2nd Edition
High-Productivity Drilling Tools Materials, Metrology, and Failure Analysis
This completely updated volume covers tool materials, tolerances, an inspection of drilling tools, requirements of tool drawings with examples, and methodologies and procedures of failure analysis. It introduces a new line of HP drilling tools called VPA designs and brings it into sharp focus signifying its importance in drilling operations.
High-Productivity Drilling Tools: Materials, Metrology, and Failure Analysis further develops the concept of the metrology of the drilling tools introduced in the first edition. For the first time, the relevant metrological parameters are clearly defined with tolerance for HPHD with practical examples of step-by-step inspection/measurement using advanced tool measurement microscopes and CNC machines. A pros and cons list as a quick and easy decision-making tool for the choice of measuring equipment for a particular application is offered along with practical examples of drilling tool drawings to help tool designers, cutting tool and manufacturing engineers, and users in their everyday activities in the design and selection of HPDT for a particular application. An unparalleled presentation of metalworking fluids (MWFs, a.k.a. coolants) is given and covers all the start of the business: selection, implementation in HPDT and drilling operation, monitoring, and maintenance. A two-step procedure for successful implementation of near-dry machining (NDM) or minimum quantity lubrication (MQL) is presented, and a discussion of the wear of the drilling tool, its proper assessments, and metrics are provided in the evaluation of tool life and quality of machined holes.
This practical book should be on the shelves of all industrial engineers, those working in production and manufacturing, process designers, tool material designers, cutting tool designers, and quality specialists. Researchers, senior undergraduate students, and graduate students will also find this book full of very helpful reference information and the source of new ideas and notions in drilling tool development.
This book is also available as a set - Drills: High-Productivity Drilling Tools, 2-Volume Set (9781032203508).
Preface
Acknowledgments
Author
Chapter 1 Metrology of Drilling Tools: Tolerances, Inspection, and Representation in Tool Drawings
1.1 Introduction
1.2 Tolerances on Drills and Drilling Tools’ Critical Features and Their Representation on Tool Drawings
1.2.1 Drilling Tool Diameter
1.2.2 Shank Diameter
1.2.3 Overall Length/Flute Length/Shank Length
1.2.4 Runout
1.2.5 Point Angle and Lip Height
1.2.6 Web Thickness and Centrality (Symmetry) of the Web
1.2.7 Flute Spacing
1.2.8 Chisel Edge Centrality
1.2.9 Back Taper Tolerance
1.2.10 Margin Width Tolerance
1.2.11 Helix, Rake, and Clearance Angles
1.2.12 Surface Roughness
1.2.13 Tool Balancing Tolerances
1.3 Fundamentals of Inspection/Measurements of Drilling Tools
1.3.1 Basic Definitions
1.3.2 Dimensional Inspection (Metrological) System
1.3.3 Important Fundamental of Tool Optical Inspection/Measurement
1.4 Gages and Microscopes for Drilling Tool Measurement/Inspection
1.4.1 Legacy Gages
1.4.2 Comparators
1.4.3 Advanced Drilling Tool Measuring Devices
Note
References
Chapter 2 Tool Materials
2.1 Introduction
2.2 Basic Properties of Tool Materials
2.2.1 Tensile and Compression Strengths
2.2.2 Modulus of Elasticity
2.2.3 Toughness
2.2.4 Wear Resistance
2.2.5 Hardness
2.2.6 Red Hardness
2.3 High‑peed Steels
2.3.1 Why HSSs?
2.3.2 Short Historical Development
2.3.3 Common Grades of HSS
2.3.4 Factors Affecting Intelligent Grade Selection of HSS
2.3.5 Formation of Properties
2.3.6 Components in HSS
2.3.7 Heat Treatment of HSS
2.3.8 Cryogenic Treatment of HSSs
2.3.9 Coating of HSS
2.4 Cemented Carbide
2.4.1 What is CC?
2.4.2 Grade Classification
2.4.3 Properties of CCs
2.4.4 Carbon Content
2.4.5 Non‑estructive Testing of Carbide Properties Using Magnetic Measurements
2.4.6 Cryogenic Treatment of CCs
2.4.7 Trends in Development
2.4.8 Carbide Blanks
2.4.9 Coating
2.5 Tool Materials: Words of Wisdom
Note
References..
Chapter 3 Metalworking Fluids (MWF)
3.1 Introduction
3.1.1 Necessity of this Chapter
3.1.2 Background Information
3.2 Type of MWFs
3.3 Basics of MWF Selection
3.3.1 Wish List
3.3.2 Common Selection Methods
3.4 MWF Application Methods
3.4.1 Flood Application
3.4.2 Through-Tool MWF Application
3.4.3 Dry and Near‑Dry (Minimum Quantity Lubricant) Applications
3.4.4 Application of CMWFs
3.5 High‑ressure MWF Supply: Essentials and Particularities of Tool Design
3.5.1 Why is High MWF Pressure Needed?
3.5.2 MWF Management in the Bottom Clearance Space (BCS)
3.6 Dry Machining
3.7 Near‑ry (MQL) Drilling Operations: Theory, Apparatus, and Particularities of Tool Design
3.7.1 Underlaying Cause for the Development of NDM (MQL)
3.7.2 Understanding the Subject
3.7.3 Implementation Aspects
3.7.4 Aerosol (Mist)
3.7.5 Classification of NDM
3.7.6 Cutting Tool
3.7.7 Chip Management
3.7.8 Machines
3.7.9 Using Near‑Net‑Shape Blanks
3.8 Cryogenic MWF
3.8.1 Introduction
3.8.2 CMWF as a Cooling Medium and Common Application Technique
3.8.3 How CMWF Can Help to Improve the Metal Cutting Process
3.9 MWF Essential Parameters To Be Maintained in HP Drilling Operations
3.9.1 Concentration
3.9.2 Water Quality
3.9.3 MWF Filtration
3.9.4 Tramp Oil
3.9.5 Conclusion Remark
References
Chapter 4 Tool Life, Wear, and Failure Analysis Procedures of Drilling Tools
4.1 Tool Life
4.2 Tool Wear
4.2.1 Background Information
4.2.2 Standard Wear Assessment
4.2.3 Advanced Wear Assessment
4.2.4 Mechanisms of Tool Wear
4.3 Tool Life Testing
4.3.1 Standard
4.3.2 Advanced
4.4 Drilling Tool Wear
4.4.1 Common Wear Regions of Drilling Tools
4.4.2 Assessment of Tool Wear of Drilling Tools
4.4.3 Design of Experiment (DOE)
4.4.4 Analysis of Drilling Tool Reliability
4.5 Drilling Tool Failure Analysis
4.5.1 Exordium
4.5.2 Traditional Notions and Approaches
4.5.3 Failure: A System‑elated Definition
4.5.4 Tool Failure Prime Sources
4.5.5 Preparation Stage of Tool Failure Analysis (TFA): Collecting Information
4.5.6 Assessment of the Collected Evidences: Obvious Root Causes
4.5.7 Normal Tool Failure Analysis
4.5.8 Special Tool Failure Analysis
Note
References
Appendix A: Geometrical Product Specification and Verification (GPS&V) Basics Related to Drilling Operations
Appendix B: Basics of Balancing
Appendix C: MWF Flow Fundamentals
Appendix D: Plastic Lowering of the Cutting Edge
Biography
Viktor P. Astakhov earned his PhD in mechanical engineering from Tula State Polytechnic University, Tula-Moscow, Russia, in 1983. He was awarded a DSc designation (Dr. habil., Docteur d’État) and the title “State Professor of Ukraine” in 1991 for the outstanding service rendered during his teaching career and for the profound impact his work had on science and technology. An internationally recognized educator, researcher, and mechanical engineer, he has won a number of national and international awards for his teaching and research. In 2011, he was elected to the SME College of Fellows.
Besides his teaching engagements, Dr. Astakhov currently serves as the tool research and application manager of Production Service Management Co. which is a part of EVIE Group of companies, a large international tool management company that provides tooling service to many industries as the automotive, aerospace, power, medical and others. He has published monographs and textbooks, book chapters, and many papers in professional journals as well as in trade periodicals. He has authored the following books: Drills: Science and Technology of Advanced Operations, Metal Working Fluids: Fundamentals and Recent Advances, Geometry of Single-Point Turning Tools and Drills: Fundamentals and Practical Applications, Tribology of Metal Cutting, Physics of Strength and Fracture Control, and Mechanics of Metal Cutting. He also serves as the editor in chief, associate editor, board member, reviewer, and advisor for many international journals and professional societies.
