User Guide • We recommend using CHAMDRILL in
Contents
1. D 433 508 006 010 D 512 587 008 012 D 591 665 010 014 D 669 823 D 827 1 020 010 018 010 018 260 430 230 360 200 300 130 230 005 008 006 010 008 012 160 260 130 230 70 160 300 460 260 430 330 590 300 520 300 520 260 390 300 520 100 160 70 130 70 160 70 160 005 003 008 008 002 002 002 008 006 012 014 004 005 005 005 005 010 010 003 004 004 009 009 014 016 005 006 006 006 005 012 012 004 005 005 010 006 016 018 006 007 007 006 008 006 008 006 009 006 010 006 009 006 0102. the drill is then required for 2xD max CLWIDRILL user Gumpe Troubleshooting Cutting Edge Chipping 1 Check the stability of the machine spindle tool and workpiece clamping rigidity Reduce feed rate increase speed Chisel Area Chipping 1 Reduce feed rate 2 Increase coolant pressure U Excessive Flank Wear 1 Check that the correct geometry is used 2 Reduce cutting speed 3 Increase internal coolant pressure 4 When drillin Excessive Flute Land Wear 1 Check that the correct geometry is used 2 Check the runout and make sure it is within 001 inch T I R radial and axial 3 Reduce cutting speed ener GCWIDRILL user cupe Troubleshooting pi Built Up Edge 1 Increase cutting speed 2 Increase coolant pressure Insufficient Pocket Gripping Torque 1 Check unlocking gripping torque with TK DCM torque key If there is no click indication replace drill head Increase coolant pressure N Ww N au N Deviation of Hole Tolerance 1 gt D nominal 006 inch lt D nominal 0012 inch Check the runout and make sure it is within 001 inch T I R radial and axial cutting points Reduce feed rate Check the chisel point runout and make sure that it is within 001 inch T I R Wrong cutting edge Replace head Increase workpiece chucking force Check the adaptati
3. Drilling Head Mounting Procedure Ga DRILL user cupe Power Force Requirements Drilling Limitations Drilling can be done on 6 maxi mum angular surface Regrinding of drill head is not recommended it may cause drill malfunction Power Force Requirements KW Net Power mi 0 0 24 31 40 50 55 63 71 79 87 94 1 02 24 31 40 50 55 63 71 79 87 94 1 02 Diameter inch Diameter inch Material SAE 4340 Speed 330 sfm Feed 008 ipr Values change for different materi als and drilling conditions GC AWDRILL user Gumpe Indications of Drilling Head Wearing Out 2 Power Restriction p 2 Px1 25 Wear Limit 1 New drilling head 2 Worn out drilling head Diameter Change O Surface Finish Declines gt D nominal 006 inch D nominal Ra Noise of Vibration Drastically Increases AN PA GA DIRILL user cupe CHAMDRILL Unlocking Change in Torque Typical Unlocking Torque Range Torque lbf inch Dia 669 1 020 Dia 433 630 gt Dia 295 413 10 12 14 16 18 20 22 24 26 28 30 No of Indexes The number of indexing changes according to machine clamping rigidity machin
4. User Guide e We recommend using CHAMDRILL in rotating or stationary applications with a maximum of 0008 outer cutting points or chisel runout for optimum performance Larger runout will influence drill performance and hole quality e In case of stationary applications we recommend clamping the drill in an orientation which directs both outer cutting points parallel to machine X axis On stationary lathe applications if there are misalignment problems it is recommended to use alignment devices such as the ISCAR ETM GYRO device Misalignment will cause poor performance of the CHAMDRILL or even tool breakage GYRO Misalignment Correction Device for Stationary Operation T I R max 0008 Angular Adj 1 Radial Adj D 08 If chip formation or chip evacuation problems are encountered follow these recommendations 1 Reduce cutting speed by 10 2 Increase internal coolant pressure 3 Apply a pecking cycle e Use of internal and external coolant during drilling is recommended for achieving prolonged edge life When only external coolant can be applied it is recommended to drill into a maximum depth of 2X the drill diameter e Semi synthetic or emulsion lubricants are recommended in order to extend tool life e Dry machining should not be performed under any circumstances e The new CHAMDRILLs can be clamped in ISCAR tooling systems such as 1 Collet chucks 2 Side lock adapters 3 Power hydraulic chucks e
5. We recommend JET 2 collet chucks for internal and external coolant jets Using CHAMDRILL in SHORTIN adaptation with collets for achieving higher tool life and improved performance Drilling sloped surfaces of a maximum 6 Reduce feed by 30 50 when penetrating a sloped surface Recommended exit surface angle is a maximum of 30 In that case feed should be reduced by 30 50 Sloped surfaces of more than 6 require spot or pre hole centering to avoid drill deviation or poor drill performance e Both options of stacked plate drilling are possible with and without gap A minimum gap of 08 between plates is recommended e Interrupted cut has direct influence on hole accuracy quality and drill tool life e CHAMDRILL can not be used on FITBORE or any other radial adjustment adaptation device e Before clamping a new drilling head apply some oil in the CHAMDRILL pocket This practice reduces pocket wear and increases the number of indexing cycles e Attached is a sketch which may help in identifying the indications of a worn out drill head see page 11 e A general troubleshooting guide is attached for suggesting solutions to the most common problems See pages 14 15 Gil DRILL DCM Indexable Head Drills Drilling Depth 3xD Range 866 to 1 020 DCM D Pocket Range L Designation d d L L Size Key 866 901 2 60 MAREEA 1 00 1 26 3 74 2 20 22 K DCM 22 906 941 2 71 BIURT
6. ZEA 1 00 126 3 92 2 20 23 K DCM 23 945 980 2 83 PIURE ELA 1 00 126 408 2 20 24 K DCM 24 984 1020 2 95 iol Muct rere ee Sem 1 00 126 4 29 2 20 25 K DCM 25 Hole tolerance D 0 02 in average conditions however it can be higher or lower according to machine and tooling conditions Gil DRILL DCM Indexable Head Drills Drilling Depth 5xD Range 866 to 1 020 DCM oD Pocket Drilling Range L Designation d d Li L Size Key Heads 866 901 4 33 WRITE 1 000 1 26 5 47 2A 22 K DCM 22 906 941 4 53 WIRT ENA 1 000 1 26 5 72 2 200 23 K DCM 23 DI 945 980 4 72 Spl Mer ey eet 1 000 1 26 5 97 2 20 24 K DCM 24 984 1020 4 92 WAVRE PANA 1 000 1 26 6 26 20 23 K DCM 25 1 Do not mount smaller drilling heads than specified range for drill body Hole tolerance D 0 02 in average conditions however it can be higher or lower according to machine and tooling conditions Drilling Heads for DCM Drills IDI Designation D Range Pocket s Size ig o8 866 901 366 22 0 906 941 385 23 0 945 980 393 24 0 984 1 02 417 25 0 Heads are available in increments of 004 SK heads for drilling cast iron available in IC 908 Ordering examples for 524 drill head IDI 133 SG IC528 M sor isom Miso K GAL DRILL user Gumpe Coolant In stationary drill applications both internal and exter nal coolant supply is recommended
7. eland gt 0 25 C Annealed 2 cast steel free cut lt 0 55 C Quenched and tempered 3 ting steel gt 0 55 C Annealed 4 Quenched and tempered 5 Low alloy steel and Annealed 6 cast steel 7 less than 5 of Quenched and tempered 8 alloying elements 9 High alloyed steel cast steel Annealed 10 and tool steel Quenched and tempered 11 ferritic martens 12 Stainless steel and martensitic 13 cast steel as austenitic 14 Cast iron nodular GGG remige peariitic 15 Pearlitic 16 Grey cast iron GG remie 1 Pearlitic 18 Ferritic 19 Malleable cast iron F Pearlitic 20 Aluminum Not cureable 21 wrought alloy Cured 22 i lt 12 Si Not cureable 23 gt 12 Si High temperature 25 gt 1 Pb Free cutting 26 Copper alloys Brass 27 Electrolitic copper 28 Duroplastics fiber plastics 29 Kon merli Hard rubber 30 7 Annealed 31 High temp alloys ag Cured 32 Annealed 33 Super alloys NiorCo based Cured 34 Cast 35 Titanium Ti all et Veo la Oys Alpha beta alloys cured 37 Hardened steel Hardened 38 Hardened 39 Chilled cast iron Cast 40 Cast iron Hardened 41 Chipformer should be selected based on our geometry recommendations Page K4 When using coolant supply only reduce cutting speed by 10 Use internal coolant supply when machining austenitic stainless steel GAAW DRILL user cupe Cutting Speed Vc sfm 160 430 330 390 300 360 300 390 230 300 Feed vs Drill Diameter ipr D 268 429 005 008
8. ing conditions workpiece material coolant cooling pressure and correct usage Torque Inspection Key Torque keys are available for checking minimal clamping torque If a click is not heard while unclamping with the torque key the drill must be replaced TK DCM 8 TK DCM 9 TK DCM 10 TK DCM 11 TK DCM 12 TK DCM 13 TK DCM 14 TK DCM 15 TK DCM 16 TK DCM 17 TK DCM 18 TK DCM 19 TK DCM 20 TK DCM 21 TK DCM 22 TK DCM 23 TK DCM 24 TK DCM 25 GC AWDRILL user Gumpe Machining Conditions Internal Coolant Pressure Recommended Cooling Pressure and Flow Rate Coolant Flow Rate gallon min A 7 92 gt Drill Diameter 1 0 D inch Minimum Coolant Pressure Psi Drill diameter D inch 27 47 63 80 1 0 xFor special drills more than 8xD it is recommended to use higher coolant pressure 217 1015 Psi To guarantee chip evacuation the coolant must always flow through the tool If the machine is not equipped with coolant through the spindle we recommend using a coolant inducer External coolant supply can be used if hole depth is less than 1xD and reduced cutting data is applied The diagram shows the coolant flow rates for different drills and pressures Coolant Mix Dry Drilling Recommended emulsion mix is 6 8 It is possible to drill without coolant in When drilling in stainless and high strength cast iron and steel Oil mist through steels a mix of 10 is recommended
9. on Use hydraulic clamping chuck MAXIN power chuck or side clamping systems Increase internal coolant pressure Inaccurate Hole Position 1 Check the runout and make sure it is within 001 inch T I R radial and axial 2 Check the stability of the machine spindle tool and workpiece clamping rigidity When drilling rough hard or sloped surface up to 6 reduce the feed rate by 30 50 during entrance 4 Drill a pre hole with a 140 point angle for centering 5 Check the chisel point runout and make sure it is within 001 inch T LR W Ww uo Surface Finish i Too Rough 1 2 In case of chip jamming increase the 2 Check the runout and make sure it is within 001 inch T I R radial and axial Adjust the feed for improved chip formation coolant flow and or reduce the cutting speed Increase the coolant pressure Check the chisel point runout and make sure it is within 001 inch T I R Use pecking cycle Burrs on Exit 1 Reduce the feed rate by 30 50 during exit 2 Replace the worn head Check the adaptation Use hydraulic clamping chuck MAXIN power chuck or side clamping systems Ww GaLW DRILL user cupe Machining Data for DCM Hates Hardness Material Material Condition Kpsi HB No lt 0 25 C Annealed 1 Non alloy ste
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