In a presentation that balances theory and practice, Drills: Science and Technology of Advanced Operations details the basic concepts, terminology, and essentials of drilling. The book addresses important issues in drilling operations, and provides help with the design of such operations. It debunks many old notions and beliefs while introducing scientifically and technically sound concepts with detailed explanations.
The book presents a nine-step drilling tool failure analysis methodology that includes part autopsy and tool reconstruction procedure. A special feature of the book is the presentation of special mechanisms of carbide (e.g. cobalt leaching) and polycrystalline (PCD) tool wear and failure presented and correlated with the tool design, manufacturing, and implementation practice. The author also introduces the system approach to the design of the drilling system formulating the coherency law. Using this law as the guideline, he shows how to formulate the requirement to the components of such a system, pointing out that the drilling tool is the key component to be improved.
Teaching how to achieve this improvement, the book provides the comprehensive scientific and engineering foundations for drilling tool design, manufacturing, and applications of high-performance tools. It includes detailed explanations of the design features, tool manufacturing and implementation practices, metrology of drilling and drilling tools, and the tool failure analysis. It gives you the information needed for proper manufacturing and selection of a tool material for any given application.
Table of Contents
Drilling System for HP Drills: Structure, Properties, Components, and Failure Analysis
Tool Failure as a System Problem: Investigation, Assessment, and Recommendations
Traditional Notions and Approaches
Failure: A System-Related Definition
Tool Failure Prime Sources
Preparation Stage: Collecting Information
Part Autopsy and Tool Reconstruction Surgery
Words of Wisdom
High Speed Steels
Twist and Straight-Flute Drills: Geometry and Design Components
Constraints on the Drill Penetration Rate: Drill
Force Balance as the Major Prerequisite Feature in HP Drill Design/Manufacturing
Drill Design Optimization Based on the Load over the Drill Cutting Edge
PCD and Deep-Hole Drills
PCD Drilling Tools
Metalworking Fluid in Drilling
MWF Application Methods
High-Pressure MWF Supply: Theory, Apparatus, and Particularities of Tool Design
Near-Dry (Minimum Quantity Lubricant) Drilling Operations: Theory, Apparatus, and Particularities of Tool Design
Increasing Tool Life with CMWF
Application of CMWFs
MWF Essential Parameters to Be Maintained in HP Drilling
Metrology of Drilling Operations and Drills
Standard Reference Temperature
Large-Scale Features: Bore Tolerancing
Large-Scale Features: Geometrical Tolerances
Appendix A: Axial Force, Torque, and Power in Drilling Operations
Appendix B: Tool Material Fundamentals
Appendix C: Basics of the Tool Geometry
"… very valuable knowledge … new procedures to find the root causes of tool failure with accuracy … based on the innovative concepts … the right methodologies and practices to help … selection of the drilling system components to manufacture high-quality products, improve the efficiency of the drilling process and development of the next generation of high-performance (HP) drills."
—J. C. Outeiro, Arts et Metiers ParisTech
"… explains drilling (science and technology of advanced operations) with high quality and innovation. … a useful reference for academics, researchers, mechanical, manufacturing, industrial engineers, and professionals familiar with machining technology."
—J. Paulo Davim, University of Aveiro
"This book can be used for undergraduate engineering courses (for example, manufacturing, mechanical, materials, etc.) or as a subject on machining and manufacturing at the postgraduate level. It can be used as a course manual for career and vocational training courses and career training classes. … a useful reference for academics; manufacturing and metal cutting researchers; mechanical, manufacturing and materials engineers; and professional in manufacturing and applications of advanced metal cutting tools primarily in the automotive and airspace industries."
—Int. J. Machining and Machinability of Materials, Vol. 17, No. 2, 2015
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