Tungaloy Report No.

409-E2

Indexable drill

Expansion with New chipbreaker

TDS type
TUNGALOY

The most economical solution for drilling!

NEW

Features
Double-sided insert with 6-cutting edges
TungSixDrill is the 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.
Central side Peripheral side

Optimal distance between each cutting edge This prevents the overlapping of damaged edges

One insert type can be used on both the central and peripheral edge
Customers only require one type of insert. This simplies inventory control.

Optimized cutting balance

Optimized cutting balance of TungSix-Drill provides excellent hole accuracy.
Hole diameter
Competitors
Hole diameter (mm)
28.2 28.1 28.0 27.9

Hole diameter (mm)

28.2 28.1 28.0 27.9

f = 0.06 mm/rev f = 0.1 mm/rev f = 0.15 mm/rev

f = 0.06 mm/rev f = 0.1 mm/rev f = 0.15 mm/rev

Entrance

Middle

Bottom

Entrance

Middle

Bottom

Dc = 28 mm Vc = 140 m/min

Dc = 28 mm Vc = 140 m/min

New revolutionary grade

AH9030
Cast iron

AH9030

Special Surface Technology

TUNGALOY

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

New generation PVD coating with advanced wear and oxidation resistance provides stable long tool life.

NEW
Stainless

Unique substrate with high heat-resistance prevents crater wear.

NEW

AH6030 AH6030
Special Surface Technology
TUNGALOY

Super alloys

Hard Materials

Wear resistance

Fracture resistance

Smooth insert surface prevents chip adhesion and improves chip control. New PVD coating with high adhesion strength prevents fracture caused by chip welding. Exclusive carbide substrate with high fracture resistance.

Enhanced corner of central insert

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

Negative angle relief

Positive angle relief

Fracture

Twisted coolant holes

Twisted coolant holes improve coolant ow. This improves chip evacuation, cooling and lubrication of the cutting edges.
3

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

DJ type

For General purpose

Suitable for cutting of a wide range of work material

Central insert Identication for central edge side Chipbreaker for central edge
The chipbreaker has thick width and gentle curves. This prevents chips from packing.

Peripheral insert Identication for peripheral edge side Chipbreaker for peripheral edge
The high rake angle and high breaker wall reduce cutting forces and improve chipbreaking.

Low cutting forces and long tool life

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

Wiper design
Can improve surface nish

NEW

DS type

For drilling stainless and gummy steels

Demonstrates exceptional chip control

Central insert Identication for central edge side Dimple

Creates smooth chip curling.

Peripheral insert Identication for peripheral edge side

Reinforced land
Prevents fracture and chipping.

Optimum chipbreaker width and contact area

Provides excellent chip control.

System to avoid wrong insert clamping

TungSix-Drill has been adapted to ensure the new system prevents incorrect insert clamping. Incorrect clamping of central and peripheral insert does not happen.
Note: The drill is designed to avoid wrong insert clamping. Please check the central and peripheral insert faces before setting the insert.
4

Correct clamping

Incorrect clamping
Pheripheral insert Central insert seat

OK Central insert

Central insert seat

Central insert Central insert seat

Peripheral insert Central insert seat

Insert hole ts screw hole

Insert hole doesn't t screw hole

Correctly clamped !

Screw cant enter screw hole

Cutting performance
Reduction of cutting force

Power consumption (kw)

TungSix-Drill adapts its positive land, this enables the drill to reduce the cutting forces even when using doublesided inserts. The cutting forces are almost equal to competitors with single sided inserts.

Spindle power consumption

4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 f = 0.06 f = 0.1 f = 0.15 Dc = 28 mm Vc = 140 m/min Work material: S55C / C55

Competitors

Feed: f (mm/rev)

Chip control

S45C
Cutting speed: Vc (m/min)
100 0.2 150 200

SUS316L
150

DS
Cutting speed: Vc (m/min)
200

Feed: f (mm/rev)

Feed: f (mm/rev)

0.15

0.1

0.08

0.1

20 mm

20 mm

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

: TDS280W32-3 Drill : WWMU08X408R-DJ Insert : AH9030 Grade Work material : S45C / C45 : NC lathe Machine Hool diameter : 28 mm : H = 70 mm Hole depth Coolant : Wet

Chips are stable and controlled in the above range. The DS type allows excellent chip control even when cutting stainless steels that have difcult to split chips.

: TDS280W30-3 Drill : WWMU08X408R-DS Insert : AH6030 Grade Work material : SUS316L Machine : Vertical M/C Hool diameter : 28 mm : H = 70 mm Hole depth Coolant : Wet

Tool life
Excellent wear resistance of AH9030
Corner wear width on peripheral edge Vc (mm)
0.4 0.3 0.2 0.1 0
Competitor A Competitor B

Drill Insert Grade Work material Cutting speed Feed Hole diameter Hole depth Machine Coolant

: TDS280W32-3 : WWMU08X408R-DJ : AH9030 : S55C / C55 : Vc = 140 m/min : f = 0.1 mm/rev : 28 mm : H = 84 mm : Horizontal M/C, BT40 : Wet (Internal supply)

10

15

20

AH9030 offers superior to wear resistance against competitors.

Machining length (m)

Thougness of central insert

Maximum ank wear width on central edge VBmax (mm)
0.35 0.3 0.25 0.2 0.15 0.1 0.05 0 0.5 1
Competitor A

Fracture
Drill Insert Grade Work material Cutting speed Feed Hole diameter Hole depth Machine Coolant : TDS280W32-3 : WWMU08X408R-DJ : AH9030 : Pre-hardened steel (40HRC) : Vc = 100 m/min : f = 0.08 mm/rev : 28 mm : H = 28 mm : Vertical M/C, BT50 : Wet (Internal supply)

Machining length (m)

Enhanced corner of central cutting edge prevents fracture even in prehardened steel machining.

Comparison of tool life for steel (AH9030)

Maximum ank wear width on central edge VBmax (mm)
0.4 0.3 0.2 0.1 0
Competitor A Competitor B

Drill : TDS280W32-3 Insert : WWMU08X408R-DJ Grade : AH9030 Work material: S55C Cutting speed: Vc = 250 m/min Feed : f = 0.1 mm/rev Hole diameter: 28 mm Hole depth : H = 84 mm Machine : Horizontal M/C, BT40 Coolant : Wet (Internal supply)

Machining length (m)

The wear and oxidation resistance of AH9030 is enhanced when high speed machining.

Comparison of tool life for stainless steel (AH6030)

Corner wear width on peripheral edge Vc (mm)
0.3 0.25 0.2 0.15 0.1 0.05 0 5 10

Comparison of damage on edge (After 6.7m machining)

Fracture
Competitor A

Drill : TDS280W32-3 Insert : WWMU08X408R-DS Grade : AH6030 Work material: SUS304 Cutting speed: Vc = 200 m/min Feed : f = 0.1 mm/rev Hole diameter: 28 mm Hole depth : H = 84 mm Machine : Vertical M/C, BT50 Coolant : Wet (Internal supply)

Competitor A

Machining length (m)

Even when machining stainless steel, cutting edge damage on AH6030 is minimal. This is credit to its high adhesion strength.

Standard cutting conditions

Work materials
Low carbon steels (C < 0.3) SS400, SM490, S25C etc. (St42-1, St52-3, C25 etc.) Carbon steels (C > 0.3) S45C, S55C etc. (C45, C55 etc.) Low alloy steels SCM415 etc. Alloy steels SCM440, SCr420 etc. (42CrMo4, 20Cr4 etc.) Stainless steels (Austenitic) SUS304, SUS316 etc. (X5CrNi18-9, X5CrNiMo17-12-2 etc.) Stainless steels (Martensitic and ferritic) SUS430, SUS416 etc. (X6Cr17, X20Cr13 etc.) Stainless steels (Precipitation hardening) SUS630 etc. (X5CrNiCuNb16-4 etc.) Grey cast irons FC250 etc. (GG25 etc.) Ductile cast irons FCD700 etc. (GGG70 etc.) Aluminium alloy High temperature alloy Inconel718 etc Titanium Alooy Ti-6Al-4V etc. Hardened steel Over 40HRC Selection criteria
First choice Priority on wear resistance First choice Priority on impact resistance First choice Priority on wear resistance First choice Priority on impact resistance First choice

Chipbreaker

Grade

Cutting Speed

Feed: f (mm/rev) Dc (mm)

First choice

First choice

First choice Priority on impact resistance First choice Priority on impact resistance First choice

First choice

First choice

First choice Priority on impact resistance

DS DJ DJ DS DS DJ DJ DS DS DJ DS DJ DS DJ DJ DS DJ DS DS DJ DS DJ DS DJ DJ DS

AH6030 AH9030 AH9030 AH6030 AH6030 AH9030 AH9030 AH6030 AH6030 AH9030 AH6030 AH9030 AH6030 AH9030 AH9030 AH6030 AH9030 AH6030 AH6030 AH9030 AH6030 AH9030 AH6030 AH9030 AH9030 AH6030

Vc (m/min) 160 - 250 160 - 320 80 - 250 80 - 250 160 - 250 160 - 250 80 - 200 80 - 200 100 - 200 100 - 200 100 - 200 100 - 200 80 - 120 80 - 120 80 - 250 80 - 200 80 - 200 80 - 150 200 - 400 200 - 400 20 - 60 20 - 60 40 - 120 40 - 120 50 - 100 40 - 80

28 - 38
0.04 - 0.10 0.04 - 0.10 0.06 - 0.16 0.04 - 0.13 0.04 - 0.12 0.06 - 0.14 0.06 - 0.16 0.04 - 0.13 0.04 - 0.12 0.04 - 0.12 0.04 - 0.12 0.04 - 0.12 0.04 - 0.10 0.04 - 0.10 0.06 - 0.18 0.06 - 0.16 0.06 - 0.18 0.06 - 0.16 0.10 - 0.20 0.10 - 0.20 0.04 - 0.08 0.04 - 0.08 0.06 - 0.12 0.06 - 0.12 0.04 - 0.08 0.04 - 0.08

39 - 54
0.04 - 0.10 0.04 - 0.10 0.08 - 0.18 0.04 - 0.15 0.04 - 0.12 0.06 - 0.14 0.08 - 0.18 0.04 - 0.15 0.04 - 0.12 0.04 - 0.12 0.04 - 0.12 0.04 - 0.12 0.04 - 0.10 0.04 - 0.10 0.08 - 0.20 0.08 - 0.18 0.08 - 0.20 0.08 - 0.18 0.10 - 0.25 0.10 - 0.25 0.04 - 0.10 0.04 - 0.10 0.06 - 0.14 0.06 - 0.14 0.04 - 0.10 0.04 - 0.10

Application range
Feed f (mm/rev) Upper table

In case of Interrupted cutting, feed should be decreased.

0.05

0.05

0.05

OK Plane surface OKSlant surface OK Cross hole OK Plunging

Application

Feed f (mm/rev)

0.1

0.05

Disapprove

Disapprove

OK Boring
Application

OK

Round surface

Stacked plate

Back boring

Drills
Dsh6 Rs L
Clamping screw Torx driver CSTB-3 T-9D CSTB-4 T-15D CSTB-5 T-20D CSTB-5 T-20D

Dc

Dimensions (mm) Cat. No TDS280W32-2 TDS290W32-2 TDS300W32-2 TDS310W32-2 TDS320W32-2 TDS330W40-2 TDS340W40-2 TDS350W40-2 TDS360W40-2 TDS370W40-2 TDS380W40-2 TDS390W40-2 TDS400W40-2 TDS410W40-2 TDS420W40-2 TDS430W40-2 TDS440W40-2 TDS450W40-2 TDS460W40-2 TDS470W40-2 TDS480W40-2 TDS490W40-2 TDS500W40-2 TDS510W40-2 TDS520W40-2 TDS530W40-2 TDS540W40-2 Stock Dc Ds D 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 40 55 40 55 50 40 50 32 40 r 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 65 65 65 55 rs L 145 148 151 154 157 170 173 176 179 182 185 188 191 194 197 200 203 206 209 212 215 218 221 224 227 230 233

Max Offset (Radius) 1.3 1.1 0.8 0.5 0.2 1.7 1.4 1.2 0.9 0.7 0.4 2.2 1.9 1.7 1.5 1.3 1 0.7 0.4 2.6 2.4 2.2 2 1.7 1.5 1.3 1

Weight Applicable inserts (kg) 0.6 0.7 0.7 0.7 0.8 1.2 1.2 1.2 1.3 1.3 1.3 1.4 1.4 1.5 1.6 1.6 1.7 1.7 1.8 1.9 1.9 1.9 2.0 2.1 2.2 2.3 2.4 WWMU13X512R-DJ WWMU11X512R-DJ WWMU09X510R-DJ WWMU08X408R-DJ

L/D = 2

: Stocked items

Inserts
DJ chipbreaker
Stocked grades Dimensions (mm) Applicable drill diameters

r
d1 d

Cat. No. WWMU08X408R-DJ WWMU09X510R-DJ WWMU11X512R-DJ WWMU13X512R-DJ

TUNGALOY

AH9030

d
8.0 9.7

T
3.9 4.9

d1
3.4 4.4 5.5 5.5

r
0.8 1.0 1.2 1.2

Dc (mm)
28.0 ~ 32.0 33.0 ~ 38.0 39.0 ~ 46.0 47.0 ~ 54.0

T
8

11.3 5.7 13.0 5.7

R L

Rs

Dimensions (mm) Cat. No TDS280W32-3 TDS290W32-3 TDS300W32-3 TDS310W32-3 TDS320W32-3 TDS330W40-3 TDS340W40-3 TDS350W40-3 TDS360W40-3 TDS370W40-3 TDS380W40-3 TDS390W40-3 TDS400W40-3 TDS410W40-3 TDS420W40-3 TDS430W40-3 TDS440W40-3 TDS450W40-3 TDS460W40-3 TDS470W40-3 TDS480W40-3 TDS490W40-3 TDS500W40-3 TDS510W40-3 TDS520W40-3 TDS530W40-3 TDS540W40-3 Stock Dc Ds D 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 40 55 40 55 50 40 50 32 40 r 84 87 90 93 96 99 102 105 108 111 114 117 120 123 126 129 132 135 138 141 144 147 150 153 156 159 162 65 65 65 55 rs L 173 177 181 185 189 203 207 211 215 219 223 227 231 235 239 243 247 251 255 259 263 267 271 275 279 283 287

Max Offset (Radius) 1.3 1.1 0.8 0.5 0.2 1.7 1.4 1.2 0.9 0.7 0.4 2.2 1.9 1.7 1.5 1.3 1 0.7 0.4 2.6 2.4 2.2 2 1.7 1.5 1.3 1

Weight Applicable inserts (kg) 0.7 0.7 0.8 0.8 0.9 1.3 1.3 1.3 1.4 1.4 1.5 1.6 1.6 1.7 1.8 1.8 1.9 2.0 2.1 2.2 2.3 2.3 2.4 2.5 2.6 2.7 2.9 WWMU13X512R-DJ WWMU11X512R-DJ WWMU09X510R-DJ WWMU08X408R-DJ

Clamping screw

Torx driver

CSTB-3

T-9D

CSTB-4

T-15D

CSTB-5

T-20D

CSTB-5

T-20D

: Stocked items

NEW

DS chipbreaker
Stocked grades Dimensions (mm)

r
d1 d

Cat. No. WWMU08X408R-DS WWMU09X510R-DS WWMU11X512R-DS WWMU13X512R-DS

TUNGALOY

AH6030

d
8.0 9.7

T
3.9 4.9

d1
3.4 4.4 5.5 5.5

r
0.8 1.0 1.2 1.2

Applicable drill diameters

Dc (mm)
28.0 ~ 32.0 33.0 ~ 38.0 39.0 ~ 46.0 47.0 ~ 54.0

11.3 5.7 13.0 5.7

Dsh6

Dc

L/D = 3

New chamfering tool "TDXCF Series"

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

Features
High productivity with two inserts. Optimum space between the drill body and chamfering inserts prevents cutting edges from fracture.

Chamfering tool

Max. chamfering width: C 2.5 mm Chamfering angle: 45 Two inserts type

Optimum clearance prevents chipping on edge

Insert

Flute for chip evacuation

Space for drill body

Clamping screw of chamfering tool

Insert grade is GH130 which has TiCNO coating for steels. Suitable for machining steel, stainless steels and cast irons.
10

Cutting edge of chamfer insert

Cutting performance
Surface nish
Tool Feed: f (mm/rev)

0.1

0.13

Tool Work material

TDS280W25-3 (L/D = 3)

TDXCF

: TDXCF280L30 : Carbon steel S55C / C55 (245HB) Machine : Vertical M/C, BT40 Coolant : Wet Cutting condition : Vc = 140 m/min Chamfering width : C = 2.0 mm

New chamfering tools TDXCF provides stable surface nish.

Cutting force
TDXCF
Conventional

Sharp cutting edge decreases cutting forces by 50% !!

Thrust force (kN) : TDXCF280L30 : Carbon steel S55C / C55 (245HB) : Vertical M/C, BT40 Machine : Wet Coolant Cutting condition : Vc = 140 m/min : f = 0.10 m/rev Feed Chamfering width : C = 2.0 mm Tool Work material

Thrust force (kN)

Drilling time (min)

Drilling time (min)

Chip control
TDXCF

Conventional

: TDXCF280L30 : Carbon steel S55C / C55 (245HB) : Vertical M/C, BT40 Machine : Wet Coolant Cutting condition : Vc = 140 m/min Chamfering width : C = 2.0 mm Tool Work material

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

Chamfering tool insert & part list

Cat. No. Insert Grade, Stock GH130 Insert clamping screw Torque

(Nm) 3.5

Ring clamping screw

Torque

(Nm) 8.0

Wrench for insert

Wrench for ring

TDXCF540L30

TDXCF280L30

XHGX090700R-45A

CSPB-4S

CM8 x 20

T-15D

P-5

: Stocked items

11

Chamfering ring (TDXCF Series)

Max. drilling depth

c

Dimensions (mm) Cat. No. TDXCF280L30 TDXCF290L30 TDXCF300L30 TDXCF310L30 TDXCF320L30 TDXCF330L30 TDXCF340L30 TDXCF350L30 TDXCF360L30 TDXCF370L30 TDXCF380L30 TDXCF390L30 TDXCF400L30 TDXCF410L30 TDXCF420L30 TDXCF430L30 TDXCF440L30 TDXCF450L30 TDXCF460L30 TDXCF470L30 TDXCF480L30 TDXCF490L30 TDXCF500L30 TDXCF510L30 TDXCF520L30 TDXCF530L30 TDXCF540L30 Stock Ds 26.9 27.9 28.9 29.9 30.9 31.8 32.8 33.8 34.8 35.8 36.8 37.8 38.8 39.8 40.6 41.6 42.6 43.6 44.6 45.6 46.6 47.6 48.6 49.6 50.6 51.6 52.6 Dc 64 64 64 64 64 64 64 64 85 85 85 85 85 85 85 85 85 85 85 85 85 85 85 85 85 85 85 L 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30
Drill dia. Dc

Max. drilling depth (mm) Application drill TDS280W32- TDS290W32- TDS300W32- TDS310W32- TDS320W32- TDS330W40- TDS340W40- TDS350W40- TDS360W40- TDS370W40- TDS380W40- TDS390W40- TDS400W40- TDS410W40- TDS420W40- TDS430W40- TDS440W40- TDS450W40- TDS460W40- TDS470W40- TDS480W40- TDS490W40- TDS500W40- TDS510W40- TDS520W40- TDS530W40- TDS540W40- L/D = 2 36.9 39.2 41.5 43.8 46.1 48.4 50.7 53.0 56.3 57.6 59.9 62.2 64.5 66.8 69.1 71.4 73.7 76.0 79.3 80.6 82.9 85.2 87.5 89.8 92.1 94.4 96.7 L/D = 3 64.9 68.2 71.5 74.8 78.1 81.4 84.7 88 92.3 94.6 97.9 101.2 104.5 107.8 111.1 114.4 117.7 121 125.3 127.6 130.9 134.2 137.5 140.8 144.1 147.4 150.7

28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

: Stocked items

12

Points of caution when mounting the chamfering ring on drill body

Place the ring on the drill body and match the ring ute with the drill 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.
Insert is in the wrong position due to incorrectly placed ring

OK

Match the ring ute with the drill ute

(Insert will be automatically set to the right position)

The ring ute does not match the drill ute

Adjustable drilling diameter holder

Enables diameter of TungSix-Drill to adjust easily Specication

BT / DIN69871 type HSK type

S.s.

1

1

S.s.

G J

2

2

Cat. No. TUNGBORE BT40 EM32 TUNGBORE BT40 EM40 TUNGBORE BT50 EM32 TUNGBORE BT50 EM40 TUNGBORE HSK A 63 EM32 TUNGBORE HSK A 63 EM40 TUNGBORE DIN69871 40 EM32 TUNGBORE DIN69871 40 EM40 TUNGBORE DIN69871 50 EM32 TUNGBORE DIN69871 50 EM40

Dimensions (mm) Stock

S.s. 40
40 50 50 63 63 40 40 50 50

d
32.00 40.00 32.00 40.00 32.00 40.00 32 40 32 40

D
72.0 72.0 72.0 72.0 72.0 72.0 72 72 72 72

L
123.50 123.50 134.50 134.50

L1
96.5 96.5 96.5 96.5

L2
71.0 71.0 71.0 71.0 71.0 71.0 71 71 71 71

J
M10 M10 M10 M10 M10 M10 M10 M10 M10 M10

G
M16 M16 M24 M24 M16 M16 M24 M24

Tool Dia. Dc (mm)

28.0 - 32.0 33.0 - 54.0 28.0 - 32.0 33.0 - 54.0 28.0 - 32.0 33.0 - 54.0 28.0 - 32.0 33.0 - 54.0 28.0 - 32.0 33.0 - 54.0

142.00 116.0 142.00 116.0 135.6 135.6 115.6 115.6 116.5 116.5 96.5 96.5

: Stocked items
Min. Dc -0.3

Drill shank
Max. Dc +1.3

Constraint surface

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.

13

Adjustable range of TungSix-Drill combined with TungBore

Tool diameter Dc (mm) Adjustable range (mm) Min. dia. Max. dia. Tool diameter Dc (mm) Adjustable range (mm) Min. dia. Max. dia.

28 29 30 31 32 33 34 35 36 37 38 39 40 41

28 29 30 31 32 33 34 35 36 37 38 39 40 41

29.3 30.3 31.3 32 32.4 34.3 35.3 36.3 37.3 38.3 38.8 40.3 41.3 42.3

42 43 44 45 46 47 48 49 50 51 52 53 54

42 43 44 45 46 47 48 49 50 51 52 53 54

43.3 44.3 45.3 46.3 46.8 48.3 49.3 50.3 51.3 52.3 53.3 54.3 55.3

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

EZ sleeve (Eccentric sleeves for TungSix-Drill)

The function of EZ sleeves
Adjusting the hole diameter when drilling
Adjusting the hole diameter in tool-rotating applications.

Adjusting cutting edge height on lathe

Adjusting the cutting edge height in rotating work applications.

By using EZ sleeve, the hole diameter can be adjusted in the range from +0.6 mm to -0.2 mm.

By using EZ sleeve, the cutting edge height can be adjusted in the range from +0.3 mm to -0.2 mm. That reduces troubles caused by improper cuttingedge 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)

14

Setting of EZ sleeve
Adjusting the hole diameter on M/C
Set the EZ sleeve between the drill shank and the holder. Align the scale on the periphery of EZ sleeve with the center of the at on drill ange.
Flat

Adjusting cutting edge height on lathe

Set the EZ sleeve between the drill shank and the toolblock. Align the scale on the front face of the EZ sleeve with the center of the at on drill ange.
Fixing bolt A Flat Fixing bolt B EZ sleeve Flange

Flange

EZ sleeve

of is ne ax hi X - ac m

In the gure shown on right, the sleeve is set and the hole diameter will be increased by 0.4 mm.

Fixing bolt A
+0.4 +0.2

In the gure shown on right, the sleeve is set and the center of the drill will shift by 0.1 mm to the plus (+) direction.

Fixing bolt B

When rotating EZ sleeve, xing bolts A and B have to be loosened. After setting the hole diameter, x the drill body with bolt A. Then lightly tighten the bolt B to x EZ sleeve. If the bolt B is over tightened, EZ sleeve may be damaged.

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.

Specications
L1 L3 L4

Sleeve Cat. No. Stock

D1 D2 D3 L1 20 25 32 40 25 32 40 50 46 51 54 69 49 52 62 63

L2 5 5 5 5

L3 32.5 38 43 55

L4 4 4 4 4

Adjusting range of Adjusting range of nishing diameter cutting edge height

EZ2025
D1 D2 D3

+0.4 ~ -0.2 +0.2 ~ -0.15 +0.4 ~ -0.2 +0.2 ~ -0.15 +0.4 ~ -0.2 +0.2 ~ -0.15 +0.6 ~ -0.2 +0.3 ~ -0.2

EZ2532 EZ3240
L2

EZ4050

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

Cautious points
Using TungSix-Drill
Ensure that the drilling machine to be used has sufcient 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.

Cautionary points for setting inserts

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 excessively deformed or worn out by Proper handling of wrench long term use.

Cutting uid
Be sure to supply cutting uid through the tool. A water soluble emulsiable type cutting uid should be used. Fluid pressure of 1 MPa or higher and uid quantity of 7 l/min or more are essential. For 4D and 5D type, a uid pressure of 1.5 MPa or higher and uid quantity of 10 l/min or more is recommended.

15

Use of TungSix-Drill on lathes

Setting of drill body is an important issue for stable machining
Mounting the drill on turret (tool post)
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 at with the xing screw, the cutting edges are guaranteed to be parallel to the X-axis of the machine.

Turret

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

Xma axis ch of ine

Direction of xing bolt on tool block

Ce ntr al

ed ge Pe rip he ral ed ge

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

Checking of cutting edge height

The cutting edge height is an important factor for stable machining. The cutting edge of central insert should be 0.2 mm 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 isnt a reference bar, the ground part of a boring bar can be used as a substitute.
Di sh ffere 0.2 ould nce mm be : ab ou t

Turret of the lathe

Dial gauge

le dg Xe ax ma chis of ine

Ce ntr a

Overhang length of drill

Pe rip he ral ed ge

Reference bar

Main spindle

Same length as the overhang of drill

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

Boring bar as a substitution

Checking of setting conditions by trial cutting

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 0.5 mm 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 1mm, it is excessively below center. In these cases, the cutting edge height has to be checked again. When trial cutting, the feed should be 0.1 mm/rev or less, drilling depth should be up to 10 mm.

About 0.5 mm diameter

Core on the center

Drilling depth: Up to 10 mm

Adjusting of cutting edge height

When the condition of the cutting edge height is incorrect, the height should be adjusted with the following methods. 1

In the case of above-center

When machining with such condition, the central cutting edge may be easily chipped. So this condition has to be rectied. Solution #1: Change the mounting direction. Solution #2: Rotate drill body 180 In #2, additional cotter is required on the opposite side. Mounting direction
Ce ntr al Pe rip he ral ed ge

ed ge

X-axis of machine Center of drill

Pe rip he ral ed ge

Rotate 180
Center of drill

XCe ntr al

ax

is

of

ed ge

ma

ch

Mounting direction

In the case of slightly above-center (about 0.05 mm)

In the case of excessive belowcenter (0.2 mm or more)

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.

17

Machining with offset on the lathe

A larger hole than the drill diameter can be machined !

Drilling with offset
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 previous page.
Xax is of ma ch ine
Ce ntr al ed ge Pe rip he ral ed ge Ce ntr al ed ge Pe rip he ral ed ge

Interferences
Offsetting to the direction of decreased diameters

Direction of increased diameters

Offset value must be less than 0.1 mm.

Direction of decreased diameters

Hole diameter machined with offset are roughly calculated as following.

Drilled diameter = Drill diameter + offset value x 2

Example: Drill diameter: 20 mm Offset value: 0.2 mm Drilled hole diameter = 20 + 0.2 x 2 = 20.4 mm

O de ffset dri pen valu Ce ll b d o e ( ntr al od n t +) ed ge y. he is ea Pe rip ch h

era le dg e

Offsetting to the direction of increased diameters

Shapes of hole bottom

Un-evenness of the hole-bottom face when machined with TungSix-Drill is smaller than with HSS drills !
The shape of the hole bottom machined with TungSixDrill is closer to at compared with those machined with HSS drills.
Drill diameter Dc (mm) Hmax (mm)

Hole bottom shape obtained with TungSix-Drill

Maximum unevenness Hmax Hmax

Drill diameter Dc

28 ~32 1.8

33 ~38 2.1

39 ~ 46 2.5

47 ~ 54 2.7

18

Practical examples
Workpiece type Drill Insert Grade

Connecting rod TDS280W32-2 WWMU08X408R-DJ AH9030 C55

Housing

TDS420W40-2 WWMU08X408R-DS AH9030 GGG45

Work material

Cutting speed: Vc (m/min) Feed: f (mm/rev) Feed speed : Vf (mm) Drilling depth : H (mm) Machine Coolant

193 0.15 329 30 Vertical M/C, BT40 Wet

Machining length (m/insert)

120 0.2 180 80 NC lathe Wet

Machining length (m/insert)
40 30 20 10 0 Competitor

Cutting conditions

50 40 30 20 10 0 Competitor

Tool life times!

1.8

Tool life tripled!

Results

AH9030 achieves longer tool life even when machining with external coolant supply, due to the high oxidation resistance.

Tough cutting edge prevents chipping and edge fracture, even when interrupted machining. Increasing in tool life and higher number of insert corners drastically reduce machining cost.

Workpiece type Drill Insert Grade

Slewing ring TDS390W40-3 WWMU11X512R-DJ AH9030 42CrMo4

Valve

TDS280W32-2 WWMU08X408R-DJ AH9030 Alloy steel

Work material

Cutting speed: Vc (m/min) Feed: f (mm/rev) Feed speed : Vf (mm) Drilling depth : H (mm) Machine Coolant
Machining length (m/insert)

200 0.15 245 90 Drilling center, BT50 Wet

120 100 80 60 40 20 0

180 0.18 369 50 Horizontal M/C, BT40 Wet

60 50 40 30 20 10 0

Cutting conditions

Tool life 1.5 times!

Competitor

Machining length (m/insert)

Tool life 2.2 times!

Competitor

Results

TungSix-Drill allows efcient drilling with higher speed and feed. The increased number of insert corners signicantly reduces insert consumption.

Improved tool life per corner leads to reduction of insert consumption. DJ chipbreaker allows excellent chip control and stable machining without vibration.

19

Workpiece type Drill Insert Grade

Flange of valve TDS290W32-2, Dc = 29 mm WWMU08X408R-DS AH6030 X5CrNi18-9

Flange of machine part

TDS350W40-3, Dc = 35 mm WWMU09X510R-DS AH6030 Inconel 625

Work material

Cutting speed: Vc (m/min) Feed: f (mm/rev) Feed speed : Vf (mm) Drilling depth : H (mm) Machine Coolant

140 0.075 120 29 Vertical M/C, BT50 Wet

120 100 80 60 40 20 0

40 0.06 22 60 Vertical M/C, BT50 Wet

3.5 3 2.5 2 1.5 1 0.5 0

Cutting conditions

Machining length (m/insert)

Tool life 3.2 times!

Competitor

Machining length (m/insert)

Tool life 3 times!

Competitor

Results

The DS chipbreaker creates well controlled chips and the AH6030 provides longer tool life with improved chipping resistance.

AH6030 with high reliability allows longer tool life. When machining super alloys such as Inconel, inserts with higher number of corners are very effective for reducing tool cost.

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Mar. 2013 (TJ)