Mounting hole

UM DANDIA PCD HELI-DRILL™ - the unique UM DANDIA™ sandwich drill point combined with helical guide pads and flute, designed as a "one-shot" solution.

Objective

Increase capacity on an existing production line by reducing cycle time.

The potential saving for the mounting holes was relatively large, as each of the 8 holes has a drilling depth of 96,5 mm. The holes are drilled from solid material (no precasting pilot hole).

Kyocera Unimerco tool solution

PCD spiral-fluted drill on solid carbide tool body with sandwich drill point.

Adjustable UM DANDIA™ tool holder to ensure optimum run out.

Tool no.: 210400/000030

Result

The feed rate was increased to a remarkable 9,000 mm/min. at 15,000 rpm. This is 3.6 times faster than the previous carbide drill, which performed 2,500 mm/min. at 8,000 rpm. Even at these data, the process reliability is good.

The ongoing tool costs are slightly higher than those of the carbide drill, but the savings from the reduced cycle time is several times higher.

Achievements

• Feed rate increase by a factor of 3.6
• 22.70 seconds saved per cylinder head

Data

• 15,000 rpm
• 9,000 mm/min. feed rate
• Tool life not set yet (still running)
• Recommended cutting data:
  10,000 - 15,000 rpm, f 0,6
  (vf 6,000 - 9,000 mm/min.)
  Decreased feed rate for first 8-10 mm

Machining centre

• 40 bar internal coolant
• 10% emulsion
• Material : ALSi9Mg