturing economics are high priorities and many times this means that special tool solutions are necessary. Flexibility is not much of an issue but the cost per hole is.

The engine block and head have many holes, most of which have threads or are guide and coolant holes. The majority are relatively small in diameter - some deep or needing long tool reach. But there are also large holes that need boring operations, for example cylinder holes. Special combination-tools are common here to provide steps and chamfers to be made in one pass with a drill or boring tool. The workpiece materials involved are mainly cast iron and aluminium, but which are undergoing development especially with the growing demand for more effcient engines. Some of the materials, like compac-ted graphite iron and austempered ductile iron are more demanding, needing optimized insert geometries and grades and even new solutions and methods.

Connecting rods are dominated by their two main holes - one large for the crank and one smaller for the pin, as well as the smaller bolt holes. Made in forged steel or through powder metallurgy, in very large numbers, manufacturing efficiency has been and is

more than ever the dominant factor. While the larger crank-hole is an exisiting hole that needs rough and finish boring the pin-hole needs drilling, boring and sometimes reaming. Modern indexable insert drills that provide high penetration rates are crucial here, having the capacity to reduce cycle times.

The bolt holes are most efficiently made with solid carbide drills.

Hole making in the Automotive industry

174

CoroDrill® 880

In contrast crankshafts and camshafts have holes but in the form of centre holes, oil holes and some weight-reduction holes mostly of small diameters.

Transmissions need housings as the structure and to protect them. To reduce weight, alu-minium has become increasingly popular for use here with holes needed to be made in the castings. The size variation of bolt, guide and bearing holes vary to some extent, with dedicated aluminium-machining tools, such as PCD but also solid carbide drills like the CoroDrill Delta-C 850 for aluminium, playing an increasingly important role for drilling and boring.

All the different steel and cast-iron compo-nents that go to make up the mechanical part of a car have holes that rely on the evolvement of efficient tools. Brakes, discs, steering, wheels, spindles, axles, etc. probably have more holes than the rest put together and often out-sourced with machining produc-tivity as a big issue. Developing the drilling and boring with standard tools as well as engineered specials help to maintain this as a competitive enterprise.

Hole making in the Automotive industry - universal joint yoke

12 mm

Ø25 mm H7

Reamer 830

175

CoroDrill® 880


Hole making in the Automotive industry - Connecting rod

50 mm

M10 (Dc Ø8.6 mm)

Ø24 H7

Reamer 830

Ø10.5 mm

176

CoroDrill® 850 CoroDrill® 842

Hole making in the Automotive industry - Cylinder head

Ø8 mm

Ø12 mm

M1

2

25 mm

M10

20 m

m

25 m

m

30 mm

Applications example see page 206

Cast iron

Non-ferrous metals

Applications example see page 201 and 202

177

CoroDrill® 850 CoroDrill® 842

Hole making in the Automotive industry - Cylinder block

Cast iron

Non-ferrous metalsØ

16

mm

30 mm

80 m

m

Ø12 mm

30 mm

M1

0

Applications example see page 206

Applications example see page 201 and 202

179

Hole making in the Aerospace industry

Hole making in the aerospace industry …… is used for both making holes and cavities in frames as well as holes in the engine components. The materials used are often very demanding, such as heat resistant super alloys, titanium and stainless steel, in addition to aluminium alloys. Hole making is in some cases among the last operations that have to be performed on components. This means that reliability, as regards performance and quality, are essential as the parts have accumu-lated considerable value in manufacturing.

There are many, especially small, holes drilled in the engine components where tools and methods are subject to strict control and so need careful selection and trials before being established as the means of production for a certain period of time.

The hundreds of holes made in engine components, in demanding materials, vary from small, down to diameters of 5 mm, on casings, shafts and discs for assembly. Access holes on casings, with diameters ranging between 20 to 80 mm, are often helically milled. The engine shafts have deep holes drilled, finished by boring using tuned tools.

The frame workpieces especially are very machining intensive, needing a lot of mate-rial to be removed, In frames, structural parts have numerous pockets and pre-drilling and plunge drilling of corners are operations that are performed frequently. These parts also have large diameter holes, often ranging from 20 to 100 mm in diameter, where drilling and

boring hole making operations are needed. In the assembly, small diameter holes for rivets are produced on drilling rigs, where drilling has to take place through two or three components often made of different materials.

Landing gears have very deep holes which are drilled and bored. These may require tool overhangs of up to fourteen times the dia-meter, needing modern solutions in the form of tuned, re-inforced boring bars. Deep hole drilling is employed to make the holes in the forgings.

180

C

D

B

A

CMC 20.22

Hole making in the Aerospace industry - Aero engine

Component feature solutions

Casing

Ø60 mm

Ø22 mm

20 m

m

5 mm

Ø8.00 mm

15 mm

5/16-24 UNF

Waspalloy

181

CoroDrill® 880

CoroMill® Plura

Coromant Capto® CoroTurn® XS

CoroDrill® Delta-C


CoroMill® Plura

CoroMill® 300

CoroMill® Plura


CoroDrill® Delta-C

CoroMill® Plura


1 Drill

CoroDrill 880 – Ø21.00 mmvc 30 m/min fn 0.05 mm/rCentre insert - LM 1044Periphery insert - LM H13A

2. Circular interpolate – hole Ø22 mm

R216.24-12050CAK26P 1620 Ø12.00 mmvc 75 m/min ae 0.5 mm fz 0.1 mm/tooth ap 10 mm

3. Chamfer

C4-CXS-47-06 CXS-06T045-20-6225R 1025vc 75 m/min fz 0.1 mm/tooth

1. Drill

R840-0700-30-A1A 1220 Ø7.00 mmvc 25 m/minfn 0.1 mm/r

2. Finish bore

R216.24-08050A19P 1620 Ø8.00 mmvc 40 m/min fn 0.2 mm/r

3. Chamfer


2. Circular interpolate – Ø60 mm

R216.24-12050CAK26P 1620Ø12 mmvc 75 m/min fz 0.1 mm/tooth ap 10 mm

1. Helical ramping – hole Ø59 mm

R300-12400E-PL 1030 Ø35 mmvc 25 m/min fz 0.2 mm/tooth ap 2.0 mm

3. Chamfer


1. Drill

R840-0690-30-A1A 1220 Ø6.90 mmvc 25 m/min fn 0.1 mm/r

3. Thread mill

R217.33C060240AC13N 1630vc 75 m/min fz 0.07 mm/tooth

2. Chamfer

C4-CXS-47-05 CXS-05T045-20-5220R 1025vc 75 m/minfz 0.1 mm/tooth

OPERATION DØ8.00 mm, hole 5 mm deep

OPERATION AØ22 mm, hole 20 mm deep

OPERATION BØ60 mm, hole 20 mm deep

OPERATION C5/16-24 UNF hole 15 mm deep

182

B

A

20.22

Hole making in the Aerospace industry - Aero engine


Shaft

Ø12 mm

20 mm

1500 mm

Ø120 mm

Inconel 718

18�

CoroDrill® Delta-C

CoroMill® Plura


3. Chamfer


2. Finish bore

R216.24-12050CAK26P 1620 Ø12.00vc 40 m/minfn 0.2 mm/r

1. Drill

R840-1100-30-A1A 1220 Ø11.00 mmvc 25 m/minfn 0.1 mm/r


1. Drill

T-Max 424.1 DHD Ø110 mmvc 43 m/min fn 0.23 mm/r

2. Rough bore – hole Ø119.5 mm

CoroTurn SL – Silent boring bar, Ø80 mmDNMG 150608-23 1105vc 40 m/min fn 0.2 mm/rap 2.0 mm

3. Finish bore – hole Ø120.0 mm

CoroTurn SL – Silent boring bar, Ø80 mmDNMG 150608-23 1105vc 40 m/min fn 0.2 mm/r ap 0.25 mm

OPERATION BØ120 mm, hole 1500 mm deep

184

CMC 23-22

AB

CoroDrill® 880 CoroBore® 820 CoroBore® 825

U-Max®

Hole making in the Aerospace industry -Landing gear


4. Chamfer

SPMT 120408-WL H13ACamfering end millvc 75 m/min fz 0.1 mm/tooth

2. Rough bore

CCMT 09T308-KM H13A Ø69.0 mmvc 40 m/min fn 0.6 (3x0.2) mm/r

3. Finish bore

TCMT 110308-KF H13A Ø70.0 mmvc 60 m/minfn 0.15 mm/r

1. Drill

CoroDrill 880 Ø60.0 mmvc 50 m/minfn 0.1 mm/rCentre insert - LM 1044Periphery insert - LM H13A

Landing gear

1. Drill

CoroDrill 805 Ø65 mmvc 30 m/min, fn 0.16 mm/r

2. Rough bore – Ø69.5 mm

CoroTurn SL Silent boring bar, Ø50 mmDNMG 150608-23 H13Avc 40 m/min fn 0.2 mm/r ap 2.0 mm

3. Finish bore Ø70.00 mm

CoroTurn SL Silent boring bar, Ø50 mmDNMG 150608-23 H13Avc 80 m/mm fn 0.2 mm/r ap 0,25 mm

OPERATION AHole Ø70.00 mm, hole 45 mm deep

OPERATION BØ70.00 mm, hole 500 mm deep

Ø70 m

m

Ø70 m

m

Ti6.4

185

CMC 23-22

A

CoroMill® 300 CoroMill® Plura U Max®

Hole making in the Aerospace industry - Main Landing Gear


Main Landing Gear

2. Circular interpolate – hole Ø150.00 mm

R216.24-20050GAK44P 1620Ø20 mmvc 175, fz 0.05 mm/tootjap 20 mm

1 Helical ramping – hole Ø149.0 mm

R300-12400E-PL 1030 Ø80 mmvc 25 m/min fz 0.2 mm/tooth ap 3.0 mm

3. Chamfer

SPMT 120408-WL H13ACamfering end millvc 75 m/minfz 0.1 mm/tooth


Ø150 mm

Ti5553

75 mm

187

Hole making in the Small Part Machining industry

With the growing need of manufacturing industries for small, precision components, the area of small part machining is seeing a lot of developments in machine tools, methods and tooling.

Most of the components are drilled and bored. CoroDrill Delta-C combined with CoroTurn XS provide new levels of performance.

Bar fed sliding head machines and NC-lathes are the most common machine types and consequently hole making is made with non- rotating tools. Good alignment spindle-tools are essential for the performance.

The number of small parts being machined is increasing by the day and many have holes that are drilled and bored. CoroDrill Delta-C combined with CoroTurn XS provide new levels of performance in sliding head machines as well as CNC-lathes.

188

Sliding head machine HydroGrip or CoroGripholders for minimal run-out

CoroDrill Delta-C and CoroTurn XS an unbeatable couple in hole making

189

A B

Hole making in the Small Part Machining - Connector


3. Internal threading

CorotTurn® XS vc 100 m/min nap 7

2. Internal turning

CoroTurn® XS vc 100 m/min ap 0.15 m/minfn 0.08 mm/r

1. Drill

CoroDrill® Delta-C R840 Ø10.25 mmvc 60 m/minfn 0.14 mm/r

OPERATION A

3. Internal grooving

CoroTurn® XS vc 100 m/min fn 0.015 mm/r

2. Internal turning

CoroTurn® XS vc 100 m/min ap 0.15 m/minfn 0.08 mm/r

1. Drill

CoroDrill® Delta-C R840 Ø14 mmvc 70 m/minfn 0.2 mm/r

OPERATION B

MARK

Austenitic Stainless SteelCMC 05.21SS 2343AISI 316

191

Hole making generally in industries

Because of the increasing pressure of com-petitiveness, the metal removal rate, security and quality consistency of hole making is becoming more of an important cost factor in most industries. The machining of holes is performed almost everywhere and the effi-ciency of the tools and the methods should be regularily assessed, whether for flexible one-piece or large-batch production.

Suppliers of machined parts are having to take more responsibility of the products they machine and this entails staying on top of not only machinery but also the machining processes. Selecting the right drill, boring tool, reamer and milling tool as well as method directly affects cycle times, number of set-ups, tolerance and surface finish levels and level of operator attendance. A proven advantage with modern hole making tools is the ability to machine most workpiece mate-rials as well as having the possibility to opti-mize according to material with dedicated indexable inserts.

For example, the relatively new and growing sector of wind power entails making different holes in housings and mechanical compo-nents. The drilling of the numerous holes here holds a potential for improvement as it does for drilling the multitude of holes in heat-exchanger plates in other energy sectors. Various electrical and transmission housings require drills and boring tools of various sizes, the quality of which make quite a difference to productivity.

Areas where a productive indexable insert drill, like CoroDrill 880, can make a large difference to the total machining times are in the manufacturing of pumps, valves, flanges and in the oil and gas industry. Each com-ponent consist of many holes of the same diameter.

Hydraulic block components have numerous port and bolt holes many of which are still drilled and bored using out-dated, slow tools. The latest indexable insert drills as well as brazed and solid carbide drills can reduce the through-put times. Paper industry com-ponents are large and usually require many medium-sized holes, both precision and open-tolerance holes in different materials. Modern hole making technology has for many years helped to improve productivity here and is continuing to do so.

The list is long of industry applications where hole making perfomance makes a diffe-rence to the cost per component, the time it takes for it to pass through production and the resources needed in the machine shop.

192

CoroDrill® 880

CoroDrill® 880


Hole making generally in industries - Windmill production - Power generation

Hole making generally in industries - Heat exchanger - Power generation

Ø30-50 mm

4xD

Ø10-40 mm

4xD

Steel

Stainless Steel

Steel

CoroDrill® 880wirh adjustable holder for closer hole tolerance

19�

CoroDrill® 880 CoroBore® 820 CoroMill® 390

Hole making generally in industries - Pump and valve

First choice: CoroBore 820Complementary: CoroMill 390

Ø15-30 mm

1xD

Ø1

00

-30

0 m

m

Stainless Steel

Cast iron

194

CoroDrill® 880 for heat exchanger plates

Component: Heat Exchanger PlatoMaterial: ASTMA 182 Unalloyed steel (CMC 02.1)Holes per component: 1542 pcsTool: CoroDrill 880Insert: Central -LM 1044 and

Peripheral -LM 4044Machine tool: Horizontal ISO 40 Machining centre

Cutting data CoroDrill® 880n (rpm) 4000vc (m/min) 232fn (mm/rev) 0.06vf (mm/min) 135

Comments: These plates are in a very tricky material and chip evacuation is critical. CoroDrill 880 was able to increase speed (vc) from vc 131 to vc 232 with same insert tool life compared to earlier method.

CoroDrill® 880 Application examples

Hole diameter (mm): 19.5Hole tolerance (mm): 0 +0.25Hole depth: 2×D

Material: Type of production: Medium seriesIndustry: Power generation

CoroDrill® 880 the high productivity choice in flange manufacturing

Component: Flange for oil industryMaterial: Austenitic stainless steel (CMC 05.21)Tool: CoroDrill 880Insert: Central -LM 1044 and

Peripheral -LM 4024Machine tool: Machining centre, vertical ISO40

Cutting data CoroDrill® 880n (rpm) 3083vc (m/min) 185fn (mm/rev) 0.12vf (mm/min) 370Time per hole 2.6

Comments: With high productivity the CoroDrill is a exemplary choice in stainless steel.

Hole diameter (mm): 19Hole tolerance (mm): 0 +0.25Hole depth: 0.8×D

Material: Type of production: Large seriesIndustry: Flange manufacturing

40

19.5

15

19

195

CoroDrill® 880 in cast iron components

Component: Rear shaft housingMaterial: Nodular, Peritic Cast Iron (CMC 09.2)Holes per component: 39 pcsTool: CoroDrill 880Insert: Central -GR 1044 and

Peripheral -GR 4024Machine tool: Machining centre, horizontal ISO50


Comments: Higher speed made the most significant difference in productivity +32 % compared with the existing exchange tip drill. Difference in cost per hole was even greater.

Hole diameter (mm): 20.5Hole tolerance (mm): 0/+0.3Hole depth: 3xD

Material: Type of production: Large seriesIndustry: Automotive

CoroDrill® 880 5xD drilling in bearing

Component: BearingMaterial: Low carbon steel, (CMC 01.1)Holes per component: 53 pcsTool: CoroDrill 880Insert: Central -LM 1044 and

Peripheral -LM 4024Machine tool: Conventional drilling machine with swivel connection

Cutting data CoroDrill® 880n (rpm) 3500vc (m/min) 308fn (mm/rev) 0.12vf (mm/min) 420Time per hole 21

Comments: Even in long chipping material and deep holes high productivity is possible with the CoroDrill 880.

Hole diameter (mm): 28 Material: Hole tolerance (mm): 0/0.4 Type of production: Small series Hole depth: 4.5×D Industry: Automotive

62.5

Ø28

125

196

CoroDrill® 880 offset hole with chamfer

Component: Tri axisMaterial: Unalloyed steel (CMC 02.1)Holes: 28.4 mm with 1mm 45º chamferTool: CoroDrill 880,Insert: Central -GM 1044 and

Peripheral -GM 4024Machine tool: Lathe


Comments: With the CoroDrill 880 a tight tolerance hole with chamfer is possible in one stroke, with a standard drill.

Hole diameter (mm): 28 Material: Hole tolerance (mm): 0/0.15 Type of production: Large series Hole depth: 1.3×D Industry: Automotive

CoroDrill® 880 tight tolerance with adjustable holder

Component: Tube caseMaterial: Stainless steel (CMC 05.21)Tool: CoroDrill 880Insert: Central -LM 1044 and

Peripheral -LM 4044Machine tool: Machining centre


Comments: Good tolerance and high productivity was possible due to adjustable holder.

Hole diameter (mm): 16.5 Material: Hole tolerance (mm): ±0.07 Type of production: Large series Hole depth: 2.9×D Industry: General machining

CoroDrill® 880 Application examples

35

Ø2

8.4

47

Ø16.5

1x45°

197

CoroDrill® 880 in con rod manufacturing (small eye)

Component: Con rodMaterial: Low-alloy steel (CMC 02.1)Tool: 880-D2350L25-03Insert: Central -GR and

Peripheral -GR Machine tool: Machining centre, vertical ISO50

Cutting data CoroDrill® 880 Reamer 830n (rpm) 3200 1592vc (m/min) 240 120fn (mm/rev) 0.20 0.72vf (mm/min) 650 1146Time per hole (sec.) 2.8 1.57

Comments: The productivity combination CoroDrill 880 and Reamer 830.

Hole diameter (mm): 23.5 Material: Hole tolerance (mm): Ø24 H7 Type of production: Large series Hole depth: 1.3×D Industry: Automotive

30

23.5

CoroDrill® 880 and Reamer 830 Application examples

198

CoroDrill® Delta-C 840 - Application examples

CoroDrill® Delta-C GC1220 lasted longer and halved the cutting time per hole

Component: Fork top clampsMaterial: Unalloyed steel, (CMC 01.2) HB200Tool: R840-0500-50-A1A 1220

Cutting data GC1040 GC1220vc (m/min) 47 79fn (mm/rev) 0.12 0.14Tool life, no. of holes 2600 3000Time per hole (min) 0.06 0.03Productivity increase 50%Tool life increase 15%

Comments: More holes faster with GC1220. Improved chip breaking also safer driling.

Hole diameter (mm): 5 Material: Hole tolerance (mm): IT8 Type of production: Large series Hole depth: 4.6×D Industry: Motorcycle

CoroDrill® Delta-C GC1220 machining of heat exchanger plate

Material: Unalloyed steel, Non-hardened (CMC 01.1) HB125

Tool: R840-1920-30-A1A 1220

Cutting data Competitor GC1220vc (m/min) 95 120fn (mm/rev) 0.26 0.3Time per hole (min) 0.085 0.059Tool life, m 40 40Productivity increase 45%Savings 17%

Hole diameter (mm): 19.2 Material: Hole tolerance (mm): IT9 Type of production: Small series Hole depth: 1.8×D Industry: Power generation

Ø5.0

23.0

Ø19.2

35

199

CoroDrill® Delta-C GC1220 machining of an extraction plate

Material: Austenitic stainless steel, (CMC 05.21) HB180

Tool: R840-1600-30-A1A 1220, cylindrical shankCoolant: Semi synthetic 3-4% internal coolant 8 barMachine tool: Vertical MC

Cutting data Old type R840 GC1020 GC1220vc (m/min) 68 75fn (mm/rev) 0.22 0.22Time per hole (min) 0.069 0.061Tool life, m 12 19.8 (+ 60%)Productivity increase 11%Savings 22%

Hole diameter (mm): 16 Material: Hole tolerance (mm): IT9 Type of production: Small series Hole depth: 1.3×D Industry: Power generation

CoroDrill® Delta-C GC1220 machining of valve body

Material: Grey cast iron, (CMC 08.1) HB200Tool: R840-0850-50-A0A 1220, cylindrical shankCoolant: 5% internal coolant 30 l/min through holeMachine tool: MC horizontal

Cutting data R840 New R842 GC1220 GC1210vc (m/min) 85 100fn (mm/rev) 0.24 0.24Time per hole (min) 0.18 0.16Tool life, m 76 125 (+ 64%)Productivity increase 18%Savings 30%

Hole diameter (mm): 8.5 Material: Hole tolerance (mm): IT9 Type of production: Small series Hole depth: 3xD Industry: Pump and valve

Ø16

20

Ø8.5

25

200

CoroDrill® Delta-C GC1220 Machining of a camshaft component

Material: Unalloyed steel, HB240-280 (CMC 01.4)

Tool: R840-0950-50-A1A 1220, cylindrical shankCoolant: 6 % internal 30 barMachine tool: MC Horizontal 35 kW

Cutting data Competitor R840 GC1220vc (m/min) 60 60fn (mm/rev) 0.14 0.14Tool life, m 75 150Tool life increase 100%

Comments: Not possible to increase cutting data due to other operations made in the same machine, but tool life is doubled.

Hole diameter (mm): 9.5 Material: Hole tolerance (mm): IT8 Type of production: Large series Hole depth: 5xD Industry: Automotive

Ø9.5

49


201

SS 0125; HB 180

CGI; HB 210-240


New CoroDrill® Delta-C drills more holes in cast iron – with less wear

Component: Test pieceMaterial: Cast iron, (CMC 08.1) HB 180Tool: R842-0850-50-A1A, GC1210,Machine tool: Pedersen, Vertical MC, ISO 45

Cutting data CoroDrill® Delta-C CoroDrill® Delta-C R842, GC1210 R840, GC1220n (rpm) 6550 6550 vc (m/min) 175 175fn (mm/rev) 0.25 0.25vf (mm/min) 1638 1638

Performance: The R842 drill in grade GC 1210 - with corner chamfer developed for cast iron - slowed down propagation of wear and produced 66% more holes than the R840 drill in grade GC 1220 did.

Hole diameter (mm): 8.5 Material: Hole tolerance (mm): IT8 Type of production: - Hole depth: 5xD Industry: -

New CoroDrill® Delta-C – a good solution for drilling hard wearing irons

Component: Test pieceMaterial: Compacted graphite iron (CGI) HB 210-240Tool: R842-0850-50-A1A, GC1210Machine tool: Pedersen, Vertical MC, ISO 45


Performance: In the hard to machine compacted graphite iron (CGI), the new drill R842 in grade GC 1210 showed 50% less wear than the existing drill R 840 in grade GC 1220 - at the same number of holes produced.

Hole diameter (mm): 8.5 Material: Hole tolerance (mm): IT8 Type of production: - Hole depth: 5xD Industry: -

Ø8.5

Ø8.5

40

40

202

Precision drilling at high feed rates with CoroDrill® 842 gave better holes at lower costs

Component: Gear box housingMaterial: Grey cast iron, (CMC 08.2) HB 245Tool: R842-1020-50-A1A, GC1210Machine tool: Makino A77- Horizontal MC


Performance: When used at elevated cutting speed for higher productivity, the new drill R842 in grade GC1210 - outperformed the present version, R840 in grade GC1220 - by drilling 60% more holes.

24

Ø1

0.2

Hole diameter (mm): 10.2 Material: Hole tolerance (mm): IT9 Type of production: Large series Hole depth: 5xD Industry: Automotiv

New Tailor Made CoroDrill® Delta-C successful in steel drilling

Component: SleeveMaterial: C45 (CMC 01.2); HB180Tool: Special R842, GC1210 without corner chamferMachine tool: Quser - Vertical MC, ISO 40


Performance: CoroDrill Delta-C R842 in grade GC1210 and with geometry adapted to steel drilling, produced 36 mm deep holes with a total length of 116 meter, whilst the reference drill produced only 14 meter, The reference drill generated also exit burrs.

Hole diameter (mm): 8.5 Material: Hole tolerance (mm): IT9 Type of production: Large series Hole depth: 36 Industry: Automotive


Ø8.5

36

20�

CoroDrill® Delta-C 844 - Application example

CoroDrill® Delta-C 844

Component: Drill BitMaterial: CMC 04.1 42-45 HRCHoles per component: 11Tool: R844Machine tool: M/C

Cutting data CoroDrill® 844n (rpm) 1850vc (m/min) 70fn (mm/rev) 0,13vf (mm/min) 241Time per component (min) 0.55Cost per component (EUR) 10 EUR

Comments: 33% in productivity increase and a 38% increase in tool life. Yearly saving = 15700 EUR.

Hole diameter (mm): 11.99 Material: Hole tolerance (mm): IT6 (precision) Type of production: Large series Hole depth: 1xD Industry: Mining and construction

Ø11.99 mm

204



Component: Cylinder headMaterial: AluminiumHoles per component: 4 pcsTool: R850-0700-70-A1A R850-1100-70-A1AMachine tool: M/C

Cutting data R850 Ø7 mm R850 Ø11 mmn (rpm) 6000 8000 vc (m/min) 132 276fn (mm/rev) 0.29 0.25vf (mm/min) 1250 2000 Time per comp (min) 0.03 0.1 Savings 10.400 EUR

Comments: Savings in production time 813 hours/year.

Hole diameter (mm): 11 and 7 Material: Hole tolerance (mm): IT9 Type of production: Large series Hole depth: 6xD Industry: Motorcycle

CoroDrill® Delta-C R850 39% higher penetration rate with maintained tool life

Component: HousingMaterial: Aluminium alloy 8% SiHoles per component: 7 pcsTool: R850-0670-70-A1AMachine tool: M/C

Cutting data Straight fluted drill R850n (rpm) 9976 9976 vc (m/min) 210 210fn (mm/rev) 0.23 0.32vf (mm/min) 2294 3192Tool life, minTime per hole (min) 0.011 0.008Productivity increase 39%Savings 18.900 EUR

Comments: Hole quality improved and with less burr formation.


25.4

Ø7Ø11

Ø6.7

65

205

CoroDrill® Delta-C R850 22% higher cutting speed with 70% longer tool life

Component: BracketMaterial: Aluminium alloy 9% SiHoles per component: 3 pcsTool: R850-0800-70-A1AMachine tool: M/C

Cutting data Conventional drill R850n (rpm) 7160 8750 vc (m/min) 180 220fn (mm/rev) 0.24 0.25vf (mm/min) 1718 2187Time per hole (min) 0.023 0.018Productivity increase 27%Savings 40.500 EUR

Comments: Higher productivity and longer tool life.


Ø20.5

4123

206

CoroDrill® Delta-C R850 vs PCD-drill

Component: Cylinder headMaterial: Aluminium alloyHoles per component: 16 pcsTool: R850-1120-30-A1AMachine tool: M/C Transfer line

Cutting data R850 PCD-drilln (rpm) 3.500 3.500 vc (m/min) 123 123fn (mm/rev) 0.15 0.15vf (mm/min) 525 525Tool life, m 1520 2045

Comments: Easier regrinding, better hole quality with R850. Hole cost 20% less than PCD.


CoroDrill® Delta-C R850 vs PCD-drill

Component: Engine blockMaterial: Aluminium alloyHoles per component: 24 pcsTool: R850-0740-70-A1AMachine tool: M/C Transfer line

Cutting data R850 PCD-drilln (rpm) 4.300 4.300 vc (m/min) 100 100fn (mm/rev) 0.17 0.17vf (mm/min) 730 730Tool life, m 950 1270

Comments: Easier regrinding, better hole quality with R850. Hole cost 33% less than PCD.



207

CoroDrill® 805 - Application example

CoroDrill® 805

Component: Bearing partMaterial: Steel low-alloy (CMC 02.1)Holes per component: 1Tool: CoroDrill 805 Ø35.00Machine tool: MoriSeiki

Cutting data CoroDrill® 805 HSS-drilln (rpm) 728 182vc (m/min) 80 20fn (mm/rev) 0.18 0.08vf (mm/min) 131 15Time per component (min) 0.21 1.9

Comments: 9 times higher feed rate with CoroDrill 805 and improved hole quality. Both CoroDrill 805 and the HSS-drill require a pilot hole.

Hole diameter (mm): 35 Material: Hole tolerance (mm): IT10 Type of production: Medium series Hole depth: 5.3xD Industry: Mechanical

CoroDrill® 805

Component: Inlet hole in plastic mouldMaterial: Alloyed tool steel (CMC 02.2)Holes per component: 1Tool: CoroDrill 805Machine tool: Horizontal machining centre

Cutting data CoroDrill® 805n (rpm) 424vc (m/min) 60fn (mm/rev) 0.2vf (mm/min) 85Time per component (min) 4

Comments: The CoroDrill 805 opens up applications earlier only possible with gun drills. The productivity increase is considerable.

Hole diameter (mm): 45 Material: Hole tolerance (mm): IT10 Type of production: Small series Hole depth: 7.5xD Industry: Die & Mould

185

Ø35

Ø45

208

CoroBore® 820 - Max productivity

Component: CoverMaterial: (CMC 02.2)Blank dia mm: 57Finished dia mm: 65Hole dept mm: 130 PcsAdaptor C5-R820C-AA3050A 1Slide R820C-AR16SCFCA 3Insert CCMT 09T308-PR 4225 3

Cutting data n (rpm) 784vc (m/min) 160fn (mm/rev) 0.9vf (mm/min) 706fz (mm/insert) 0.3ap (mm) 4Time per hole (sec) 11Savings 50%

Comments: 50% higher penetration rate with maintained tool life compared to tool with two inserts

CoroBore 820 - Application example

Hole diameter (mm): 65Hole tolerance (mm): IT10Hole depth: 2xD

Material: Type of production: Medium seriesIndustry: General engineering

CoroBore® 820 vs DuoBore (twin edge)

Component: Valve housingMaterial: GG25 (CMC 08.1) Hole depth: 199 mm

Machine tool: Makino A77 horizontal machining centre

PcsAdaptor C8-R820I-AA3089A 1Slide R820I-AR36DCFN16A 3Insert CNMG 160608-KM 3

Cutting data CoroBore 820 DuoBoren (rpm) 200 200vc (m/min) 148 148fn (mm/rev) 0.48 0.32vf (mm/min) 96 64Tool life min 150 150Tool life meter 74 49Savings 10% (Boring is a small part of total machining)

Comments: 50% higher penetration rate with maintained tool life

Hole diameter (mm): 235Hole tolerance (mm): +-0.1Hole depth: 199

Material: Type of production: Medium seriesIndustry: Valve manufacture

199 mm

Ø235 m

m

Ø57Ø65

209

CoroBore® 820 - Step boring - Off centre boring

Component: Mould baseMaterial: (CMC 02.2)Blank dia mm: 52Finished dia mm: 70Hole dept mm: 140 PcsAdaptor C5-R820C-AA3050A 1Slide R820C-AR16SCFCA09A 3Insert CCMT 09T308-PR 4225 3Chim set R820C-AS00A 1

Cutting data n (rpm) 730vc (m/min) 160fn (mm/rev) 0.3vf (mm/min) 218fz (mm/insert) 0.3ap (mm) 2Time per hole (sec) 38

Comments: This method should be used when centre lines of holes in blank and finished component not concentric.


Material: Type of production: Small seriesIndustry: Tool and die

Place shim "no1" - 1.0 mm thick - under slide 1 and set diameter to 58 mm.Place shim "no2" - 0.5 mm thick - under slide 2 and set diameter to 64 mm.Set slide "no3" without shim to diameter 70 mm.

CoroBore® 820 - Step boring - Long chipping material

Component: Mould baseMaterial: (CMC 02.2)Blank dia mm: 56Finished dia mm: 65Hole dept mm: 130 PcsAdaptor C5-R820C-AA3050A 1Slide R820C-AR16SCFCA09A 3Insert CCMT 09T308-PR 4225 3Chim set R820C-AS00A 1

Cutting data n (rpm) 784vc (m/min) 160fn (mm/rev) 0.3vf (mm/min) 235fz (mm/insert) 0.3ap (mm) 1,5Time per hole (sec) 33

Comments: This method should be used when boring in soft material with chips difficult to handle. The width of the chip is divided in to three small chips by this setting



Place shim "no1" - 1.0 mm thick - under slide 1 and set diameter to 59 mm.Place shim "no2" - 0.5 mm thick - under slide 2 and set diameter to 62 mm.Set slide "no3" without shim to diameter 65 mm.

Ø522

104

14Ø70

4

210

CoroBore® 820 - Step boring - Large depth of cut

Component: FrameMaterial: (CMC 02.1)Blank dia mm: 46Finished dia mm: 70Hole depth mm: 140 PcsAdaptor C5-R820C-AA3050A 1Slide R820C-AR16SCFCA09A 3Insert CCMT 09T308-PR 4225 3Shim set R820C-AS00A 1

Cutting data n (rpm) 728vc (m/min) 160fn (mm/rev) 0.3vf (mm/min) 218fz (mm/insert) 0.3ap (mm) 4Time per hole (sec) 38

Comments: This method should be used when depth of cut is large.



Place shim "no1" - 1.0 mm thick - under slide 1 and set diameter to 54 mm.Place shim "no2" - 0.5 mm thick - under slide 2 and set diameter to 62 mm.set slide "no3" without shim to diameter 70 mm.


Ø54Ø62Ø70

211

CoroBore® 825 - Finishing

Component: HousingMaterial: (CMC 02.2)Blank dia mm: 59.7Finished dia mm: 60 H7 (0+0.030)Hole dept mm: 120 PcsAdaptor C5-R825C-AAE043A 1Slide R825C-AF23STUC1102A 1Insert TCGX 110204L-WK 1025 1

Cutting data n (rpm) 955vc (m/min) 180fn (mm/rev) 0.15vf (mm/min) 143fz (mm/insert) 0.15ap (mm) 0.15Time per hole (sec) 50

1. Deduct diameter of pre-machined bore from required diameter.2. Divide the result into three (3) equal parts/depth of cut.3. Set diameter to pre-machined hole dia. plus first depth of cut.4. Measure received diameter and calculate deflection of tool.5. Adjust diameter to second depth of cut plus deflection.6. Measure received diameter and calculate deflection of tool.7. Adjust diameter to third depth of cut plus second deflection.8. Bore the third time. The diameter should now be within tolerance.

Comments: Recommendation how to pre-set a finish boring tool, CoroBore 825, in order to achieve H7 toler-ance.


Hole diameter (mm): 60Hole tolerance (mm): H7 (precision)Hole depth: 2xD

Material: Type of production: Small seriesIndustry: General engineering

60.030 60.000 0.030 0.010 0.010 0.010

Ds Dm Ds-Dm

Set dia Dia aftermeasuring

cut

Difference

A1(Ds-Dm)/3

A2(Ds-Dm)/3

A3(Ds-Dm)/3

Divide difference into 3 equal radial cuts

0.010 60.020 0.020

+ A1 Dr1 X1(Dr1-Dm)

Adjustment Measureddiameter

Difference

First diameter adjustment

0.030 60.025 0.005

+ A2 Dr2 X2(Dr2-Dr1)

Second diameter adjustment

0.015 60.030

+ A3(A3xX2)

Dr3

Third diameter adjustment

212

Reamer 830

Component: Shift-forkMaterial: Ck45 (CMC 01.2)Tool: 830A-E06D2200H7S14Length of the bore: 25 mm

Cutting data n (rpm) 2170vc (m/min) 150fn (mm/rev) 0.6vf (mm/min) 1300fz (mm/insert) 0.1ap (mm) 0.15Time per hole (sec) 1.12Tool life 14000 bores

Comments: This is the most productive tool available for large series

Reamer 830 - Application example

Hole diameter (mm): 22Hole tolerance (mm): H7 (Precision)Hole depth: 1.1xD


Ø22

25

21�

CoroMill® 390 and CoroMill® Plura

Component: Gear box housingMaterial: CMC 08.02

Operation A: Face Milling CoroMill 390

Operation B: Circular interpolation Dc 160 mm CoroMill 390

Operation C: Circular interpolation Dc 140 mm CoroMill 390

Operation D: Circular interpolation, ruffing Dc 124.5 mm CoroMill 390

Two alternative options for finishing machining:

Operation Ea: Circular interpolation, finishing Dc 125 mm H7 CoroMill Plura

Operation Eb: Circular interpolation, finish boring Dc 125 mm H7 CoroBore 825

Comments: In this example with the large shallow hole CoroMill Plura is the most productive and versatile tooling solution for producing precision tolerance holes.

CoroMill® Plura vs CoroBore® 825 Application example

Hole diameter (mm): 125Hole tolerance (mm): H7 (Precision)Hole depth: <1×D


Operation A, B, C and D

Operation Ea

Operation Eb

214

T-Max U drill T-Max U trepanner CoroMill® 300

Material: CMC 02.2 Low alloyed steel CMC 02.2 Low alloyed steel CMC 02.2 Low alloyed steelTool: R416.9-0800-25-01 R416.7-0800-25-01 R300-050Q22-12M (z=4)Diameter, Dc (mm) 80 80 50

Cutting data n (rpm) 600 600 955vc (m/min) 150 150 150fn (mm/rev) 0.18 0.18 1.2 (fz=0.30)vf (mm/min) 110 110 430 (vfm=1150)ap (mm) - - 4.94Dvf (mm) - - 30

Result:P (kW) 30 14 6Mv (Nm) 480 330 60Time per hole (min) 0.93 0.93 4.66

Comments: From productivity point of view the drilling tools are superior, 5 times faster than milling the hole by helical interpolation.However, when drilling large holes power and torque can be a machine limitation. The T-MAX U trepanner is a good solution that combines low power requirement and high productivity,but only in through hole applications. In blind holes or when power and torque requirement need to be further reduced a milling cutter can be a good solution.

Large through hole D 80 mm - Application example

Hole diameter (mm): 80Hole tolerance (mm): OpenHole depth: 1.25xD

Material: Type of production: -Industry: -

100 mm

Ø80 mm

215

C4-CXS-47-05 CXS-05T045-20-5215R 7 15

CXS-05T045-20-5220R

8

20

C4-CXS-47-06 CXS-06T045-20-6220R 20 CXS-06T045-20-6225R 25

C4CXS-47-07 CXS07T045-20-7220R 9 20

CXS-07T045-20-7240R

CoroTurn® XS - Application examples

CoroTurn® XS - Back chamfering/de-burring

Note: to adjust chamfer size alter Z position (do not adjust diameter as this could cause rubbing on hole diameter).

Hole diameter (mm): 7.0 Material: Chamfer size (mm): 0.5 Type of production: Medium series Setting radius (mm): 2.75 Industry: Aerospace

1. Position the cutter centrally over the drilled hole with the cutter rotating (vc75) and move axially to flange depth (Z = flange height - chamfer size)

2. Feed cutter to engage with radius compensation

(Y = hole radius)

3. Interpolate 360° (fz 0.1 mm)

4. Feed back to hole centre

5. Retract cutter

Programming sequence when using CoroTurn XS back chamfering tools

Adaptor Insert Min hole size Max hole depth

When machining aerospace engine components, one tricky but often neglected operation is de-burring holes.

By using a CoroTurn XS back chamfering tool it is pos-sible to increase productivity while providing a repeat-able, mechanised, safe process – eliminating the need for manual de-burring and special tools.

The Coromant Capto CoroTurn XS adaptor must be used to provide the correct clearance when used in rotating applications.

Zero point for tool length and radius

Sandvik Coromant Holemaking Part4

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Transcript of Sandvik Coromant Holemaking Part4