TR409 TungSixDrill US - Productivity Inc TungSix... · Plane surface Slant surface Cross hole Plunging Boring Round surface Stacked plate Back boring Low carbon steels (C < 0.3)

NEW

Keeping the Customer First

T U N G A LOY

The most economical solution for drilling!

Tungaloy Report No. 409-US

Indexable drill

TDS type

2

1 2

3

4

6

5

f = .002 ipr f = .002 iprf = .004 ipr f = .004 iprf = .006 ipr f = .006 ipr

1.131

1.129

1.127

1.125

1.131

1.129

1.127

1.125

øDc = ø1.125"Vc = 460 sfm

øDc = ø1.125"Vc = 460 sfm

Hole diameterCompetitors

Entrance EntranceMiddle MiddleBottom Bottom

Double-sided insert with 6-cutting edges

One insert type can be used on both the central and peripheral edge

Optimized cutting balance

Features

TungSix-Drill is the fi rst indexable drill in the world to adapt double-sided inserts with 6-cutting edges. The 6-cutting edges reduce the number of inserts consumed.

Customers only require onetype of insert. This simplifi es inventory control.

Optimized cutting bal-ance of TungSix-Drill provides excellent hole accuracy.

Central side Peripheral side

Hole diameter (i

n)

Hole diameter (i

n)

Optimal distance between each cutting edge

This prevents the overlapping of damaged edges

3

AH9030

New revolutionary grade

Enhanced corner of central insert

Twisted coolant holes

The corner of the central cutting edge on the TungSix-Drill improves performance by adapting a negative angle relief. This enhanced corner prevents fracture.

Twisted coolant holes improve coolant fl ow. This

improves chip evacuation, cooling and lubrication

of the cutting edges.

Negative angle reliefNegative angle relief Positive angle reliefPositive angle relief

FractureFracture

PVD coated grade

T U N G A LOY

New generation PVD coating

Special Surface Technology

Smooth insert surface prevents chip adhesion and provides smooth chip fl ow.

Adhesion reinforcement technologyThis specialized treatment enhances the adhesion between the coating and the substrate. Drastically improves chipping and fracture resistance.

Advanced wear and oxidation resistance.

Competitors

Cutting force Cutting force

4

AH903014.5 90.8 2.8 (Ti, Al)N 5

P20 - P35

AH903014.5 90.8 2.8 (Ti, Al)N 5

M20 - M35

OK

Application Features

Grade Substrate Coating layer

Grades

Chipbreakers

DJ type General purpose chipbreaker for almost all applications. Features low cutting forces and allows stable drilling.

TungSix-Drill has been

adapted to ensure the

new system prevents

incorrect insert

clamping. Incorrect

clamping of central and

peripheral insert does

not happen.

System to avoid wrong insert clamping

Steel

Stainless

For steels and stainless steelsExcellent wear and oxidationresistance in medium to high cuttingspeed conditions. "PremiumTec"prevents edge welding.

Applicationcode

Specificgravity

MainComposition

Hardness(HRA)

T.R.S.(GPa)

Thickness(μm)

Note: The drill is designed toavoid wrong insert clamping. Please check the central and peripheral insert faces before setting the insert.

Correct clamping Incorrect clamping

Insert hole fi ts screw hole Insert hole doesn't fi t screw hole

Correctly clamped ! Screw can’t enter screw hole

Central insert Pheripheral insertCentral insert seat

Central insert seat

Central insertPeripheral insert

Central insertseat

Central insertseat

The chipbreaker has thickwidth and gentle curves. This prevents chips from packing.

The high rake angle and highbreaker wall reduce cutting forces and improve chipbreak-ing.

Bumps and grooves formed on the rake face reduce cutting forces and deliver longer tool life.

Can improve surface fi nish

Chipbreaker for central edge

Identifi cation for central edge side

Chipbreaker for peripheral edge

Identifi cation for pe-ripheral edge side

Low cutting forces and long tool life

Wiper design

Central insert Peripheral insert

5

4.5

4

3.5

3

2.5

2

1.5

1

0.5

0f = .002 f = .004 f = .006

.016

.012

.008

.004

020 40 60

.014

.012

.010

.008

.006

.004

.002

0 2 4

330 500 660

.100"

.004

.006

.008

Cutting performance

: TDSU1125-03

: WWMU08X408R-DJ

: AH9030

: 1045

: NC lathe

: ø1.125"

: H = 2.8"

: Wet

Fe

ed

: f (ip

r)

Cutting speed: Vc (sfm)

Chips are stably controlled in thisrange. The chips created are the ideal shape.

TungSix-Drill adapts its positive land, this

enables the drill to reduce the cutting

forces even when using double-sided

inserts. The cutting forces are almost equal

to competitors with single sided inserts.

øDc = ø1.125"Vc = 460 sfmWork material: 1055

Spindle power consumption

Po

wer

co

nsum

ptio

n (k

w)

Feed: f (ipr)

Competitors

Reduction of cutting force Chip control

Excellent wear resistance of AH9030

Thougness of central insert

AH9030 offers superior wear resistance against competitors.

Enhanced corner of central cuttingedge prevents fracture even in pre-hardened steel machining.

Competitor A

Competitor A

Competitor B

Co

rner

wear

wid

th

on p

erip

hera

l ed

ge

Vc (in

)

Maxim

um

fl a

nk w

ear

wid

th

on

centr

al ed

ge V

Bm

ax (in

)

Tool life

: TDSU1125-03: WWMU08X408R-DJ: AH9030: 1055: Vc = 460 sfm: f = .004 ipr: ø1.125": H = 2.8": Horizontal M/C, BT40: Wet (Internal supply)

: TDSU1125-03: WWMU08X408R-DJ: AH9030: Pre-hardened steel (40HRC): Vc = 330 sfm: f = .003 ipr: ø1.125": H = 1.125": Vertical M/C, BT50: Wet (Internal supply)

Fracture

DrillInsertGradeWork materialMachineHool diameterHole depthCoolant

DrillInsertGradeWork materialCutting speedFeedHole diameterHole depthMachineCoolant

DrillInsertGradeWork materialCutting speedFeedHole diameterHole depthMachineCoolant

Machining length (ft)

Machining length (ft)

6

øDc øDs øD r rs L

TDSU1125-02 ★ 1.125

1.250 1.575

2.250

2.280

5.892 .043 1.5

WWMU08X408R-DJ CSTB-3 T-9DTDSU1187-02 ★ 1.187 2.374 6.079 .019 1.6

TDSU1250-02 ★ 1.250 2.500 6.267 .008 1.7

TDSU1312-02 ★ 1.312

1.500

1.969

2.624

2.688

6.862 .055 2.5


TDSU1437-02 ★ 1.437 2.874 7.237 .027 2.8

TDSU1500-02 ★ 1.500 3.000 7.424 .015 2.9

TDSU1562-02 ★ 1.562 3.124 7.612 .074 3.0

WWMU11X512R-DJ

CSTB-5 T-20D

TDSU1625-02 ★ 1.625

2.165

3.250 7.799 .059 3.3

TDSU1687-02 ★ 1.687 3.374 7.987 .051 3.5

TDSU1750-02 ★ 1.750 3.500 8.174 .027 3.7

TDSU1812-02 ★ 1.812 3.624 8.362 .015 3.9

TDSU1875-02 ★ 1.875 3.750 8.549 .094 4.2

WWMU13X512R-DJTDSU1937-02 ★ 1.937 3.874 8.737 .078 4.3

TDSU2000-02 ★ 2.000 4.000 8.924 .067 4.6

øDc (in)AH9030ød T ød1 rε

WWMU08X408R-DJ � .315 .154 .134 .031 ø1.125 ~ ø1.250

WWMU09X510R-DJ � .382 .193 .173 .039 ø1.312 ~ ø1.500

WWMU11X512R-DJ � .445 .224 .217 .047 ø1.562 ~ ø1.812

WWMU13X512R-DJ � .512 .224 .217 .047 ø1.875 ~ ø2.000

rε

T

ød1

ød

L/D = 2

T U N G A LOY

R R

øc

øsh

6

ø

NEW

Inserts

Drills

DJ chipbreaker

Cat. No.

Stocked grades Dimensions (in)

Cat. No StockDimensions (in)

Applicable insertsMax

Offset(Radius)

Weight

(lb)

Clamping screw Torx driver

Applicable drilldiameters

★: 3rd Quarter , 2012

7

L/D = 3

øDc øDs øD r rs L

TDSU1125-03 ● 1.125

1.250 1.575

3.375

2.280

7.017 .043 1.7


TDSU1250-03 ● 1.250 3.750 7.517 .008 1.9

TDSU1312-03 ★ 1.312

1.500

1.969

3.936

2.688

8.174 .055 2.8

WWMU09X510R-DJ CSTB-4 T-15DTDSU1375-03 ● 1.375 4.125 8.424 .047 2.9

TDSU1437-03 ★ 1.437 4.311 8.674 .027 3.1

TDSU1500-03 ● 1.500 4.500 8.924 .015 3.3

TDSU1562-03 ★ 1.562 4.686 9.174 .074 3.4

WWMU11X512R-DJ

CSTB-5 T-20D

TDSU1625-03 ★ 1.625

2.165

4.875 9.424 .059 3.8

TDSU1687-03 ★ 1.687 5.061 9.674 .051 4.1

TDSU1750-03 ★ 1.750 5.250 9.924 .027 4.3

TDSU1812-03 ★ 1.812 5.436 10.174 .015 4.6

TDSU1875-03 ★ 1.875 5.625 10.424 .094 4.9

WWMU13X512R-DJTDSU1937-03 ★ 1.937 5.811 10.674 .078 5.1

TDSU2000-03 ★ 2.000 6.000 10.924 .067 5.5

LR Rs

øDc

øDsh

6

øD

Cat. No StockDimensions (in)

Applicable insertsMax

Offset(Radius)

Weight

(lb)

Clamping screw Torx driver

�: 2nd Quarter , 2012★: 3rd Quarter , 2012

8

Vc (sfm)øDc (in)

ø1.125 ~ ø1.500 ø1.562 ~ø2.000

500 - 1000 .0015 - .004 .0015 - .004

250 - 800 .002- .006 .003 - .007

500 - 800 .002 - .005 .002 - .006

250 - 650 .002 - .006 .003 - .007

300 - 650 .0015 - .005 .0015 - .005

300 - 650 .0015 - .005 .0015 - .005

250 - 380 .0015 - .004 .0015 - .004

250 - 800 .002 - .007 .003 - .008

250 - 650 .002 - .007 .003 - .008

f (ipr).002 .002 .002

f (ipr).004 .002

OK

OK

OK

OK

OK OK

Standard cutting conditions

Application range

Work materialsFeed: f (ipr)

Cutting Speed

Application

Application

Feed

Feed

Upper table

Plane surface Slant surface Cross hole Plunging

Boring Round surface Stacked plate Back boring

Low carbon steels (C < 0.3) 1010,1025, etc.

Carbon steels (C > 0.3)1045,1055, etc.

Low alloy steels5120, etc.

Alloy steels4137,4140, etc.

Stainless steels (Austenitic)304,316, etc.

Stainless steels (Martensitic and ferritic) 430,416, etc.

Stainless steels (Precipitation hardening) S17400, etc.

Gray cast ironsNo.250B, etc.

Ductile cast irons100-70-03, etc.

In case of Interrupted cutting, feed should be decreased.

Disapprove Disapprove

9

New chamfering tool "TDXCF Series"

Features

High productivity with two inserts

Optimum space between the drill body and chamfering inserts prevents cutting edges from fracture

The TDXCF Series with the TungSix-Drill completes both drilling and chamfering at the same time. This reduces machining processes by chamfering anddrilling simultaneously.

Insert grade is GH130 which has TiCNO coating for steels Cutting

edge of chamfer insert

Clamping screw of chamfering tool

Insert

Optimum clearance prevents chipping on edge

Chamfering tool Max. chamfering width: C .098"Chamfering angle: 45ºTwo inserts type

Suitable for machining steel, stainless steels and cast irons

Flute for chip evacuation

Space for drill body

10

.004 .005

TDXCF

TDXCF

(ft-lb) (ft-lb)GH130

TDXCF280L30

~

TDXCF540L30XHGX090700R-45A � CSPB-4S 2.58 CM8 x 20 5.90 T-15D P-5

TD

S2

80

W2

5-3

(L/D

= 3

)

TD

XC

F

Cutting performance

: TDXCF280L30: Carbon steel 1055 (245HB)　: Vertical M/C, BT40: Wet: Vc = 460 sfm: C = .08"

Feed: f (ipr)Tool

New chamfering tools TDXCF provides stable surface fi nish

Continuous spiral chips prevent them from wrapping around the drill body or work piece

Conventional

Thru

st

forc

e (kN

)

Thru

st

forc

e (kN

)Drilling time (min) Drilling time (min)

Sharp cutting edge decreases cutting forces by 50%!!!

Chamfering tool insert & part list

: TDXCF280L30: Carbon steel 1055 (245HB)　: Vertical M/C, BT40: Wet: Vc = 460 sfm: f = .004 ipr: C = .08"

Surface finish

Cutting force

Chip control

Conventional

Tool Work material

Machine CoolantCutting speed Chamfering width

Cat. No. Insert Grade,Stock

Insertclamping

screw

Torque TorqueRingclamping

screw

Wrench

for insert

Wrench

for ring

Tool Work material

Machine CoolantCutting speedFeed Chamfering width

Tool Work material

Machine CoolantCutting speed Chamfering width

: TDXCF280L30: Carbon steel 1055 (245HB)　: Vertical M/C, BT40: Wet: Vc = 460 sfm: C = .08"

� : Stocked items

11

øDs øDc LøDc

L/D = 2 L/D = 3

TDXCF280L30 ● 1.059 2.520 1.181

TDXCF290L30 ● 1.098 2.520 1.181 1.125 TDSU-1125-* 1.338 2.463

TDXCF300L30 ● 1.138 2.520 1.181 1.187 TDSU-1187-* 1.456 2.643

TDXCF310L30 ● 1.177 2.520 1.181

TDXCF320L30 ● 1.217 2.520 1.181 1.250 TDSU-1250-* 1.614 2.864

TDXCF330L30 1.252 2.520 1.181

TDXCF340L30 1.291 2.520 1.181 1.312 TDSU-1312-* 1.732 3.044

TDXCF350L30 1.331 2.520 1.181 1.375 TDSU-1375-* 1.889 3.264

TDXCF360L30 1.370 3.346 1.181

TDXCF370L30 1.409 3.346 1.181 1.437 TDSU-1437-* 2.007 3.444

TDXCF380L30 1.449 3.346 1.181 1.500 TDSU-1500-* 2.164 3.664

TDXCF390L30 1.488 3.346 1.181

TDXCF400L30 1.528 3.346 1.181 1.562 TDSU-1562-* 2.322 3.884

TDXCF410L30 1.567 3.346 1.181 1.625 TDSU-1625-* 2.440 4.065

TDXCF420L30 1.598 3.346 1.181

TDXCF430L30 1.638 3.346 1.181 1.687 TDSU-1687-* 2.598 4.285

TDXCF440L30 1.677 3.346 1.181

TDXCF450L30 1.717 3.346 1.181 1.750 TDSU-1750-* 2.755 4.505

TDXCF460L30 1.756 3.346 1.181 1.812 TDSU-1812-* 2.873 4.685

TDXCF470L30 1.795 3.346 1.181

TDXCF480L30 1.835 3.346 1.181 1.875 TDSU-1875-* 3.031 4.906

TDXCF490L30 1.874 3.346 1.181

TDXCF500L30 1.913 3.346 1.181 1.937 TDSU-1937-* 3.188 5.125

TDXCF510L30 1.953 3.346 1.181 2.000 TDSU-2000-* 3.306 5.306

TDXCF520L30 1.992 3.346 1.181

TDXCF530L30 2.031 3.346 1.181

TDXCF540L30 2.071 3.346 1.181

øc ø

s

Max. drilling depth

Chamfering ring (TDXCF Series)

� : Stocked items

Cat. No. Stock Application drillDrill dia.

Max. drilling depth (in)Dimensions (in)

12

OK

Max.

øD

c +

1.3

Min

.

øD

c -

0.3

L

øD

L2

G

ødJ

S.s.

Points of caution when mounting the chamfering ring on drill body

Match the ring fl ute with the drill fl ute

(Insert will be automatically set to the right position)

The ring fl ute does not match the drill fl ute

Insert is in the wrong position due to incorrectly placed ring

Adjustable drilling diameter holder

Enables diameter of TungSix-Drill to adjust easily

Specification

Place the ring on the drill body and match the ring

fl ute with the drill fl ute. Temporarily clamp the ring

on the body by lightly tightening the ring screw.

Place the inserts on the ring and lightly tighten the

insert screws.

Adjust the ring to the right position with a Presetter,

height gauge or Vernier caliper.

Securely tighten the ring screw and then the insert

screw.

The bore section is actually made from two shifted circular sections. The clamping screw pushes the drill shank through a narrow opening, forcing elastic deformation of the holder. Contact is made around more than 180°, providing a high clamping force.

Drillshank

Constraintsurface

� : Stocked items

S.s. ød øD L L2 J G

TUNGBORE CAT40 EM3/4 � 40 .750 2.835 5.337 2.795 M10 5/8-11

TUNGBORE CAT40 EM3/4 B � 40 .750 2.835 5.337 2.795 M10 5/8-11

TUNGBORE CAT40 EM1 � 40 1.000 2.835 5.337 2.795 M10 5/8-11

TUNGBORE CAT40 EM1 B � 40 1.000 2.835 5.337 2.795 M10 5/8-11

TUNGBORE CAT40 EM1-1/4 � 40 1.250 2.835 5.337 2.795 M10 5/8-11

TUNGBORE CAT40 EM1-1/4 B � 40 1.250 2.835 5.337 2.795 M10 5/8-11

TUNGBORE CAT40 EM1-1/2 � 40 1.500 2.835 5.337 2.795 M10 5/8-11

TUNGBORE CAT40 EM1-1/2 B � 40 1.500 2.835 5.337 2.795 M10 5/8-11

TUNGBORE CAT50 EM3/4 � 50 .750 2.835 5.179 2.795 M10 1-8

TUNGBORE CAT50 EM1 � 50 1.000 2.835 5.179 2.795 M10 1-8

TUNGBORE CAT50 EM1 B � 50 1.000 2.835 5.179 2.795 M10 1-8

TUNGBORE CAT50 EM1-1/4 � 50 1.250 2.835 5.179 2.795 M10 1-8

TUNGBORE CAT50 EM1-1/4 B � 50 1.250 2.835 5.179 2.795 M10 1-8

TUNGBORE CAT50 EM1-1/2 � 50 1.500 2.835 5.179 2.795 M10 1-8

TUNGBORE CAT50 EM1-1/2 B � 50 1.500 2.835 5.179 2.795 M10 1-8

Dimensions (inch)Cat. No. Stock

13

1.125 1.125 1.168 1.625 1.625 1.675

1.187 1.187 1.207 1.687 1.687 1.737

1.250 1.250 1.258 1.750 1.750 1.778

1.312 1.312 1.362 1.812 1.812 1.828

1.375 1.375 1.422 1.875 1.875 1.925

1.437 1.437 1.465 1.937 1.937 1.987

1.500 1.500 1.516 2.000 2.000 2.050

1.562 1.562 1.637

The function of EZ sleeves

Adjusting the hole diameter when drilling

Adjusting the hole diameter in tool-rotating applications.

By using EZ sleeve, the hole diameter can

be adjusted in the range from +.024" to

-.008".

Adjusting cutting edge height on lathe

Adjusting the cutting edge height in rotating work applications.

By using EZ sleeve, the cutting edge height

can be adjusted in the range from +.012"

to -.008". That reduces troubles caused by

improper cutting-edge height.

Scale for adjusting the hole diameter in milling machine

(Periphery of sleeve)

Scale for adjusting cutting edge height in turning

(Front face of sleeve)

EZ sleeve (Eccentric sleeves for TungSix-Drill)

Adjustable range of TungSix-Drill combined with TungBore

Regarding adjustment, please refer to the operating instructions in the TungBore leafl et for the TungHold (No. 389-E)

Tool diameterøDc (in)

Adjustable range (in)

Min. dia. ø Max. dia. ø

Tool diameter øDc (in)

Adjustable range (in)

Min. dia. ø Max. dia. ø

14

øD1 øD2 øD3 L1 L2 L3 L4

EZ0.75-1.25 ● .750 1.25 1.75 2.00 .197 1.575 .375 +.016 ~ -.008 +.008 ~ -.006

EZ1.00-1.50 ● 1.00 1.50 2.00 2.50 .197 1.965 .375 +.016 ~ -.008 +.008 ~ -.006

EZ1.25-2.00 ● 1.25 2.00 2.50 2.70 .197 1.965 .375 +.016 ~ -.008 +.008 ~ -.006

EZ1.50-2.00 ● 1.50 2.00 2.75 2.90 .197 1.965 .375 +.022 ~ -.008 +.012 ~ -.008

øD1

øD2

øD3

L1

L2

L3

L4

（＋）

（－）

+0.4+0.2

●Ensure that the drilling machine to be used has suffi cient rigidity and motor output

●Not recommended for drilling stacked plates

●Be sure to carry out proper alignment when drilling is to be performed on a rotating workpiece

●Before installing the insert in the drill body, remove all foreign matter

from the insert pocket

●When clamping and unclamping the

insert, the center-line of the wrench

should be aligned with the center-line of the screw. (Misalignment

may result in deformation of the socket of the screw head or the tip

of the wrench)

●When installing the insert, eliminate all play between the insert

pocket and the bottom face of the

insert

●Replace the screw before it is ex-

cessively deformed or worn out by

long term use

●Be sure to supply cutting fl uid through the tool

●A water soluble emulsifi able type cutting fl uid should be used

●Fluid pressure of 1 MPa or higher and fl uid quantity of 7 l/min or

more are essential. (For 4D and 5D type, a fl uid pressure of 1.5 MPa

or higher and fl uid quantity of 10 l/min or more is recommended)

Using TungSix-Drill

Cutting fl uid

Cautionary points for setting inserts

Specifi cations

Cautious points

Setting of EZ sleeve

Adjusting the hole diameter on M/C Adjusting cutting edge height on lathe

In the fi gure shown on right, the sleeve is set and the hole diameter will be increased by .016".

Set the EZ sleeve be-tween the drill shank and the holder. Align the scale on the periphery of EZ sleeve with the center of the fl at on drill fl ange.

Set the EZ sleeve be-tween the drill shank and the toolblock. Align the scale on the front face of the EZ sleeve with the center of the fl at on drill fl ange.

In the fi gure shown on right, the sleeve is set and the center of the drill will shift by .004" to the plus (+) direction.

EZ sleeve

Note: Select the sleeve so that the D1 of the sleeve will be same as the diameter of the drill shank.

Proper handling of wrench

Cautious points●Cannot be used for collet chuck holders

●For adjustments over L/D 4, please reduce feed rate

●For smaller adjustment, the drill itself will interfere with the

hole diameter. (It is recommended that hole diameter should

be adjusted to a larger diameter than the drill diameter)

When rotating EZ sleeve, fi xing bolts “A” and “B” have to

be loosened. After setting the hole diameter, fi x the drill

body with bolt “A”. Then lightly tighten the bolt ”B” to fi x

EZ sleeve. If the bolt “B” is over tightened, EZ sleeve may

be damaged.

Fixing bolt “A”

Fixing bolt “B”

X-axis of

machine

Flat

Flange

Fixing bolt “A”

Flat

Flange

EZ sleeve

Fixing bolt “B”

Sleeve Stock Cat. No.Adjusting range of

finishing diameter

Adjusting range of

cutting edge height

15

� When mounting drill body, the cutting edges should be parallel to the X-axis of the machine� Usually, the drill body is mounted with the direction that the peripheral insert can be seen by the operator� As the cotter on shank is parallel to the cutting edges, by tightening the fl at with the fi xing screw, the cutting

edges are guaranteed to be parallel to the X-axis of the machine

Setting of drill body is an important issue for stable machining

Direction of fi xing bolt on tool block

Usually, the drill body is mounted with the direction that the peripheral insert can be seen from the operator

� The cutting edge height is an important factor for stable machining� The cutting edge of central insert should be .008" lower than the rotating axis of machine� For checking the difference between rotating center and the tool block, please use a reference bar that is

from ground solid bar� In this case, the checking of the center height should be measured at the same position as the overhang

length of the drill required� When there isn’t a reference bar, the ground part of a boring bar can be used as a substitute

Mainspindle

If the condition of cutting edge height is not good, the height should be set by adjusting the turret.A simple method is shown in page 16.

Dial gauge

Overhang length of drill

Same length as the overhang of

drill

Reference bar

Turret of the lathe

Boring bar as a substitution

Cutting edges should be parallel to the X-axis of the machine

X-axis of machine

Central edge

Central edge

Peripheral edge

Peripheral edge

Turret

Diff

eren

ce:

shoul

d b

e ab

out

.008

"Mounting the drill on turret (tool post)

Checking of cutting edge height

Use of TungSix-Drill on lathes

X-axis of

machine

Central edge

Central edge

Peripheral edge

Peripheral edge

16

1

2 3

When the condition of the cutting edge height is incorrect, the height should be adjusted with the followingmethods.

When machining with such condition, the central cutting edge may be easily chipped. So this condition has to be rectifi ed.

Solution #1: Change the mounting direction. Solution #2: Rotate drill body 180°In #2, additional cotter is required on the opposite side.

In this case, shifting the mounting position to another position may improve the condition.

When this occurs, the large diameter of the core remains and heavy vibration may occur. To improve this situation: Use EZ sleeve (the eccentric sleeve) and adjust the cutting edge height to correct value. Information on EZ sleeve, is on page 13.

In the case of “slightly above-center” (about .002")

In the case of “excessive below-center” (.008" or more)

In the case of “above-center”

Core on the center

Drilling depth: Up to .400"

Ab

ou

t .0

20

"d

iam

ete

r

Mounting direction

Mounting direction

Center of drill

Rotate Rotate 180°180°

Checking of setting conditions by trial cutting

Adjusting of cutting edge height

� After mounting the drill body, the tool center should be

checked by trial cutting before production

� When the drill body is properly set, a core with about

ø.020" diameter is left on the bottom of hole

� If there is no core, the drill is “above center”

� If the core diameter is larger than ø.040", it is “excessively

below center” (In these cases, the cutting edge height

has to be checked again)

� When trial cutting, the feed should be .004 ipr or less,

drilling depth should be up to .400"

X-axis of machine X-axis of machCenter of drill

Central edge

Central edge

Central edge

Central edge

Peripheral edge

Peripheral edge

Peripheral edge

Peripheral edge

17

ø1.125 ~1.25

ø1.312 ~1.50

ø1.562 ~ 1.812

ø1.875 ~ 2.00

Hmax (in) .069 .083 .096 .105

A larger hole than the drill diameter can be machined!

� When drilling on the lathe, the hole diameter can be adjusted by offsetting the drill body along the X-

axis of machine

� When drilling with offset, the drill body must be correctly mounted with cutting edges parallel to the X-

axis of the machine (“Mounting the drill on the turret” can be viewed on page 15)

Offsetting to the direction of decreased diameters

Offsetting to the direction of increased diameters

Hole diameter machined with offset are roughly

calculated as following.

Drilled diameter = Drill diameter + offset value x 2Example:

Drill diameter: ø1.125"

Offset value: .020"

Drilled hole diameter = 1.125 + .020 x 2 = ø1.165"

● Drilling with offset

InterferencesInterferences

Offset value must be less than .004".

Direction of Direction of increased diametersincreased diameters

Direction of de-Direction of de-creased diam-creased diam-

eterseters

Unevenness of the hole-bottom face when machined with TungSix-Drill is smaller than with HSS drills!

The shape of the hole bottom machined with TungSix-Drill is

closer to fl at compared with those machined with HSS drills.

DrilldiameterøDc (in)

Drill diameter øDc

Hole bottom shape obtained with TungSix-Drill

Maxim

um

unevenness

Hm

ax H

max

Shapes of hole bottom

Machining with offset on the lathe

X-axis of machine

Offset value (+) is

depend on the each

drill body.

Central edge

Central edge

Central edge

Central edge

Peripheral edge

Peripheral edge

Peripheral edge

Peripheral edge

Central edge

Central edgePeripheral edge

Peripheral edge

18

Ab

no

rmal w

ear

of

insert

Chip

pin

g a

nd

fra

ctu

re o

f in

sert

Type and place of trouble Cause Countemeasures

Troubleshooting

Centralcuttingedge

Peripheralcuttingedge

Common

Centralcuttingedge

Peripheralcuttingedge

Common

Reliefsurface

Reliefsurface

Reliefsurface

Craterwear

Chipbreaker

Rotating centerof drill

Peripheral cornerarea

Unusedcorner and

cutting edge

Contact boundary

Flaking

Common

Inappropriate cutting conditions

Inappropriate cutting conditions

Coolant types and supply method

Vibration during machining

Looseness of insert clamping

Excessive heat occurrence

Remarkable chip rubbing

Improper chip control, chip packing

Misalignment in work rotating

Machining with large offset

Drilling into non fl at surface

Too high a feed rate

Reuse of chipped corner

Use of insert in excess of tool life

Drilling into non fl at surface

Presence of interrupted portion onthe way of machining

Reuse of chipped corner

Improper chip control, chip packing

Chip recutting

Mechanical impact

Use of insert in excess of tool life


Work hardness is too high

Thermal impact

Looseness in insert clamping

¡Increase the cutting speed by 10% within standard conditions.¡Lower the feed rate by 10%.

¡Decrease the cutting speed by 10% within standard conditions.¡When the feed rate is extremely low or high, set to standard

conditions.

¡Confi rm that the cutting fl uid fl ow is higher than 7 liter/min.¡The concentration of coolant must be higher than 5%.¡Use the coolant superior in lubricity.¡Change to internal coolant supply from external one.

¡Change to the machine with higher torque.¡Change to the clamp method with rigidity.¡Change the drill holding method.

¡Tighten the screw.

¡Change to internal cutting fl uid supply from external one.¡Increase the supply rate of the cutting fl uid.

(Higher than 10 liter/min.)¡Lower the feed rate by 20% within standard conditions.¡Lower the cutting speed by 20% within standard conditions.

¡Lower the feed rate by 20% within standard conditions.¡Lower the cutting speed by 20% within standard conditions.

¡Increase the cutting speed by 20% and lower the feed rate by 20% within standard conditions.

¡Raise the coolant pressure (for higher than 1.5 MPa).

¡Set the misalignment to 0 ~ .008".

¡Check the manual and use the tool in the allowable offset range.

¡Flatten the entry surface in pre-machining.¡Set the feed rate for lower than .002 ipr in rough surface

area.

¡Lower the feed rate by 20 ~ 50% within standard conditions.

¡Confi rm the corner when exchanging inserts.

¡Exchange the corner or the peripheral insert before the corner wear reaches .012".

¡Flatten the entry surface in pre-machining.¡Set the feed rate for lower than .002 ipr at rough surface

area.

¡Set the feed rate for lower than .002 ipr in interrupted area.

¡Confi rm the corner when exchanging inserts.


¡Raise the fl uid pressure (for higher than 1.5 MPa).

¡Lower the feed rate by 20% within standard conditions.

¡Change to continuous feed in case of pick feeding.

¡Exchange the corner or the insert before the notch wear reaches .012".

¡Change to the machine with higher rigidity.¡Change to the clamp method with rigidity.¡Change the drill setting method.

¡Set the feed rate for lower than .002 ipr.

¡Change to internal cutting fl uid supply from external one.¡Lower the feed rate by 20% within standard conditions.


19

Ru

bb

ing

scra

tch

on

drill

bo

dy

Infe

rio

r ho

le a

ccu

racy

Chip

co

ntr

ol

Oth

er

tro

ub

le Type and place of trouble Cause Countemeasures

Periphery of drillbody

Hole diameter

Surface fi nish

Common

Entangling

Chip packing

Common

Chatter

Machine stop

Large burr

Misalignment in work-rotating

Offset-machining in excess of allowable value

Offsetting toward decreasing diameter

Drilling into or through non fl at surface

Fracturing of peripheral insert

Workpiece defl ection

Chip packing

Misalignment in work-rotating

Improper offsetting.

Drilling into or through non fl at surface

Workpiece defl ection

Coolant types and supply method

Improper cutting conditions

Insert failure

Chip packing

Looseness of insert clamping screw


Insert failure

External coolant supplying

Chips produced by central edge

Improper coolant supply


Use of excessively damaged drill body



Excessively worn insert



Insuffi cient machine power and torque

Galling

Insert failure



¡Use the tool in the allowable offset range.

¡Set offset direction extended diameter of workpiece

¡Flatten the entry surface in pre-machining.¡Set the feed rate for lower than .002 ipr in rough surface area.

¡Exchange the insert.

¡Change to the clamp method with rigidity.


¡Raise the fl uid pressure (for higher than 1.5 MPa).


¡Adjust offset contents.

¡Flatten the entry surface in pre-machining.¡Set the feed rate for lower than .002 ipr at rough surface area.

¡Change to the clamp method with rigidity.

¡The concentration of coolant must be higher than 5%.¡Use the coolant superior in lubricity.¡Change to internal coolant supply from external one.

¡Increase the cutting speed by 20% within standard conditions.¡Lower the feed rate by 20% within standard conditions.





¡Work within standard conditions.¡Increase the cutting speed by 10% within standard conditions.¡Increase the feed rate by 10% within standard conditions.

¡Exchange inserts.

¡Change to internal coolant supply from external one.

¡Work by step feed.¡Use dwell function for 0.1 sec approximately.

¡There is a tendency to shorten the chips when shifting to higher speed and feed.

¡Change to internal coolant supply from external one.¡Raise the coolant pressure (for higher than 1.5 MPa).



¡Exchange the drill holder.


¡Lower the cutting speed by 20% within standard conditions.¡Increase the feed rate by 10% within standard conditions.


¡Change to the machine with higher torque rigidity.¡Change to the clamp method with rigidity.¡Change the drill holding method.


¡Use the range of number of revolutions suited machine spec. Lower the feed rate by 20 ~ 50%.

¡Exchange inserts before the failure becomes larger.¡Check that the coolant fl ows powerfully from the drill.¡Lower the cutting speed and the feed rate by 20% within standard

conditions.


¡Lower the feed rate by 20 ~ 50% just before leaving from the workpiece.

Distributed by:

June. 2012 (TA)

3726 N Ventura Drive, Arlington Heights, IL 60004, U.S.A.Inside Sales: +1-888-554-8394Technical Support: +1-888-554-8391 Fax: +1-888-554-8392

Tungaloy Canada 432 Elgin St. Unit 3, Brantford, Ontario N3S 7P7, Canada Phone: +1-519-758-5779 Fax: +1-519-758-5791

Tungaloy de Mexico S.A.C Los Arellano 113, Parque Industrial Siglo XXI

Aguascalientes, AGS, Mexico 20290

Phone:+52-449-929-5410 Fax:+52-449-929-5411

www.tungaloyamerica.com

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