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TAC DRILL Manual

TDX-type TAC Drill Manual

DW chipbreaker

DS chipbreaker

DJ chipbreaker


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CONTENTSWhat is TDX Drill ? 1

Nomenclature for TAC Drill 1 Cutting mechanism of TAC Drill 1

Features of TDX Drill 2

Components of TDX Drill series 3 Body 3 Inserts 3 Optional components 3

Features of drill body 4

Features of chipbreakers 5 DJ chipbreaker 5 DS chipbreaker 5 DW chipbreaker 5

Application area of each chipbreaker type 6Features and applications of insert grades 6

Insert selection guide 7

Recommended cutting conditions 7 Points to consider 7

Chip shapes 8 Chip shapes produced by central edge 8 Chip shapes produced by peripheral edge 9 Medium to high carbon steels, alloy steels, etc. Stainless steels, low carbon steels, low alloy steels, etc.

Chip control for snarled chips 10 Chip control for low carbon steels at low cutting speeds 11 Chip control for aluminum alloys 12

Chip shapes (DW chipbreaker) 13 Comparison of chip shapes at high feeds 13 Chip shapes at normal conditions 13 Chip shapes of stainless steels, alloy steels, and low carbon steels 13

Cutting performance of long body types14

Selection of L/D in drill specifications 15

Machining data 16 Tool life comparison in drilling alloy steel 16 Tool life comparison in drilling stainless steel 16 Improvement in drilling of stainless steel 16 Machining of hardened steel with small diameter ( 13 mm) drill 17 Machining example of hardened steel 17 Improvement in drilling of hard cast iron 17 Deep hole drilling of low carbon steel with large-diameter ( 50 mm) drill 18 MQL deep-hole drilling of carbon steel with small diameter ( 12.5 mm) drill 18 High-efficiency drilling with DW insert (GH730) 19

Finished hole diameters 20

Determination of tool life 21 Tool life determination for insert 21 Tool life determination for drill body 22


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CONTENTSCutting forces 22

Surface finish 23

Shapes of hole bottom 24

Use of TDX drill on machining centers 24 Selecting toolholders 24 Adjusting drilling diameter 24

Use of TDX drill on lathes 25 Mounting of drill body on turret (tool post) 25 Checking of cutting edge height 25 Checking of setting conditions by try machining 26 Adjusting of cutting edge height 26

Offset machining on lathes 27 Offset machining 27

Cautions when using on lathes 28 Through-hole drilling 28 When a disc-like uncut piece is left on the exit side 28 When machining a large-diameter hole in excess of the maximum drilling diameter 28 When using TDX drill on lathe without internal coolant supply 28

Special machining 29 Surface conditions to be machined 29 Drilling of interrupted hole 29 Drilling of stacked plates 30

Enlarging of drilled hole 30

MQL machining 31 What is MQL machining ? 31 Cautious points in selecting drilling conditions 31

Cautious points in use 32 Cutting fluids 32 Maximum drilling depth 32 Machining of through hole 32 Drilling through-hole on work-rotating condition 32

Troubleshooting 33,34

Specifications of TDX drills 35 L/D=2 (metric) 35 L/D=2 (inch) 36 L/D=3 (metric) 37 L/D=3 (inch) 38 L/D=4 (metric) 39 L/D=5 (metric) 40

Test report format 41

Specifications of inserts for TDX drills 42

EZ-sleeves specially designed for TDX drills 42

Use EZ sleeves for the following purposes 42 Setting of EZ sleeve 43 Specifications 43


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A drill which has dual indexable-inserts configured on the front end of a steel holder. Both inserts share the cutting zone.

Insert grades and geometries can be selected to suit the machining situation.

Nomenclature for TAC Drill

Cutting mechanism of TAC Drill

Maximum drilling depth Shank length

Overall length

D r i

l l d i a m e

t e r

Taper pipe thread ( PT screw )Central insert

Peripheral insert

Flute Flange

Shank

S h a n

k d i a m e

t e r

Flange diameter

What is TDX Drill ?

Central insert Peripheral insert

Cutting zone of central edgeCutting zone of peripheral edge

Drill diameter D

Peripheral insert

Central insert

1


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Four cutting edges per insert can beeconomically utilized by indexing it asshown below.

Outstanding economy

Can enter the cut smoothly with lessvibration and allows stable machining.

Stable drilling and low vibration

T h e n e w l y d e s i g n e d 3 - d i m e n s i o n a lchipbreakers provide exceptional chip controlover a wide range of work materials.Specially designed chip pocket helps toeffectively remove chips from the cutting zone.

Exceptional chip control

The stable cutting balance allows excellent

chip evacuation and good surface finish.

Good surface quality

The thicker insert design increases impactresistance and extends tool life.

Exceptional reliability

Insertchanging

Central insert

Peripheral insert

Indexing

Features of TDX Drill

2


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Body

Three types of chipbreaker geometries and four insert grades areavailable. Inserts are selectable from the eight combinations of gradesand chipbreaker types.

Eccentric sleeves specifically designed for the TDX drills extendthe application range.

Inserts

Optional components

Components of TDX Drill series

Only Tungaloy offers a full lineup of drill diameters (12.5 to 54.0)and L/D ratios (2, 3, 4 and 5) !

3

Drill diameter

Unavailable

C o m p e t

i t i v e

i n d e x a b

l e i n s e r

t d r i

l l s

Chipbreaker types

Grades DJ

AH740

AH120

T1015

GH730

DS DW


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New drills specially designed for deep holes have realized stable

drilling of deep holes up to 5 times the drill diameters !!

Existing 4-corner inserts can be eco-nomically used for these new drills.

Higher reliability

New oil-hole design and increased cross-sectional area of the flute have vastly im-proved chip evacuation ability.

Excellent chip control

By optimizing the flute design, the de-flection of the drill body could be sup-pressed to a minimum.

Highly rigid tool design

The design of the insert configuration al-lows stable deep hole drilling up to 5times the drill diameter.

Ideally balanced design

Example of stable drilling with small diameter drill

Entrance BottomEntrance Bottom

C o m p e t

i t o r

A ( 1 3 )

S p

i n d l e p o w e r c o n s u m p

t i o n

( A )

A m o u n

t o

f o v e r s

i z e

( m m

)

A m o u n

t o

f o v e r s

i z e

( m m

)

Spindle power consumption

Amount of oversize

Spindle power consumption

A m o u

n t o f

o v e r s

i z e

1.0

0.8

0.6

0.4

0.2

0

1.0

0.8

0.6

0.4

0.2

0

15

10

5

0

15

10

5

0

Competitor A (13)TDX

Machine : Vertical machiningcenter (BT50)

Work material : High carbon steel(JIS S55C)

Drilling depth : 52 mm(L/D=4, Blind hole)

Cutting speed : V c =150 m/minFeed : f =0.1 mm/rev

Features of drill body

4


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General purpose chipbreaker usable for almost all ap-plications. Features low cutting forces and allows

stable drilling.

Three types of chipbreakers are available for various applications

Bumps and grooves formed onthe rake face reduce the con-tact area with chips resulting in

reduction of cutting forces andlonger tool life.

Low cutting forces and long tool life

Deeply formed chip groove per-forms exceptionally free cutting ac-tion and effective chipbreaking.

Relatively shallow chip groove pre-vents chips from packing.

Chipbreaker for central edge

Performs excellent chip control for gummy materi-als such as stainless steels and low carbon steels.

Exceptionally free cutting ac-tion improves chip control.

Sharp cutting edges

Strengthened corner geometry mini-mizes insert breakage even in drillingstainless steels

Strengthened corner

Can effectively form gummy materialchips into short sections.

Entirely new rakeface design

In comparison with conventional inserts, this chipbreaker

allows higher feeds and produces superior surface finish.

Increased land width plus a twostep relief angle strengthens thecorner section .

Extraordinarily strengthened corner

Can improve surface roughnessat normal feeds and minimizessurface degradation at highfeeds.

Wiper design

Can forcibly curl thickchips produced in highfeeds and causes them tobreak into short sections.

Also it allows for large vol-ume chip removal.

Strong chipbreaker for high feeds

Features of chipbreakers

5

Chipbreaker for peripheral edge


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DS

DW

DJ

0.05 0.1 0.15 0.2f Stainless steels

Steels

Cast irons

Stainless steels Steels Cast irons

Application area of each chipbreaker type

Features and applications of insert grades

6

By combining ultra f ine grain cemented carbide with Flash-coat,this grade provides both wear resistance and impact resistance.Can be used for a wide range of applications.

By combining ultra f ine grain cemented carbide with Premium-coat,the impact resistance is improved without sacrificing wear resistance.Combined with DW-chipbreaker, this grade can be used for high-feedmachining of steels.

By combining specially designed hard carbide substrate withnewly developed multilayer compound coatings, this gradeprovides excellent wear resistance in machining cast irons.

By combining highly reliable carbide substrate with Flash-coat,this grade provides superior impact resistance and wear resistancein high-speed machining. Best suitable for drilling stainless steels.

AH740

GH730

T1015

AH120

0.05 0.1 0.15 0.2

AH120 AH120

T1015 T1015

GH730 GH730 AH740 AH740

f 100 150 200 250 300

V c


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Select the appropriate insert by following this guide.

For high-feed machining, apply a feedrate that is approximately 1.5 times thestandard feed conditions.

High-speed machining means cuttingspeeds over 150 m/min.

When using DW insert for troubleshoot-ing, use it within the range of standardcutting conditions.

Points to consider

Selecting the cutting conditions is an important point for proper machining.Therefore, when selecting cutting conditions, place the priority on chip con-trol.

The cutting condition range which allows proper chip control depends on thetypes of chipbreaker and the material to be machined.

The chart at right shows the basic flow to select cutting conditions.

When the hardness of the workmaterial is higher than 40 HRC,the feed should be reduced towithin 1/2 of the values shown inthe table.

When machining difficult-to-cut

materials such as heat-resistingalloys which develop heat exces-sively during machining, reducethe cutting speed to within 1/2 ofthe values for carbon steels.

Initially use this guide to select and

adjust cutting conditions toachieve appropriate chip control.

Check the cutting condition rangewhich is appropriate to the spindlepower and rigidity of the machine

to be used.

Check the cutting condition rangein which abnormal tool failure such

as chipping and breakage doesnot occur.

Select the cutting condi-tions appropriate to thescheduled tool life and

machining time.

Insert selection guide

Recommended cutting conditions

7

Work materialsFirst

choiceHigh-feedmachining

High-speed machiningBreakage Wear

TroubleshootingSurface finish

Low carbon steels (C < 0.3)JIS SS400, SM490, S25C, etc.

Carbon steels (C > 0.3)JIS S45C, S55C, etc.Low alloy steelsJIS SCM415, etc.

Alloy steel sJIS SCM440, SCr420, etc.Stainless steels (Austenitic)JIS SUS304, SUS316. etc.Stainless steels(Martensitic and ferritic)JIS SUS430, SUS416, etc.Stainless steels (Precipitation hardening)JIS SUS 630, etc.Gray cast irons

JIS FC250, etc.Ductile cast ironsJIS FCD700, etc.

Aluminum al loysJIS A2017. ADC12, etc.

Work materialsCuttingspeed Series

V c (m/min)

Feed f (mm/rev)

Low carbon steels (C < 0.3)JIS SS400, SM490, S25C, etc.

Carbon steels (C > 0.3)JIS S45C, S55C, etc.

Low alloy steelsJIS SCM415, etc.

Alloy s teelsJIS SCM440, SCr420, etc.

Stainless steels (Austenitic)JIS SUS304, SUS316. etc.Stainless steels(Martensitic and ferritic)JIS SUS430, SUS416, etc.Stainless steels(Precipitation hardening)JIS SUS 630, etc.

Gray cast ironsJIS FC250, etc.

Ductile cast ironsJIS FCD700, etc.

Aluminum alloysJIS A2017. ADC12, etc.


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In TAC drills, because the central insert and the peripheral insert cut entirely different zones, two typesof chips are produced. The following are the features of each shape.

Chip shape produced with central insert

Relation between chip shapes and feeds (In the case of central insert)

Example of chip shape in work-rotating applications (In the case of central insert) (26, S45C, Vc = 100m/min, f = 0.1mm/rev)

100mm

Chip shapes

Carbon steels, alloy steels, etc. Low carbon steels, stainless steels, etc.

8

A conical coil shape whose apex point coincides with the rotating cen-ter of the drill is the basic shape. The chips are broken into small sec-tions with increases in feed. But, excessively high feed causes the chipto increase in thickness and develops vibration which disturbs stablemachining.

In TDX drills, marked chips shown below are the most preferableshapes. This type of chip is broken into adequate length by centrifugalforces when used in tool-rotating condition. On the other hand, when

used in work-rotating condition such as on a lathe, a continuously longchip is often produced without entangling.


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Comparison of chip shapes produced with central inserts (22 drills, vertical machining center)

TDX DS Competitor C

Comparison of surface finish influ enced by variations of chip shapes (22, SUS316L, NC lathe, Vc =100m/min, f =0.08mm/rev)

Surface finish is affected by chip shapesproduced with the central insert.

Chip problems such as entangling are mainly caused by chips pro-duced with the peripheral insert. These problems are dependent onthe types of work material and the cutting conditions.

As shown below, when the feed is extremely low, the chips jumpover the chipbreaker groove and the continuously long chips maywrap around the drill body.

When the feed is too high, the chips increase the thickness and can

not be curled. Therefore, it is important to select proper cutting conditions to suit

the machining so that well controlled chips will be formed.

Chip shape produced with peripheral insert

Relation between feeds and chip control

Just after start of cutting, a continuously long,coil-shaped chip is formed, but when the drillingdepth reaches to 0.5 D to 1 D, the chip tends toshorten the length.

The chip shape in the early stage of cut , as boththe cutting speed and feed are increased, tendsto shorten the length.

Chip shape in early stage of cut

Start of cut

Feed is too low. Adequate feed Feed is too high.

Chips likely to wrap around drill body. Likely to cause chip packing

Allo y st eel(JIS SCM440)

Stainless steel(JIS SUS304)

Mild steel(JIS SS400)

V c f V c f V c f

DS chipbreakerDJ chipbreaker DS chipbreaker T D X

d r i

l l

C o m p e t

i t i v e

d r i l

l A

C o m p e t

i t i v e

d r i

l l B

C o m p e t

i t i v e

d r i l

l C

9


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Chip shapes formed with the peripheral insert are roughly classified, depending on the types of work materials, into two different types, general steels (JIS S45C, SCM440, etc.) and long-chip steels (JISSS400, SUS316, S10C, SCM415, etc.). These features are described below.

Medium to high carbon steels, alloy steels, etc.

As shown below, several turns of coil are an ideal shape. As the feed increases, the curl radius and the number of turns tend to decrease.

Typical chip shapes of general steels Variation of chip shapes relating to feeds

Stainless steels, low-carbon steels, low-alloy steels, etc.

When machining long-chip materials such as stainless steels and mild steels, a wrong selection of cuttingconditions results in chip entangling and tool breakage at worst. Therefore, cutting conditions should be care-fully selected.

C shaped, continuous coils of several to ten turns having adequately divided length are ideal shape.

Ideal chip shapes

For machining stainless steels or low carbon steels,DS chipbreaker is recommended.When using a TDX drill in tool-rotating condition, DSchipbreaker produces compact chips and allows morestable machining than DJ chipbreaker. Especially

when using it in work-rotating condition, DSchipbreaker provides outstanding affect on chip con-trol.

Mild steel (JIS SS400)Stainless steel (JIS SUS 304)V c fV c f

D S

c h i p b r e a k e r

D J


Chips shapes which tend to entangle and remedies against them

Apple-peel-like chipsThese chips are often produced inmachining mild steels or low-carbon

steels at low-speeds and low-feeds.

Increase the cutting speed in stagesby 20% within the range of standardcutting conditions. If there is no ef-fect, increase the feed by about 10 %as the cutting speed is raised by 20%.

Short-lead chipsThese chips are often produced inmachining stainless steels at low-feeds and tend to entangle to the tool

in spite of short length.

Increase the feed by about 10 %. Ifthere is no effect, increase the cuttingspeed in stages by 10% within therange of standard cutting conditions.

Very long chipsOften produced in machining mildsteels or low-carbon steels underimproper cutting conditions.

Increase the cutting speed in stages by20% within the range of standard cut-ting conditions. If there is no effect, de-crease the feed by about 10 % as thecutting speed is raised by 20%.

10

f = 0.07mm/rev f = 0.13mm/revf = 0.1mm/rev


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Chip control for low-carbon steels at low cutting speeds

In the cases shown below, the demonstrated cutting speed is less than 60 m/min. As shown below, the use of DS chipbreaker allows effective chip control.

When the cutting speed can not be raised to the standard cutting conditions because of machine limitation. (Especially when using a small diameter drill) Safety problems could result from violently scattering chips.

Low carbon steel ( JIS S25C ) , NC lathe, 13, Vc = 60m/min

Mild steel ( JIS SS400 ) , Machining center , 13, Vc = 60m/min

DS chipbreaker DJ chipbreaker Competitor A Feed Competitor B

f

f

f

f

f

f

DS chipbreaker DJ chipbreaker Competitor A Competitor BFeed

Remarkable vibration

r

rr

r

r

r

r

r

r

r

r

r

r

r

r

11

Remarkable vibration


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Stainless steel (JIS SUS304) Alloy steel (JIS SCM440)V c f

Mild steel (JIS SS400)V c fV c f

D J c h i p b r e a k e r

D S c h i p b r e a k e r

C o m p e t i t o r " A "

C o m p e t i t o r " B "

C

o m p e t i t o r " C "

Comparison of chip shapes ( 22 drill, vertical machining center )

When machining a gummy material, as the cuttingspeed increases, chips are likely to be broken intoshorter sections. But, in tool-rotating applicationssuch as on a machining center, chips are likely tobe violently scattered because of the increasedcentrifugal forces as the cutting speed increases.In such cases, a safety protection to cover the cut-ting zone is essential.

Aluminum alloys

Chip control for aluminum alloys listedbelow is relatively easy and can be carriedout by using standard inserts. Aluminum alloys for casting (JIS AC4B, etc.) Aluminum alloys for die casting (JIS ADC12, etc.)

Al-Cu based aluminum alloys (JIS A2017, etc.) Al-Zn-Mg based aluminum alloys (JIS A7075, etc.) Heat-treated aluminum alloys ( -T6, etc.)

The following aluminum alloys are highly adhering andtend to be thick chips. Therefore, referring to the chartat right, select an appropriate chipbreaker and cuttingconditions for the machining purpose. In addition,as the peripheral edge especially tends to producelong and uncontrolled chips, step-feed drilling shouldbe carried out depending on the circumstance. Al-Mg based aluminum alloy (JIS A5052)

Applicable

Al-Cu based aluminum alloy (JIS A2017)d=25 mm (blind hole)

Vertical machining center,wet cuttingToolholder : TDX180L054W25 (18)Insert : XPMT06X308R-DW (GH730)

Vc =200 m/minf =0.1 mm/rev

Difficult to apply

Al-Mg ba s ed aluminum allo y (JIS A5052)d= 25 mm ( blind hole)Machine: Ver tical mac hining center, wet cuttin gToolholder : TDX190L 057W25 (19 )Insert : XPM T06X30 8R-DW (GH73 0)Vc =300 m/min f =0.15 mm/rev

Cutting speed

F e e

d m m

/ r e v

Selection guide for chipbreaker types and cutting conditionsin machining Al-Mg based aluminum alloys

For the following aluminum alloys, because of remarkable chip adhering and packing on thechip groove, TDX drills can not be used. Pure aluminum alloys (JIS A1000, etc.)

Not applicable

Withoutstep feed

With step feedevery 0.5 mm

Note: When chips heavily adhere to the chipgroove, con-tinuous machining is difficult in some instances.

12


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DW chipbreaker is designed to forcibly break thick chips. The use of DW chipbreaker allows highlyefficient machining in higher feed rate.

Comparison of chip shapes (JIS S55C,22, Vc=100 m/min, f=0.2mm/rev, Vertical machining center)

Comparison of chip shapes at high feeds When using a conventional chipbreaker at high feeds, the central edge produces short chips. But, as the chip

thickness increases, the occurrence of vibration makes the machining unstable. Additionally, the chips pro-duced with the peripheral edge are too thick and can not be curled.

DW chipbreaker is designed to have a special section shape suitable for high feeds and to break thick chipsinto short length by forcibly curling them.

For high-feed machining, the guideline to select thefeed is about 1.5 times the standard cutting condi-tions. High-feed machining will cause a heavy-loadon the machine. Therefore, it should be carried outonly when the machine has sufficient power and ri-gidity.Cutting fluid should be supplied in adequate vol-ume through the tool. Fluid pressure of a minimum1.5 MPa and volume of a minimum 10 l/min are rec-

ommended.

DW chipbreaker can control chips even innormal conditions. But, because the cuttingforces are higher than those of DJ chipbreaker,the first choice chipbreaker in normal conditionsis the DJ chipbreaker. DW chipbreaker shouldbe used where increased insert strength andimproved surface finish are required.

Chip shapes in normal conditions

Although DW chipbreaker can be used for relatively gummy materials, DS chipbreaker hasan advantage over DW in compactness of thechips produced with the peripheral insert andthe stability in machining.

DW chipbreaker is not recommended for high-feed machining of stainless steels.

Chip shapes(Mild steel (JIS SS400), 22, Vc =300 m/min,f =0.08 mm/rev, Vertical machining center)

Chip shapes in machining stainless steel, alloy steels, low carbon steels

Chip shapes (DW chipbreaker)

Chips produced with central edge Chips produced with peripheral edge

D

W


D J

c h i p

b r e a k e r


D W

c h i p

b r e a k e r

D J

c h i p

b r e a k e r


D W


D J

c h i p

b r e a k e r

C o m p e

t i t i v e

A

C o m p e

t i t i v e

B

13

Chip shapes(Mild steel (JIS SCM400), 22, Vc =150 m/min,f =0.1 mm/rev, Vertical machining center)


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S p

i n d l e p o w e r

( A )

Machining time ( s ) 150 m/min

S p

i n d l e p o w

e r

( A )


S p

i n d l e p o w e r

( A )


S p

i n d l e p o w e r

( A )


S p

i n d l e p o w e r

( A )


S p

i n d l e p o w e r

( A )


Chip packing

Competitor(13)

TDX

TDX

TDX

Toolholder TDX130L052W20-4 (13)Insert XPMT040104R-DJ (AH740)

Toolholder : TDX130L052W20-4 (13)Insert : XPMT040104R-DS AH120

Toolholder : TDX130L052W20-4 (13)Insert : XPMT040104R-DS AH120

d=52 mm (L/D=4, blind hole) Vertical machining centerwet cuttingV c =150 m/min

230HB

130HB

Unstable power consumption

170HB

Alloy steel(JIS SCM440)

Mild steel(JIS SS400)

Stainless steel(JIS SUS304)



Chip packing

A

Competitor(13) B

Competitor(13) C

Allows stable machining for almost all work materials !

Cutting performance of long body types

14


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For the best performance, select the most appropriate tool for themachining depth.

Comparison of L/D ratios and performance

Followings are test results comparing the performance of L/D=2 and L/D=5 drills used for the same machining.The L/D=2 drill shows less tool failure and longer tool life.

Number of holes machined

M a c

h i n i n g

d i a m e

t e r m m

Stainless steel (JIS SUS304),170 HBd=24 mm (blind hole)

After machining 171 holes(4.1 m in length)

Vertical machining centerwet cutting12.5 DS (AH120)Vc =150 m/minf =0.05 mm/rev

T o o

l f a

i l u r e

S h a p e o

f h o

l e b o

t t o m

Selecting of L/D specification

15

Flank wear widthVB : 0.107mm Flank wear widthVB : 0.132mmFlank wear widthVB : 0.107mm Flank wear widthVB : 0.132mm


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Recognize the high performance of TDX drills !

The chart at right shows a comparison of toollife curves of several drills in machining alloysteel. DJ insert (AH740) showed stable wearwithout any irregular failure.

Machining length m

C o r n e r - w e a r w

i d t h o

f p e r i p

h e r a

l i n s e r t

V C m m

Competitor "B-1 " Competitor "B-2 "

Competitor"C "

Competitor "A"

DJ (AH740)

Broken central edge

Occurrenceof chipentangling

Alloy steel (JIS SCM440), 240HBd=30 mm (blind hole)

Vertical machining center 18,

Wet cuttingVc = 100 m/min f = 0.08 mm/rev

Machining data

The following chart shows a comparison of tool life curves of several drills in machining stainless steel. DS insert (AH120)

showed stable wear and superior wear resistance even in high-speed conditions.

Machining length m Machining length m

DS AH120

CompetitorB

CompetitorC

Cutting speed : Vc =150 m/min

C o r n e r w e a r w

i d t h o

f p e r

i p h e r a l e d g e

m m


i d t h o

f p e r

i p h e r a l e d g e

m m

Cutting speed : Vc =220 m/min

Competitor A

Competitor A

CompetitorB Competitor

C

DS AH120

In this example, compared to a competitive drill, greatimprovement (600 pcs./corner, two times) in the toollife and cutting conditions was achieved.

Stainless steel (JIS SUS304),120HBDrilling length: d=23 mm (Blind hole)

Machine : CNC lathe (Wet cutting)Drill body : TDX180L054W25Insert : XPMT06X308R-DS (AH120)Vc =120 m/minf =0.06 mm/rev

16

Tool life comparison in drilling alloy steel

Improvement in drilling stainless steel

Proven economy Under the condition of Vc =150 m/min,machining costs per 1 m were calculatedfrom the machining length before thecorner wear width reaches to Vc =0.1 mm.The results are shown in the table to theright. The cost of TDX drill was 1/2 to 1/3times those of competitive drills.

No. of corners

per insertVC=0.1mm

Tool life criterion

Index of running costs 1)

Competitor B

Competitor A

Competitor C

1) Competitor A was placed to 100.

Tool life comparison in drilling stainless steel

Stainless steel (JIS SUS304), 120 HBd=25 mm (blind hole) , Vertical machining center 19 mm,wet cutting, f =0.08 mm/rev


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In the machining of hardened steel with small diameter drills, reliability to insert breakage was evaluated. Almost all inserts were broken in the competitive drills. However, the TDX drill showed normal wear and could continue further machining.

Number of holes machined (Holes)


i d t h o

f p e r i p

h e r a

l e d g e

V c m m

Competitor D (Both central and peripheral inserts were broken)

Competitor B (Both central and peripheral inserts were broken)

Competitor A(Central insert was broken)

DJ (AH740) inserts (Normal wear)

Die steel (JIS SKD61), 50HRCDrilling depth : d=25 mm (Blind hole)Machine : Vertical machining centerDrill dia. : 13 mmCutting fluid : UsedV c =100 m/minf =0.02 mm/rev

After machining 1.5 m in length, theinsert showed little tool-wear and couldcontinue further machining. Themachining was also stable.

Forging die steel (50HRC)Drilling depth: d=45 mm (Blind hole)Machine : Horizontal machining centerCutting fluid : UsedDrill body : TDX220L066W25Insert : XPMT07H308R-DJ (AH740)Vc =80 m/minf =0.04 mm/rev Central edge

(VN=0.08 mm)Peripheral edge

(VBmax=0.03 mm, VC=0.08 mm)

Previously used brazed carbide drills frequently chipped. After switching to TDX drills, they developedonly small insert wear and improved surface finish. In addition, machining time was reduced to 1/10.

High-chromium cast iron(52HRC)Drilling depth : d=60 mm (Blind hole)Machine : CNC latheCutting fluid : UsedDrill body : TDX220L066W25Insert : XPMT07H308R-DJ (AH740)Vc =40 m/minf =0.02 mm/rev

60

2 3

Machining of hardened steel with small diameter (13 mm) drill

Machining example of hardened steel

Improvement in machining hard material

17


21/47

This example shows test results in which low-carbon steel was machined with a large diameter (50 mm) TDX drill.In combination with DS chipbreaker, the drill achieved good chip control and stable machining without vibration.

Mild steel (JIS SS400), 130HBDrilling depth : d=250 mm(L/D=5, Blind hole)Machine : Vertical machining centerCutting fluid : UsedDrill body : TDX500L250W40-5Insert : XPMT150512-DS(AH120)Cutting speed : Vc =200 m/minFeed : =0.07, 0.1 mm/rev

Drilling depth

P o w e r c o n s u m p

t i o n

Vc =200 m/min, f =0.07 mm/rev,

Machining time

=250 mm

12

12.5

13

1 30 60

Drilling depth (mm)

H o l e

d i a m e t e r

( m m

)

This example shows test results of MQL deep hole drilling of carbon steel with a small diameter (12.5mm) TDX drill.In spite of MQL machining, the drill achieved low-noise machining, good chip-removal, and excellenthole-diameter stability.

Carbon steel (JIS S55C), 220HBDrilling depth : d=63 mm (L/D=5, Blind hole)Machine : Vertical machining centerCutting fluid : Semi-dry (Through tool supply, 2 cc/hour)Drill body : TDX125L063W20-5

Insert : XPMT040104R-DJ (AH740)Cutting speed : Vc =180 m/minFeed : f =0.06 mm/rev

Deep-hole drilling of low-carbon steel with large diameter ( 50 mm) drill

MQL deep-hole drilling of carbon steel with small diameter (12.5 mm) TDX drill

18

50

2 5 0

12.5


22/47

High efficiency machining with DW insert (GH730)

Highly efficient, extra-low cost drilling has been realized !

Photographs below show tool wear on corners after drilling 5.2 m in length at cuttingspeed of 100 m/min and feed of 0.22 mm/rev.DW insert showed a small amount of initial wear.

Carbon steel (JIS S55C), 220HBDrilled length : 5.2 mMachine : Vertical machining centerCutting fluid : UsedDrill body : TDX220L044W25-2Insert : XPMT07H308R-DW (GH730)Cutting speed : Vc =100 m/minFeed : f =0.22 mm/rev

Vf = 318mm/min

Photographs below show tool wear on corners after drilling 5.2 m in length at cuttingspeed of 200 m/min and feed of 0.2 mm/rev.

A combination of L/D=2-designed drill body and DW (GH730) insert has realized highertable-feed comparable to those of solid drills.

Carbon steel (JIS S55C), 220HBMachine : Vertical machining centerCutting fluid : UsedDrill body :TDX220L044W25-2Insert : XPMT07H308R-DW (GH730)Cutting speed : Vc =200 m/minFeed : f =0.2 mm/rev

Vf = 579mm/min

Furthermore, the wiper effect of the insert produced a superior surface finish. Be-cause of less tool-wear, deterioration of the surface roughness was not recognized.

Competitor A Competitor BDW(GH730)

S u r f a c e r o u g

h n e s s

R a

m After drilling

first hole After drilling 5.2 m

DW(GH730) Competitor A

DW(GH730)

19

Competitor B

Competitor A Competitor B


23/47

TDX drills are not suitable for the drilling of holes requiring high accuracy. Differing from solid carbide drills, thefinished hole diameter depends on three factors , 1. the accuracy of the insert , 2. the accuracy of the drill body, and 3. the oversize of the drilled hole.

Therefore, a guideline for the hole tolerance is IT 12 or more. But, when using in a work-rotating condition, the finished diameter can be adjusted by offset machining. Even

in tool-rotating applications, use of the eccentric sleeve (EZ sleeve) allows adjusting. In some cases, the finished hole diameter machined with TDX drills is smaller than the drill diameter depending

on the work material and cutting conditions. When a severe tolerance to the finished diameter is required, a selection of drill diameter in consideration for

the stock removal and finishing such as boring are required. The charts below show the finishing diameters of TDX drills and competitive drills. In competitive drills, some

variations in finishing diameters resulting from measuring points and cutting conditions can be seen. TDX drillshowed stable finishing diameters.

Accuracy of drill body Oversize of hole diameter to the real drill diameter

Finishing diameter = Nominal drill diameter -0.1~+0.3

Accuracy of insert

Comparison of finishing diameters (34)

Finished hole diameters

20

Competitor A Competitor B Competitor CTDX drill

Entrance Center ExitHole-diameter measuring points












f =0.08 mm/rev f =0.1 mm/rev f =0.12 mm/rev

C a r b o n s t e e l ( J I S S 5 5 C )

3 4

, V c =

1 0 0 m / m i n

, D e p t h : 3

D

M i l d s t e e l ( J I S S S 4 0 0 )

3 4

, V c =

1 8 0 m / m i n

, D e p t h : 2

. 5 D

S t a i n l e s s s t e e l ( J I S S U S 3 0 4 )

3 4

, V c =

1 5 0 m

/ m i n

, D e p t h : 2 . 5

D


24/47

Change the tool a little earlier !

Tool life determination for insert As the insert failure develops, several phenomenons such as deterioration in chip controllability,increased cutting noise and increased cutting forces are observed.If the machining is continued as the failure is enlarged, it may cause breakage of the drill body. Whenthe following phenomenons are recognized, index or change the tool a little earlier.

For central inserts For peripheral inserts

Tool failure types of inserts

Insert failure and its effect on machining

Chipping, Fracture,Flaking

Variation in finishing diameters

Deteriorated chip control

Deteriorated surface finish

Flank wear, Cornerwear , Notch wear

Increased power consumption

Occurrence of chatter

Variation in cutting noise

Deteriorated surface finish

Rake face wear ,Crater wear

Deteriorated chip control

Determination of tool life

21

When excessive chipping or fracture is seen on the cutting edges. When at least one of notch wear (VN), flank wear width (VB), and corner wear width of peripheral edge (VC)

reaches 0.3 mm. When the cutting noise excessively increases.

When chip controllability remarkably deteriorates. When the net power consumption is increased by about 30 % compared to the beginning of cutting.


25/47

Tool life determination for drill body

As same as in inserts, the drill body also fails by rubbing of chips. Excessively damaged drill bodycan not achieve the original performance. Therefore, when the following phenomenons are recognized,change the drill body to new one a little earlier.

When deformation, flaws, burrs, chip adherence are occurred on the insert pocket. When the insert pocket is damaged with the insert breakage. When the chip pocket is excessively damaged with the rubbing of chips. When the excessive rubbing on the peripheral part of drill body is observed. When the other phenomenons differing from the beginning of use are observed.

Damaged chip pocketresulting from rubbing

of chips.

Example 1:The chip pocket is scooped

by rubbing of chips.

Effects A change in chip control. Likely to occur chip packing. The oil hole is exposed in some cases.

Example 2: Damaged insert pocket accompanying

with insert fracturing

Effects Bad influence on insert seating and clamping. Likely to occur insert fracturing.

Examples of damaged drill bodies

Damaged insert pocket

The charts below show a guideline for cutting forces. Use TDX drills on a machine with ample power and sufficient rigidity.

Guidelines for cutting forces

Cutting forces

22

Cutting speed: Vc=100 m/minWork material: Alloy steel (JIS SCM440),

240HBCutting fluid: Used


26/47

Superior surface finish !

A guideline for surface finish is about 25 m in maximum depth. It depends on the work material and cutting

conditions. When a better surface finish is required, a finishing operation is needed. But, as shown in the Figure below, the use of DW insert achieves better surface finishes. Surface finishes are improved as the cutting speed is increased and the feed is decreased. When machining stainless steels and low carbon steels, the chip control is important. The surface finish

obtained with DS insert is superior to those obtained with competitive inserts.

0

1

2

3

4

5

6

7

8

9

0.1 0.14 0.18 0.22

Feed f (mm/rev)

F i n i s h

e d

s u r f a c e r o u g

h n e s s

R a

m

Competitor A

Competitor D

Competitor B

-50-40-30-20-10

01020304050

-20

Axial measuring points Entrance

-50-40-30-20-10

01020304050

-20 -15 -10 -5 0

Axial measuring points Entrance

Ra Ry Rz

Ra Ry Rz

TDX+DS

Cmpetitor B

Surface finish

23

Work material: Carbon steel (JIS S55C )200HB

Drill diameter: 22 mm

Cutting speed: V c =100 m/min

Work material: Stainless steel (JIS SUS304 )180HB

Drill diameter: 18 mmCutting speed: V c =150 m/minFeed: f =0.06 mm/rev


27/47

Adjusting drilling diameter

Unevenness of the hole-bottom face machined with TDX drill is smaller than competitors !The shape of the hole bottom machined with TDX drill is closer to

flat compared with those machined with HSS drills. Evencompared with competitive indexable drills, the TDX drill excelsin flatness.

Competitive indexable-insert drill

Brazed carbide drill

HSS drill

Drill diameter D

Hole bottom shape obtained with TDX drill

Height of unevenness

In addition to the maximum unevenness (Hmax)at the outer portion, the Hmax formed in the mid-section is also smaller than those formed by com-petitive drills. Therefore, when finishing the holebottom face, the toolholder of the finishing tool isless likely to interfere with the hole bottom.

Example of hole-bottom finishing

13 15 20 25 30 35 50

H m a x

Drill diameter

Competitive indexable drills, brazed drills, and HSS drills

0.8 0.8 1.6 1.8 1.9 2.1 2.8Competitors

3.9 4.5 6.0 7.5 9.0 10.5 15.0HSS drillsBrazed drills 2.7 3.6 4.5 5.5 6.6 9.12.4

Drilldiameter

12.5 15 17.5 22 27 33 42

14.5 17 21.5 26 32 41 52

Hmax 0.6 0.8 1.0 1.1 1.3 1.9 2.3

TDX drill

Check the specifications of the toolholder

Selecting toolholders

Side-lock type toolholders for drills or milling-chuck holderscommercially available from toolholder manufacturers are rec-ommended.

Side-lock type toolholders for endmills are also usable, but thetool may be secured with only one screw.

When using some of speed-accelerator type spindles and oil-hole holders, the drill shank must be shortened to prevent in-terference with their hole bottom.

Examples of side-lock type toolholder for drills. BIG: Sidelock drill holder

Example of type:BT50-TSL32-105 KURODA: DA type sidelock holder

Example of type:BT50-SLDA32-120 NIKKEN: Sidelock holder (for drills)

Example of type:BT50-SL32C-105

By using commercially available eccentrictoolholders or EZ sleeves (eccentricsleeves specially designed for TDX drills),drilling diameters are adjustable.

As for the use of EZ sleeves, see page43.

When using EZ sleeves, use commerciallyavailable side-lock type toolholder for drills.

EZ sleeves(eccentric sleeves specially designed for TDX drills)

Shapes of hole bottom

Use of TDX drill on machining centers

24

Comparethe

difference !


28/47

Mount the drill body so that the cutting edges will be parallel to the X-axis of the machine. In normal circumstance, the drill body is mounted so that the peripheral insert can be seen from the operator. In

some machines, mounting of 180 opposite direction is also possible without problems. As the driving flat of the drill shank is machined to be parallel to the cutting edges, by tightening the flat with the

fixing screw, the cutting edges are to be parallel to the X-axis of the machine.

Setting of drill body is a key factor

Mounting the drill on turret (tool post)

X - a x i s o f m a c h i n e

Turret Direction of screwing ofmounting screw.

In normal circumstance, the drill body is mounted so thatthe peripheral insert can be seen from the operator.

Use of TDX drill on lathes

The cutting edge height is an important factor to carry out proper machining. The center axis of the tool should be below the rotating axis of the machine by 0 to 0.2 mm. Prior checking of the center height of the machine by using a reference bar is recommended. In this case, the checking of the center height should be carried out at the same position as the overhang length

of the drill. When the reference bar is not available, the ground part of a boring bar can be used as a substitute.

Checking of cutting edge height

Mainspindle

The condition of cutting edge height is not appro-priate, adjusting of the turret is basically needed.But, an easy adjusting method is described on thenext page.

B e

l o w t h e c

e n t e r b

y

a b o u t 0

. 2 m m

C e n t r a l e d g e

P e r i p h e r a l e d g e


Dial gage

Overhanga length of drill

Same as the overhang length of drill

Reference bar

A substitution by using a boring bar

25




Cutting edges are to be parallelto the X-axis of the machine


29/47

When the condition of the cutting-edge height is improper, the following method is used for the adjusting.

Adjusting of cutting-edge height

After mounting the drill body, check the condition of be-low-center by trial cutting before the real machining.

If the drill body is properly set, a core of about 0.5 mm in

diameter is left in the bottom of the hole. If core is not left at all, it means above- center. If the core

diameter is larger than 1 mm, it means excessive below-center. In such cases, again check the cutting edge height.

For the conditions of the trial cutting, low feeds of less than0.1 mm/rev and drilling depth up to 10 mm are recom-mended as a guideline.

If machining is carried out in such condition, the center cutting edge is likely to be chipped.Rotate the mounting direction by 180 . If the mounting direction can not be changed, rotate the drillbody by 180 . But in this case, additional machining of driving flat which is parallel to the cuttingedge is required.

Rotating by180

Center of drill

Mounting direction

Mountingdirection

X-axis of machine

C e n t r a l c u t t i n g e d g e

P e r i p h e r a l c u t t i n g e d g e

C e n t r a l c u t t i n g e d g e

P e r i p h e r a l c u t t i n g e d g e


In this case, in addition to the method q , shiftingof the mounting position to another turretposition may improve the condition.

If the drill body is mounted in such condition, thecore diameter is increased. If machining is carriedout as the core diameter is larger than 1 mm, it willresult in an unstable machining condition such asheavy vibration.In such cases, adjust the cutting edge height byusing EZ-sleeve (the eccentric sleeve designedspecially for TDX drills) or adjust the accuracy ofthe turret itself.For the use ofEZ sleeve, refer to page 43.

Core in center portion

Drilling depth: Up to 10 mm

A b o u

t 0

. 5 m m

i n d i a m

e t e r

q In the case of above-center

w In the case of a little (about 0.05 mm) above-center

e In the case of excessive (over 0.2 mm) below-center

26

Checking of setting conditions by trial cutting


30/47

A larger hole than the drill diameter can be machined !

When the drill is used in a work-rotating mode such as in lathes, offsetting of the drill in the X-axis of themachine allows fine adjustment of the drilled hole diameter.

When the offset machining is carried out, the drill body should be mounted so that the cutting edge will beparallel to the X-axis of the machine. Mount the tool referring to the aforesaid setting method.

Maximum allowable displacement and maximum drilling diametersDirection of increased drilling diameter (+)

D r i l l d i a m e t e r

M a x

. d i s p l a c e m e n t

M a x

. d r i l l i n g

d i a m

e t e r


M a x


M a x

. d r i l l i n g

d i a m

e t e r


M a x


M a x

. d r i l l i n g

d i a m

e t e r


M a x


M a x

. d r i l l i n g

d i a m

e t e r


M a x


M a x

. d r i l l i n g

d i a m

e t e r


M a x


M a x

. d r i l l i n g

d i a m

e t e r


M a x


M a x

. d r i l l i n g

d i a m

e t e r

Offsetting to the direction ofdecreased drilling diameters.

Offsetting to the direction ofincreased drilling diameters.

Drilled diameters obtained by offsetting are roughly

calculated as following.

Drilled diameter = Drill diameter + Displacement X 2Example:

Drill diameter: 20 mmDisplacement: 0.2 mm

Drilled diameter=20 + 0.2 X 2 = 20.4 mm

The allowable displacement has a dependence on the drill diameters. Offsetting must not exceed the maximumdisplacement shown in the table.

When causing insert breakage or vibration, reduce the feed.

To prevent the drill-body from interfering with workpiece, the displacement to the direction of decreased diametersshould be within 0.1 mm. Even when setting within 0.1 mm, there is a possibility of interfering depending on thecondition of the cutting-edge height and the hole straightness. Please check these carefully.

Offset machining on lathe

Offset machining

27

Displacement must notexceed -0.1 mm.

InterferenceInterference



Displacement (+)



Increaseddrilling

diameters

Decreaseddrilling

diameters



X - a x i s o f t h e m a c h i n e


31/47

When the drill penetrates the hole, uncutdisc-like piece may fly-out from betweenthe chuck jaws.This piece has sharp edges and is verydangerous. A guard to cover the chuck isrequired.

Cover

Disc-like uncut piece

In machining gummy materials or high-feed machining,a disc-like uncut piece may be left on the exit side ofthe hole. By reducing the feed from the position of about3 mm toward the exit, the occurrence of the piece canbe mostly prevented.

Exit side

When machining of a large diameter hole in excess of themaximum drilling diameter is required, there is a method inwhich the hole once machined by solid drilling is enlargedby boring in several steps as shown in the Figure at right.But, in the boring operation, the chip control is more difficultthan that in the solid drilling. Therefore, use of a purpose-made boring tool is recommended for the operation.

Taper screw for pipeWhen the drill is used on a lathe without internalcoolant supply, remove the taper screw from theflange of the drill body and connect a coolantsupply hose to the position. By this, coolant can

be supplied through the tool. ( This method isapplied only to the drills of L/D=2 and 3.)In this case, the rear end of the drill shank shouldbe plugged with the removed taper screw.

Cautions when using on lathesThrough-hole drilling

When machining a large diameter hole in excess of the maximum drilling diameter

When a disc-like uncut piece is left on the exit side

When using on a lathe without internal coolant supply

28


32/47

Surface conditions to be machined

Specially difficult machining types are described in this page. This machining should be avoided where

possible by carrying out some prior machining. When having no choice but to do these types ofmachining, care should be taken to the following.(Stack drilling is excluded.)

(1) Drilling into angled face

Special caution must be taken to the following machining !

When the engaging surface or exit-side surface isangled, set the feed to within 0.05 mm/rev. Whenusing the drill of 4D or 5D design, prior flattening ofthe engaging surface by using an end mill is recom-mended.

(2) Drilling into arc face

When the engaging surface is arc, the feed at en-gagement should be set to within 0.05 mm/rev. Theradius of the arc should be greater than the five timesthe tool diameter.

Drilling of interrupted hole

The feed during the penetrating and engagement in an interrupted portion should be within 1/2 of thestandard condition. Before engaging in the interrupted portion, a disc-like chip produced in penetrat-ing must be completely removed.

Special machining

29


33/47

Drilling of stacked plates

In drilling of stacked plates, a disc-like chip is produced between the plates. Thismay increase a possibility of causing the insert and drill body to be damaged.Therefore, TDX drills are not recommended for this operation.

Clearance betweenplates

Disc-like chip

Enlarging of pre-drilled hole

When enlarging a pre-drilled hole, the hole diameter should be within 1/4 of the diameter of TDX drill. Ifchips are not well controlled, peck-drilling or dwelling (about 0.1 sec.) is recommended.

As shown in Figure below, the bottom face of the hole machined with TDX drill is slightly convex. In thenext process, if drilling is carried out to the face, the risk of drill breakage or poor hole straightness maybe increased. After pre-drilling with another drill, TDX drill should be used.

For counterboring of a hole, TCB-type counterboring cutters are recommended. The TCB-type cutterprovided with two effective cutting edges allows more efficient machining than TDX drill. In addition,the insert with dimple-type chipbreaker performs better chip control.

30


34/47

Unfavorable chip shapes in MQL machining

What is MQL machining ?

MQL machining is a new machining method where a minimum quantity (about 10 cc/hour)of lubricant mixed with air is supplied to the cutting point.This method features:q The temperature of the cutting edge is lower than that of in Absolute dry-machining.

Therefore, existing tools can be applied to the machining.w Compared with Cooled-air machining, the required apparatus is simple and low cost.

Nevertheless, pronounced effect on tool life can be obtained.The following are key points in carrying out MQL machining.

Tips in selecting cutting conditions

Preferable chip shapes in MQL machining

Carbon steel (JIS S45C), 230HBCutting speed : Vc =150 m/minFeed : f =0.05 mm/revTDX180L054W25 (18)

XPMT06X308R-DJ (AH740)

Alloy steel (JIS SCM440), 230HBCutting speed : Vc =150 m/minFeed : f =0.05 mm/revTDX180L054W25 (18)


Mild steel (JIS SS400), 150HBCutting speed : Vc =150 m/minFeed : f =0.05 mm/revTDX180L054W25 (18)


Stably continuous coil-shape chips produced with central cutting edge

Crushed chips produced withcentral cutting edge

Elongated chips produced withcentral cutting edge

When the chips produced with the cen-tral cutting edge are crushed or elon-gated without curling, reduce the feed.

Through-the -tool coolant supply is a must in MQL machining. MQL machining is not suitable for some materials, which generate high-temperature during machining, such as stainless

steels and heat-resistant steels.

About the MQL (Minimum Quantity Lubrication) machining

Cutting conditions for reference Cutting speed : V c =80 ~180 m/min Feed : f =0.03 ~ 0.08 mm/rev

31

In MQL machining, compared with wet machining, chip shape varies remarkably depending on the feed rate. Refer-ring to the following, select the proper conditions allowing stable chip removal. When selecting, find the conditions inwhich the chips produced with the central cutting edge are continuous coil-shape.


35/47

Cutting fluids

Water-soluble cutting fluids (such as JIS W1-2) shouldbe used. Water insoluble cutting fluids are not recom-mended because their fumes may catch fire.

Fluid pressure of 1 MPa or greater and fluid quantity of7 lit/min or more are essential.

For 4D and 5D types, 1.5 MPa or greater and 10 lit/minor more are recommended.

Cutting fluid should be supplied through the oil hole ofthe tool. When there is no choice other than externalsupply, reduce the cutting speed by 20 % of the stan-dard condition and limit the drilling depth to within 1.5

times the drill diameter. External supply should beavoided for machining stainless steel and heat-resis-tant steels.

Maximum drilling depth

The flute length of TDX drills is a little larger thanthe maximum drilling depth. This is needed forchip removal when drilling to the maximum drill-ing depth.

Drilling in excess of the maximum drilling lengthshould be avoided.

Additional length for penetrating

When drilling to the maximum drilling depth, theadditional length for penetrating should be within10 % of the drill diameter.

See Cautions when using on lathes on page 28.

W i t h i n 1 . 5 D

Flute lengthMaximum drilling depth

D r i

l l d i a m e

t e r

Additional length forpenetrating 0.1 X D

Cautionary points in use

Use in work-rotating condition

32


36/47

Increase cutting speed.

Reduce feed.

Decrease cutting speed.

Decrease cutting speed where feed is too low. Increase cutting

speed where feed is too high.

Check that coolant flow is 5 lit./min or more.

Increase concentration of cutting fluid.

Use cutting fluid provided with sufficient lubricity.

Change to internal coolant supply if used in external supply.

Change to more rigid machine.

Change to more rigid work clamping method.

Change tool mounting conditions. Change to T1015. (Refer to page 7)

Secure insert clamping screw.


Increase coolant supply volume.

Reduce feed.


Reduce feed.

Increase coolant supply pressure.

Change cutting conditions.


Displacement of drill center from machine center should be 0 to

0.2 mm. ( in direction to below-center)

Use in range of allowable offsetting value.

Flatten entry surface in pre-machining.

Set feed within 0.05 mm/rev in non-flat portion.

Reduce feed to about 0.1 mm/rev.

Check corner-failure in changing and indexing of insert.

Index or change insert when corner wear width of peripheral

insert reaches to 0.3 mm.



Set feed to within 0.05 mm in interrupted portion.

Check corner-failure in changing and indexing of insert.



Decrease feed

If used in peck-feeding, change to continuous feeding.

Index or change insert when notch wear width (VN) reaches to

0.3 mm.



Change tool mounting conditions.

Reduce feed. Change to internal coolant supply if used in external supply.


Change insert grade to GH730 (See page 7)

Fasten insert clamping screw securely.

Type and place of trouble Cause Countermeasures

Inappropriate cutting conditions

Inappropriate cutting conditions

Coolant types and supply method

Vibration during machining

Improper insert grade

Looseness of insert clamping

Excessive heat occurrence

Remarkable chip rubbing

Improper chip control chip packing

Misalignment in work rotating

Machining in large offset

Drilling into non flat surface

Too high a feed rate

Reuse of chipped corner

Use of insert in excess of tool life

Drilling into non flat surface

Presence of interrupted portion on

the way of machiningReuse of chipped corner

Improper chip control chip packing

Chip recutting

Mechanical impact

Use of insert in excess of tool life


Work hardness is too highThermal impact

Improper insert grade

looseness in insert clamping

Centralcuttingedge

Abnormal w

ear of insert

Trouble and countermeasures

Troubleshooting

33

Chippingand fractureofinsert

Peripheralcuttingedge

Common

Centralcuttingedge

Peripheralcuttingedge

Common

Reliefsurface

Rotating center of drill

Peripheral corner area

Chipbreaker

Crater

Reliefsurface

Reliefsurface

Unusedcorner andcutting edge

Contact boundary

Flaking

Common


37/47

Type and place of trouble Cause Countermeasures

Displacement of drill center from machine center should be 0

to 0.2 mm. ( in direction to below-center)

Use in range of allowable offsetting value.

Change direction of offsetting.



Change insert.



Increase coolant pressure

Displacement of drill center from machine center should be 0

to 0.2 mm. ( in direction to below-center)

Adjust offsetting value




Increase concentration of cutting fluid. Use cutting fluid provided with sufficient lubricity.



Decrease feed.

Change insert.

Change cutting speed.

Increase coolant pressure.


Use in range of standard cutting condition.


Decrease feed. Change insert.

Change to internal coolant supply.

Use peck-drilling method.

Insert 0.1-second dwelling before chip entangling.

Shift to higher cutting speed and feed conditions to shorten chip

length.(Primarily, chips produced with central cutting edge are likely

to lengthen especially in work-rotating machining.)

Change to internal coolant supply.

Increase coolant pressure.

Reduce feed

Increase cutting speed

Change drill holder to new one .



Increase feed

Change insert.



Change tool mounting conditions.


Decrease cutting speed and feed.

Change insert before insert is heavily damaged.

Check that taper plug screw has not come off from drill body. Check condition of coolant delivery.

Decrease cutting speed and feed.

Change or index insert.

Decrease feed.

Misalignment in work-rotating

Offset-machining in excess of allowable value

Offsetting toward decreasing diameter

Drilling into or through non flat surface

Fracturing of peripheral insert

Workpiece deflection

Chip packing

Misalignment in work-rotating

Improper offsetting.

Drilling into or through non flat surface

Workpiece deflection

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



Insufficient machine power and torque

Galling

Insert failure


34

Rubbingscratchondrill body

Inferior hole accuracy

Chip control

Other trouble

Periphery of drillbody

Hole diameter

Surface finish

Common

Entangling

Chip packing

Common

Chatter

Machine stop

Large burr


38/47

R

R

Unit: mm

TDX125L025W20-2

TDX130L026W20-2

TDX135L027W20-2

TDX140L028W20-2

TDX145L029W20-2

TDX150L030W20-2

TDX155L031W20-2TDX160L032W20-2

TDX165L033W20-2

TDX170L034W20-2

TDX175L035W25-2

TDX180L036W25-2

TDX185L037W25-2

TDX190L038W25-2

TDX195L039W25-2

TDX200L040W25-2

TDX205L041W25-2

TDX210L042W25-2

TDX215L043W25-2

TDX220L044W25-2

TDX225L045W25-2

TDX230L046W25-2

TDX235L047W25-2

TDX240L048W25-2

TDX245L049W25-2

TDX250L050W25-2

TDX255L051W25-2

TDX260L052W25-2

TDX270L054W32-2

TDX280L056W32-2

TDX290L058W32-2

TDX300L060W32-2

TDX310L062W32-2

TDX320L064W32-2

TDX330L066W40-2

TDX340L068W40-2TDX350L070W40-2

TDX360L072W40-2

TDX370L074W40-2

TDX380L076W40-2

TDX390L078W40-2

TDX400L080W40-2

TDX410L082W40-2

TDX420L084W40-2

TDX430L086W40-2

TDX440L088W40-2

TDX450L090W40-2

TDX460L092W40-2

TDX470L094W40-2

TDX480L096W40-2

TDX490L098W40-2

TDX500L100W40-2

TDX510L102W40-2

TDX520L104W40-2

TDX530L106W40-2

TDX540L108W40-2

R

R

L/D=2 (metric)

Specifications of TDX drills

35


39/4736

R

R

Unit: inch

TDXU0500L2

TDXU0531L2

TDXU0562L2

TDXU0625L2

TDXU0687L2

TDXU0750L2

TDXU0812L2

TDXU0875L2

TDXU0937L2

TDXU1000L2

TDXU1062L2

TDXU1125L2

TDXU1187L2

TDXU1250L2

TDXU1312L2

TDXU1375L2

TDXU1437L2

TDXU1500L2

TDXU1562L2

TDXU1625L2

TDXU1687L2

TDXU1750L2

TDXU1812L2

TDXU1875L2

TDXU1937L2

TDXU2000L2

R

R

L/D=2 (inch)


40/47

R

R

Unit: mm

TDX125L038W20

TDX130L039W20

TDX135L041W20

TDX140L042W20

TDX145L044W20

TDX150L045W20

TDX155L047W20TDX160L048W20

TDX165L050W20

TDX170L051W20

TDX175L053W25

TDX180L054W25

TDX185L056W25

TDX190L057W25

TDX195L059W25

TDX200L060W25

TDX205L062W25

TDX210L063W25

TDX215L065W25

TDX220L066W25

TDX225L068W25

TDX230L069W25

TDX235L071W25

TDX240L072W25

TDX245L074W25

TDX250L075W25

TDX255L077W25

TDX260L078W25

TDX270L081W32

TDX280L084W32

TDX290L087W32

TDX300L090W32

TDX310L093W32

TDX320L096W32

TDX330L099W40

TDX340L102W40TDX350L105W40

TDX360L108W40

TDX370L111W40

TDX380L114W40

TDX390L117W40

TDX400L120W40

TDX410L123W40

TDX420L126W40

TDX430L129W40

TDX440L132W40

TDX450L135W40

TDX460L138W40

TDX470L141W40

TDX480L144W40

TDX490L147W40

TDX500L150W40

TDX510L153W40

TDX520L156W40

TDX530L159W40

TDX540L162W40

R

R

L/D=3 (metric)

37


41/47

R

R

38

R

R

Unit: inch

TDXU0500

TDXU0531

TDXU0562

TDXU0625

TDXU0687

TDXU0750

TDXU0812

TDXU0875

TDXU0937

TDXU1000

TDXU1062

TDXU1125

TDXU1187

TDXU1250

TDXU1312

TDXU1375

TDXU1437

TDXU1500

TDXU1562

TDXU1625

TDXU1687

TDXU1750

TDXU1812

TDXU1875

TDXU1937

TDXU2000

L/D=3 (inch)


42/47

R

R

R

R

Unit: mm

TDX125L050W20-4

TDX130L052W20-4

TDX135L054W20-4

TDX140L056W20-4

TDX145L058W20-4

TDX150L060W20-4

TDX155L062W20-4TDX160L064W20-4

TDX165L066W20-4

TDX170L068W20-4

TDX175L070W25-4

TDX180L072W25-4

TDX185L074W25-4

TDX190L076W25-4

TDX195L078W25-4

TDX200L080W25-4

TDX205L082W25-4

TDX210L084W25-4

TDX215L086W25-4

TDX220L088W25-4

TDX225L090W25-4

TDX230L092W25-4

TDX235L094W25-4

TDX240L096W25-4

TDX245L098W25-4

TDX250L100W25-4

TDX255L102W25-4

TDX260L104W25-4

TDX270L108W32-4

TDX280L112W32-4

TDX290L116W32-4

TDX300L120W32-4

TDX310L124W32-4

TDX320L128W32-4

TDX330L132W40-4

TDX340L136W40-4TDX350L140W40-4

TDX360L144W40-4

TDX370L148W40-4

TDX380L152W40-4

TDX390L156W40-4

TDX400L160W40-4

TDX410L164W40-4

TDX420L168W40-4

TDX430L172W40-4

TDX440L176W40-4

TDX450L180W40-4

TDX460L184W40-4

TDX470L188W40-4

TDX480L192W40-4

TDX490L196W40-4

TDX500L200W40-4

TDX510L204W40-4

TDX520L208W40-4

TDX530L212W40-4

TDX540L216W40-4

L/D=4 (metric)

39


43/47

R

R

Unit: mm

TDX125L063W20-5

TDX130L065W20-5

TDX135L068W20-5

TDX140L070W20-5

TDX145L073W20-5

TDX150L075W20-5

TDX155L078W20-5TDX160L080W20-5

TDX165L083W20-5

TDX170L085W20-5

TDX175L088W25-5

TDX180L090W25-5

TDX185L093W25-5

TDX190L095W25-5

TDX195L098W25-5

TDX200L100W25-5

TDX205L103W25-5

TDX210L105W25-5

TDX215L108W25-5

TDX220L110W25-5

TDX225L113W25-5

TDX230L115W25-5

TDX235L118W25-5

TDX240L120W25-5

TDX245L123W25-5

TDX250L125W25-5

TDX255L128W25-5

TDX260L130W25-5

TDX270L135W32-5

TDX280L140W32-5

TDX290L145W32-5

TDX300L150W32-5

TDX310L155W32-5

TDX320L160W32-5

TDX330L165W40-5

TDX340L170W40-5TDX350L175W40-5

TDX360L180W40-5

TDX370L185W40-5

TDX380L190W40-5

TDX390L195W40-5

TDX400L200W40-5

TDX410L205W40-5

TDX420L210W40-5

TDX430L215W40-5

TDX440L220W40-5

TDX450L225W40-5

TDX460L230W40-5

TDX470L235W40-5

TDX480L240W40-5

TDX490L245W40-5

TDX500L250W40-5

TDX510L255W40-5

TDX520L260W40-5

TDX530L265W40-5

TDX540L270W40-5

R

R

L/D=5 (metric)

40


44/4741

TEL/FAX

CONTACT

RIGIDITY

MACHINETOOL & TYPE

TYPE OFOPERATION

CUSTOMER

COOLANTPRESSURE

COOLANTMETHOD

TYPE OFCOOLANT

MACHINING OPERATION (SKETCH)

1 2 3 4

INSERT

TEST DATA

INSERT GRADE

CURRENT

HOLDER/BODY TYPE

TOOL DESCRIPTION

( )

H.P. REQUIRED ( )

WORKPIECE/TOOL DIA.

CUTTING SPEED

FEED RATE

DEPTH OF CUT

( )

( )

( )

PIECES PER EDGE

TOOL LIFE (MINS/INCHES PER EDGE)

EDGES USED PER INSERT

PIECES PER INSERT

SURFACE FINISH ( )

REASON FOR INDEXING

CUTTING TIME/LENGTH PER PIECE

HOURLY MACHINE DEPT. COSTMACHINING COST PER PIECE

TOTAL COST PER MACHINED EDGE

INSERT COST

INSERT COST PER PIECE

REPORT#: DATE

SALES ENGINEER

MATERIAL HARDNESS

PART DESCRIPTIONWORK MATERIAL

COMMENTS:

HIGH LOWMED

WATER SOLUBLE OIL

AIR DRY

Tungaloy Corporation

T O O L I N G

R E Q U I R E D

C U T T I N G

P A R A M E T E R S

T O O L

P E R F O R M A N C E

C O S T

E V A L U A T I O N

Test report format


45/47

Adjusting finishing diameter in milling

Adjusting of the finishing diameter in tool-rotatingapplications such as on machining centers and mill-

ing machines.

By using EZ sleeve , the finishing diameter can beadjusted in the range from +0.6 mm to -0.2 mm.

Adjusting cutting edge height on lathe

Adjusting of the cutting edge height in work-rotat-ing applications such as on lathes.

By using EZ sleeve , the cutting edgeheight can be adjusted in the rangefrom +0.3 mm to -0.2 mm. It results ineliminating troubles caused by im-proper cutting-edge height.

Insert Cat. No.Stocked grades Dimensions (mm) Applicable drill

AH120 GH730 A B T d R diametersDS chipbreaker


AH120 AH740 GH730 A B T d R diametersDW chipbreaker

Use EZ sleeves for the following purposes

Specifications of inserts

EZ sleeve for TDX-type TAC drills

Scale for adjusting finishing diameterin milling (Periphery of sleeve)

Scale for adjusting cutting edge height inturning (Front face of sleeve)


AH740 GH730 T1015 T313W A B T d R diametersDJ chipbreaker

42


46/47

Adjusting finishing diameter in milling

As shown in the Figure below, set the EZ sleeve be-tween the drill shank and the toolholder.

Adjusting cutting edge height on lathe

Align the scale graduated on the periphery of the EZsleeve with the center of the flat of the drill flange.In the Figure shown below, the sleeve is set so thatthe finishing diameter will be increases by 0.4 mm.

As shown in the Figure below, set the EZ sleeve be-tween the drill shank and the toolblock.

Align the scale graduated on the front face of the EZsleeve with the center of the flat of the drill flange.In the Figure shown below, the sleeve is set so thatthe center of the drill will shift by 0.1 mm to the plus(+) direction.

When aligning the scales, insert the attached wrench into the hole on the periphery of the sleeve and rotate the sleeve.

After aligning the scales, secure the fixing bolt A positioned closer to the drill. Then, lightly secure the fixing bolt Bto prevent the sleeve from rotating.

Fixing bolt A

Flange

Fixing bolt B

X - a x i s o f

m a c h i n e

Fixing bolt A

Fixing bolt B

+ 0 . 4 + 0 . 2

Setting of EZ sleeve

Specifications

Cautious points The scale should be used only as a guide. Measuring and checking of the real finishing diameter is essential. Especially

when using for adjusting the cutting edge height on a lathe, the finishing diameter also varies with the adjusting. Check thediameter by try cutting.

When using the sleeve in milling, use a side-lock-type toolholder. Collet type toolholders and milling chucks should not beused for this purpose.

When heavy vibration develops during machining such as in combining with a long drill exceeding L/D=4 or requiring largeamount of adjusting, reduce the feed rate.

If the finishing hole diameter is excessively adjusted to the minus () direction, the drill body may interfere with the hole tobe drilled. Adjusting to the minus direction should be carried out, only when the finishing diameter is larger than the nominaldrill diameter, as a means of fine adjustment.

SleeveCat. No.

EZ2025L43

EZ2532L48

EZ3240L53

EZ4050L63

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

43


47/47

Distributed by:

Head OfficeSolid Square 580 Horikawa-Cho, Saiwai-Ku, Kawasaki, 212-8503 JapanPhone: +81-44-548-9500 Facsimile: +81-44-548-9540

International Operations DivisionKokusai Shin-Kawasaki Bldg., 2-1-5 Kitakase, Saiwai-Ku,Kawasaki, 212-0057 JapanPhone: +81-44-587-2562 Facsimile: +81-44-587-2580

Tungaloy America, Inc.1226A Michael Drive, Suite A, Wood Dale, IL 60191, U.S.A.Phone: +1-630-227-3700 Facsimile: +1-630-227-0690Sales of machining tools

Tungaloy Europe GmbHElisabeth-Selbert-Strasse 3, 40764 Langenfeld, GermanyPhone: +49-2173-90420-0 Facsimile: +49-2173-90420-18Sales of machining tools

Tungaloy France S.a.r.l.6 Avenue des Andes, 91952 Courtaboeuf Cedex, FrancePhone: +33-1-64864300 Facsimile: +33-1-69077817Sales of machining tools

Tungaloy Italia S.p.AVia E. Andolfato 10, 20126 Milano, ItalyPhone: +39-02-252012-1 Facsimile: +39-02-252012-65Sales of machining tools

Tungaloy Cutting Tool (Shanghai) Co., Ltd.United Plaza 1505, 1468 Nan Jing Road West, Shanghai 200040, ChinaPhone: +86-21-6247-0512 Facsimile: +86-21-6289-1302Sales of machining tools

Thai Tungaloy Cutting Tool Co., Ltd.11th Floor, Sorachai Bldg. 23/7, Soi Sukhumvit 63,Klongtonnue, Wattana, Bangkok 10110, ThailandPhone: +66-2-714-3130 Facsimile: +66-2-714-3134Sales of machining tools

Tungaloy Singapore(Pte.), Ltd50 Kallang Avenue #06-03, Noel Corporate Building, Singapore 339505Phone: +65-6391-1833 Facsimile: +65-6299-4557Sales of machining tools

Tungaloy Australia Pty. Ltd.Suite 3, Compark Circuit, Mulgrave Vic. 3170, Melbourne, AustraliaPhone: +61-3-9560-5088 Facsimile: +61-3-9560-5077Sales of machining tools

WorldwideSubsidiaries & Affiliates

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