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Drilling

Quality

Why do we need drilling for quality?

• Help the mechanic recognize the characteristics of what makes a quality hole

• Procedures required to drill quality holes

• Use the necessary tools to make a quality hole

• Countersink

• Shop safety

What is S tres s ?

S tres s - During takeoff, in flight, and landing.

Just sitting on the tarmac with the weight of the airplane causes stress.

Weather, Temperature..

What would happen if holes in the aircraft had some sort of defect?

Do you think these stresses affect the holes / fastener installation?

S afety

• Leather Shoes (no open toes or high heels) • No loose fitting clothing (ties, shirts or jackets) • Pants to be below the kneecap. • Loose jewelry will be taken off • Long hair will be tied back • No loose fitting gloves, • Beware of loose fitting badge holders (make sure you have a breakaway holder)

www.elvex.com

S afety

Drill Motors

Typical Drill Motor

P is tol G rip Motors

90 & 45 degree Drill Motors

Drill B it Nomenc lature

S hank

P oint A ngle

Margin

F lute

Twis t Double Margin R eamer C ore G un B arrel

C ompos ite

Drill B its and R eamers

Shank Style

Quic k C hange T hreaded Quic k C hange 90 and 45

Degree Motors

Tri-F lat

Quic k C hange T ype Drill B it S ize Identific ation

R eamer

S tandard Double Margin

E quivalenc y c ard (S tarrett C ard)

F R ONT B A C K

Hole Qualities

What qualities are we looking for in

a properly drilled hole?

Diameter - (Within T oleranc e)

A ngularity - (S traight within 2 degrees )

+/- 2 o

Drill G uides

B us hing Identific ation

Drill S tops

# 40 # 30 # 20 # 10 1/4 5/16

Give an example of a defect

and what could cause that defect

T here are many pos s ible defec ts to a drilled hole

Overs ize Unders ize E longated E ye B rowed G ouged / B arreled Tapered Drill S tarts Drill R uns Angled R ifled C hattered Over Deburred

Double Hole Mis located Mismatch Misaligned Misoriented E xtra Hole S hort E dge Margin B reak Out C racked / F ractured B ellmouth B urned Deep C ounters ink

What kind of a defect is this?

A ngled Hole

C aus ed by improper us e of drill guide or more likely

c aus ed by NOT us ing drill guide.

Rifled Hole

C aus ed by the us e of a dull drill bit or too muc h lubric ation being us ed, exc es s c utter run out, damaged

c utter margin or c hips welded to c utter

E dge Margin - (Drawing c all out or 2X diameter)

Edge margin

S urfac e F inis h - s mooth finis h ins ide the hole

E ye B rowed Hole

C aus ed by drilling of a c rooked hole then reentering the hole

s traight or drilling a hole that has a pilot on the other s ide.

What kind of a defect is this? Drill R un

Drill S tart

Not us ing a s harp drill bit, not getting the drill bit

into the pilot hole before pulling trigger or trying

to drill too fas t and mis s ed the target! !

B arreled Hole

C aus ed by the us e of too muc h lubric ant, lube holds

debris in the flutes of drill bit and hones out the hole.

Double Hole

C aus ed by walking of the drill bit, pos s ibly a dull drill

bit. Drilling a c rooked pilot hole, then drilling bac k

through the hole us ing a guide

E xtra Hole

C aus ed by not looking at the drawing for proper

layout, mis loc ated tool or c areles s drill bit plac ement.

Unders ized Hole

C aus ed when the drill bit is dull or the inc orrec t drill

bit is us ed.

R eliefs

Deburr

Chamfer

Fillet Relief

Fillet Relief Washer

F illet R elief, C hamfer, R adius

R eliefs

F ilet R elief, C hamfer

R eliefs

F illet R elief, C hamfer, R adius

Deburring T ools

Weldon

Open Countersink

Flat File

C aus ed by us ing inc orrec t deburring tool or a dull

deburring tool.

C hamfered Inc orrec tly

Not R ec ommended Deburring / R elief T ools

R otary F iles

Mac hinis t T riangle Drill bits R ed Devil S c raper

Deep C ounters ink

Mus t s et c ounters ink on s c rap material before going to a/p s truc ture.

Make s ure to loc k the s et ring. C hec k c ounters ink bearing, they do go bad.

(A new Zephyr s mall body las ts 80,500 c ounters inks max.)

C ounters inks

Locking Ring

Cage / Body

Countersink Cutter

Rotating Foot Countersink Pilot

C ounters ink C utter

Hex Drive or L oc k B olt 100 Deg. B olt

100 degree R ivet C ounters ink

100 Deg. WQ B olt

82/30 Deg. R ivet

C ounters inks

Pull back Cage / Body

C ounters inks

Rotate Foot to

change depth

This way to make shallower

C ounters inks

Rotate Foot to

change depth

This way to make it deeper

The countersink is to be set on a scrap

piece of material similar to the material

that needs to countersink

Us e of C ounters ink

S et c ounters ink on s ame type of material to be c ounters unk Matc h the c ounters ink pilot s ize to the hole s ize Hold the barrel of the c ounters ink while c ounters inking P rior to adjus ting c ounters ink deeper, always re-c ounters ink the

hole to ens ure the c utting was c omplete

drilling for quality - amazon web...

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