User guide
Contents
1. All rights reserved No part of this publication may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopy recording or any information storage and retrieval system without permission in writing from the publisher This handbook has been carefully prepared and translated Flowdrill does not accept any responsibility for errors in the handbook and any consequences resultant therefrom No guarantee can be given that the details are free from patent rights assigned to third parties All data and comparative details should be understood as being indicative without obligation Because Flowdrill friction drilling procedures are continuously being further developed the details given may not provide any indication of the current state of development availability or possibilities of delivery The producer s current lists should be consulted for information Copyright by FLOWDRILL B V HOLLAND Edition 2003 FLOWDRILL B V INDUSTRIETERREIN LAGE WEIDE SAVANNAHWEG 70 NL 3542 AW UTRECHT TEL 31 30 2416606 FAX 31 30 2413860 Email address Info oFlowarill nl URL http www Flowdrill nl DIV Mn ited by the RvA y the 150 9001 REGISTERED FIRM DNV Certification B V THE NETHERLANDS We care about the Flowdrill9 is the registered trade mark of Flowdrill b v Holland 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 02. Long Flat ou 6 6 6 6 6 6 6 6 6 6 8 8 8 10 1 Total length working part 17 1 Observation in process Possible Causes Flowdrill point wanders Worn Machine Spindle can break Flowdrill Bearings Worn collet Excessive start pressure Spindle speed too low Flowdrill overheating Spindle speed too high Colour bright red Feed rate too slow Flowdrill sparkles 17 2 Observation on Work piece Split collar daisy petals Start pressure feed too high or spindle speed too slow or final feed to slow Pilot hole or Rem FD may help Flash or burr on edge of Drill point wanders collar Excessive discoloration Feed too slow or spindle around hole speed too high 17 3Cycle Time A guide to process speed for 2 mm Fe 360 is 1 second 1 second for each millimetre of material thickness i e Flowdrill time is 3 sec approx This guide can be used up to about diam 12mm Larger Flowdrills take longer but cycle time should not exceed 15 seconds 17 3 1 Operation examples Rpm 2400 2200 F ax 800 N 1000 N Motor capacity 0 75 kW 1 kW Operation time 1 5 2 sec 2 3 5 Material Thickness 1 0 mm 2 0 mm 17 4Flowtaps Consult the cover of this technical guide for the right diameter 17 5Check the table chapter 14 0 for the right speed 17 6Lubricate before every action the Flowtap as well as the bust 33 Metric thread Thread Pitch mm Flowd
3. 10 0 11 0 12 0 13 0 14 0 15 0 16 0 17 0 18 0 Equipment for the Flowdrill system History Introduction Flowdrill Ideal for automation How the Flowdrill works Flowdrill parameters Flowdrill types Applications of Flowdrills Suitable materials Working life Influential factors Work piece material and lubrication Tapping information Flowdrill process with CNC Starter Set Parameters for metric thread tools Tables of torque and pull strength Maximum material thickness for thread holes Hints amp Tips Thread tables The Flowdrill e System The Flowdrill e System Toolholder with Nut Spanner and C Spanner FDMC2 FDMC3 Collets Fd 430e 6 up till 14 Fd 470e 12 up till 20 Rubber flex collets Flowdrills and Flowtaps Standard see cover at the back Specials Lubricants and Miscellaneous In 1923 in a little barn in the south of France Jan Claude de Valliere attemp ted to develop a tool for producing holes in thin steel sheet using the principle of frictional heat instead of cutting After many experiments he was technically successful However practical industrial applica tions were not possible because Very hard material such as tungsten carbide was not available Correct geometry of the tools was not known Diamond grinding wheels for hard materials did not exist Machinery to generate the required complicated profile were not ava
4. 4 5 6 tf 8 9 TOOL WORKING PART mm Tool Size Tool Type Drawing Number FD 7 3 L1 18mm L4 10mm Long Standard 00000 A4 000 00 00 00 PL Detail 5506 Size Job Example M8 Fe 360 3mm 13 9 Reduction cone 3 2 optional extra 13 1 Flowdrill 7 3 long average life 13 10Diamond file optional extra 10 000 holes 13 11 Ejecting drift key optional extra 13 2 Flowdrill lubricant Fd ks paste 13 3Toolholder FD MC2 locking spanners included 13 4 Collet Fd 430E 8 Starter Set 13 5Flowtap M8 average life appro 10 000 holes 13 6 Flowtap lubricant Ft mz 13 7 FD Case keeps kit together 13 8Tapping attachment option extra 30 Mild steel FE 360 2mm Indication to start with Thread size Flowdrill Diameter mm Flowdrill Rom Motor capacity kW Production time Sec 31 Pull out strength in 1kKN 100Kg Material Fe 360 Thickness 1 0 5 0 mm Material Thickness h mm 1 0 1 5 2 0 3 0 4 0 5 0 Thread M4 Torque in Nm Material Fe 360 Thickness 1 0 5 0 mm M8 s Short Flowdrill I Long Flowdrill 275 37 45 Material Thickness h mm Thread Size 32 Thread Flowdrill for Flow tapping Data based on Fe 360 Max thickness Short Short Flat Long
5. gas heating metal furniture results The standard Flowdrill design is shownof the drill feed in figure 3 Its working portion consists As the material softens axial force is of a pointed end a cone and a paralleleduced and feed rate increased fig 4 body Both the cone and the body aral e f g h polygon shaped This specially designed shape plays an essential size and shape of the Flowdrilled in the Flowdrill process The Flowdrill hole and bushing are determined by the also has a collar and a straight shankdiameter and cone shape of the Flowdrills are made of a carbide gradeFlowdrill developed to satisfy the unique characMaterial that flows back towards the teristics of the Flowdrill operation Flowdrill can be formed into a collar fig 4 i or cut off flush to the surface 4 1 The phases of Flowdrill with a flat type Flowdrill fig 4 4 1 3 High axial force 4 1 1 Initial Contact Develops heat rapidly in Flowdrill Relatively high axial pressure F ax creating thermal stress combined with high rotational speed is Increases feed rate reduces drilling needed to generate heat between Flowdrilltime and workpiece fig 4 a b c May alter the physical properties of The Flowdrill temperature rises rapidly to workpiece material about 650 750 C and the wrk piece 600 C 4 1 4 Low axial force High axial force is needed until the Flowdrill point penetrates the material Provides gradual warmin
6. rated to give maximum thread strengtlLarger Flowdrill diameters have in a Flowdrilled bushing can double thdavourable effect on Flowtap life torque required fig 11b They may also be advantageous in some very tough materials or materials 11 2 Flowtap speed fig 11c that tend to recover or shrink after forming for example M 6 thread can See also chapter 14 0 be formed using 5 3 5 4 5 5 Flowdrill depending on conditions MA 5 iy jj p A y ff E J a Cutted thread Cold formed thread Material structure is broken Material structure remains intact fig 11a Nm N Required torque is dependant on the 20 Influence of roughbor Roughbore diameter N diameter on the torqu Rpm N ER Lubrication N 9 15 9 20 925 930 935 9 40 fig 11b 2 Torque Nm 160 140 120 100 80 Example M10 in Fe 360 200 RPM 10 Nm 0 2 kWatt kW A T i Threaddiameter 20 18 16 4 12 10 B 6 4 2 1 OB 06 04 02 01 2 4 10 12 14 16 18 20 22 24 276 28 30 28 TIME WORKING PART FEED RATE Zeit Weg Vorschub CNC PROGRAM Material Mild Steel ST37 Material thickness 3 mm 2 73 2mm 150 mm min 2 4mm 250 mm min 4 7 mm 350 mm min 7 11 mm 550 mm min 11 14 mm 700 mm min 14 18 mm 1000 mm min o E lt a LL T
7. 7 P e 6 AC Landi d 5 A 4 4 4 3 4 O 28 2 Flowdrill type short for conical bushing type long for cylindrical bushing ALLELE EEE ELLE b _ fig 6 1 2 3 4 5 6 7 8 9 10 41 12 43 14 15 16 17 18 19 20 21 22 23 24 25mm fe Max short for conical bushing zomm Max short flat for conical bushing Ser Max long for cylindrical bushing o o o Max long for conical bushing Max long flat for conical bushing 16 6 1 Long Flowdrill fig 7a The long Flowdrill has a long parallel body L5 fig 7 designed to produce a hole that is cylindrical for the entire bush length Material that is backward extruded is rolled into a rim by the Flowdrill collar fig 8e 6 2 Short Flowdrill fig 7b Short Flowdrills have a shorter parallel body This design produces a bush that is conical and provides great strength when formed into a thread fig 8a 6 3 Short Special Flowdrill fig 7c Special L 4 amp L 5 dimensions are avai lable for use when Flowdrill penetration length is restricted for example in small diameter tube 17 6 4 Optional Features The following optional features can be supplied on any Flowdrill 6 4 1 Milling cutters Flat Flowdrill fig 7d The Flowdrill collar is ground into a cutter fig 8c g This removes the rim formed around the top surface of a Flowdrilled hole leaving the su
8. ductivity Generally all malle able materials can be Flowdrilled Lubrication of the Flowdrill can work against the need to generate heat but is required in small amounts to prevent pick up or adhesion on the carbide surface particularly when Flowdrilling aluminium Flowdrill lubricants are spe cially developed to meet this criterion 10 1 Remak Lubricate while is still running directly after Flowdrill operation 10 2 Flowdrill lubricants FDKS paste and FDKS fluid to use for drilling in steel stainless steel copper and brass FDUN paste to use for drilling in aluminium 10 3 Tapping lubrication High material deformation during tapping places strong demands on the lubricant used To obtain optimum speed and quality we recommend use of Flowdrill FT MZ high pressure lubricant It should be applied for each hole tapped Dispensers are available for automatic production Avoid overheating the lubricant 25 26 11 1 Tapping Torque 11 3 Recommended Flowdrill dia The torque required for tapping coldmeters for tapping backcover forming threads depends on thd3ecommended Flowdrill diameters Flowdrill diameter Rom work piece produce 65 thread depth material and lubrication Because the cold forming process toug Cold forming threads generally usehens the material thread strength is about 20 more torque than cuttinggreater than when a cutting tap is used However the conical hole shape gendfig 11a
9. g reducing stress in Flowdrill 4 1 2 Material Flow Increases drilling time which can result in excessively high temperatures Displaced material initially flows up Reduces torque on Flowdrill towards the Flowdrill when the point Requires less power input penetrates material flows in the direction fig 4k fig 4j The Flowdrill diameter 5 2 Speed n determines values for Keep speed as low as possible to obtain longer Flowdrill life Speed Rpm n min 1 5b Speed selection is influenced by mate rial thickness as well as material type Axial forces F ax N See fig 5a Power P kW 5 Thicker stainless and high carbon steel Material thickness max h mm 6 require lower speed and will usually result in shorter Flowdrill life 5 1 Axial force As a general rule soft non ferrous materials require more speed the softer Maximum axial force is proportional to the material the higher the speed the Flowdrill diameter As temperature increases axial forcdsraphics b c are based on Fe 360 required reduces feed rate increases h 2mm HE 2000 1000 E 10 11 12 18 14 15 16 17 18 19 20 21 22 23 24 25mm Flowdrill mm 5 upwo J eeuundo 0771 ANISPJOOUY eiz enisoduejs am 11 12 5 3 The effects of d
10. ifferent speed 5 4 Power kW are shown in this example Material thickness h Flowdrill dia Speed n Drilling time Flowdrill Temperature 2 0 7 3mm 3 000 min 1 1 5 sec 700 2 0 7 3mm 1750 min 1 2 0 sec 600 C Most good quality drilling machines are suitable for Flowdrill provided they meet the power and speed requirements The required power of the drilling machine is shown on chart fig 5c 13 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25mm ___ Optimum operation area Flowdrill 14 5 5 Material Thickness h Fig 6 indicates maximum material thickness that can be Flowdrilled with Maximum material thickness h Max is standard long or short Flowdrills See also proportional to the Flowdrill diameter table in chapter 16 0 Minimum thickness follows the general Special Flowdrills can be supplied to meet rule h Min approx 0 2 x D 1 up to unusual needs 2mm which rule is suitable for most of For greater thickness an extra long L 5 the bigger sizes D1 is the Flowdrill may be necessary diameter Ask for advise Flowdrill life is reduced if used on heavier gauge material or materials with high tensile strength Notes 15 When the application is outside the range of max lines given in this graphic please call our technical service for their experience 77 LIFE HAAA eA 111
11. ilable It would take almost 60 years before these problems could be solved and the Flowdrill could find its way to successful commercial use 222 fig 2a A Flowdrill fig 3 is lobed conical tungsten carbide tool When rotated at high speed and pressed with high axial force into sheet metal or thin walled tube generated heat softens the metal and allows the drill to feed forward produce a hole and simultaneously form a bushing from the displaced material fig 1 There are numerous possible applica tions for Flowdrill it increases effective wall thickness for threaded connections or soldered joints etc fig 2a f 2a Chipless drilled hole for spraying appliances No chips no broken drills 2b Gas tight connection 2c Threaded connection with rim around the hole 2d Threaded connection Flat face 2e Bearing or shaft support 2f Water tight soldering high pres sure fig 2e Collar Cylindrical part Conical part Flowdrill point fig 3 a No swarf lighting and household appliance indus tries etc b Long tool life Although the process itself has been c Accurate hole form applied for some time it is necessary for the user to understand the nature of the Flowdrill process the various types of Flowdrills and the physical requirements Much experience has been gained in thef the drilling machine for best automobile
12. le quality will be affected by surface of the workpiece as well asuild up of work piece metal on the tool welded spots should be avoided also from film caused by anodised alumi nium or zinc from galvanising 9 3 Avoid radial forces on the Flowdrill 9 13 Timely removal of built up material 9 4 Torsional stability of the Flowdrill with diamond file is important Too rapid release of torsional load caused by fast break through 14 Cleaning with a diamond file will very high feed rate can cause fatigue extend tool life 9 5 Asimilar condition can occur due to9 15 Don t dwell at depth when using wind up if start pressure is too great Flowdrills especially flat Flowdrills dwelling reduces cutter life 96 DO NOT DRILL an unfinished hole risking taper lock due to shrink 9 16 Protect the Flowdrill and drilling age machine spindle for overheating by using the special Flowdrill toolholder with cool 9 7 Instability due to wear in machineing fan spindle or collet can allow the Flowarill to wander Stress caused by misalign ment can break the Flowdrill 9 8 Finish quality in the Flowdrilled hole will deteriorate when the Flowdrill becomes worn 9 9 Regularlubrication will increase life of Flowdrill Use Fdks for lubrication of the FD every 1 5 holes on the hot rotating FD 24 Flowdrill lubrication Flowdrill results depend on the mate rial s physical properties such as tensile strength hardness chemical content and con
13. ool Size Tool Type Drawing Number FD 7 3 18mm L4 10mm Long Flat 00000 QUU sme a See UP A Flowdrill s feed rate is determined byrate pressure initial pressure is quite highFeed and rates of acceleration will vary to create frictional heating As the workaccording to Flowdrill size Flowdrill piece softens it allows the drill tospeed material type and thickness but advance the rate of advance increasesrrect feed can be established fairly with heating and also as the drill pointasily by trial and observation The aim penetrates through the material is to achieve and maintain a constant The required accelerating feed rate cadull red glow while the tool is drilling be achieved by hand or with pneumatic feed devices Example of feed for 7 3 M8 long flat If CNC is to be used this effect has td lowdrill through 3 0mm thick mild be simulated with a slow initial feedsteel As a guideline depending on rate accelerating to a high final feednachine and material CNC PROGRAM WORKING PART Weg FEED RATE Vorschub 0 2 mm 4 mm 7 mm 11 mm 14 mm 16 6 mm 150 mm min 250 mm min 350 mm min 550 mm min 700 mm min 250 mm min 29 Material Mild Steel ST37 Material thickness 3 mm 1 4 mm space adjustable for rim or boss forming Page 16 section 6 1 y 14 mm minute FEED RATE 2 3
14. rface flat fig 7d 6 4 2 Fluted point Rem Flowdrill fig 7e Fluted point all Flowdrills can be supplied with two small cutting flutes at the tip fig 8b f This style is useful for coated materials such as paint anodised and some galvanised steel depending on thickness of layer The axial force is also reduced permitting use in portable hand drills or when a work piece has insufficient support in the area to be Flowdrilled and tends to dent due to insufficient rigidity 6 4 3 Flat Rem fig 7f Flowdrills can be supplied with combination of cutting flutes and mil ling cutters fig 8d h fig 7f fig 7e 4 V ur 8a short 8b short rem 8c short flat 8d short flat rem hdd 6g 20 7 1 Flowtapping 7 1 2 Example The most common use of Flowdrills 6 in 2 mm Fe 360 to provide a high strength threaded fast ener in thin sheet metal or tube Ause Flowdrill 5 3 short Flowdrilled hole may be tapped with conventional cutting taps or preferablypse Flowtap M6 with cold form Flowtaps Flowtapping resembles Flowdrill except the strength 17 kN ting temperature is much lower instead of cutting Flowtaps cold form the thread no swarf The diameter of the Flowdrill determines the final thread form depth and strength Tables in chap ter 18 0 back cover show the recom mended Flowdrill diameter
15. rill diameter M2 M 2 5 M3 M4 M5 M6 M8 M 10 M 12 M 16 M 20 Metric thread fine Thread Pitch mm Flowdrill diameter M4 0 5 3 8 M5 0 5 4 8 M6 0 75 5 6 M6 0 5 5 8 M8 1 0 7 5 M8 0 75 7 6 M 10 1 25 9 3 M 10 1 0 9 5 M 12 1 5 11 2 M 12 1 0 11 5 M 16 1 5 15 2 M 16 1 0 155 M 20 1 5 19 2 M 20 1 0 19 5 BSP thread Thread G 1 16 G 1 8 G 1 4 G 3 8 G 1 2 G 3 4 G1 Sizes based on Fe 360 2mm US thread UNC Thread No No No No No No 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 4 5 6 8 1 1 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 0 2 Thread 1 16 1 8 1 4 3 8 1 2 3 4 4 Thread per inc Flowdrill diameter US thread UNF Thread Thread per inch Flowdrill diameter US thread NPT Thread per inch 27 27 18 18 14 14 11 5 Flowdrill diameter 7 0 9 4 12 4 15 8 19 6 24 9 31 4 Thicker material or material with greater tensile strength stainless Flowdrill diameter 0 1 mm bigger
16. s for various thread sizes 7 1 1 Advantages of Flowtaps compared with thread cutting taps No weakening of the threaded wall due to metal removal Higher production speed Better thread strength through cold forming of the material Less chance of pitch errors that can be incurred when cutting threads No swarf no pollution or chip remo val problems Less tap breakage Good tap life 21 7 2 OtherApplications 1 NE O c w 58 aS gt gt 5 9 m Bearing support Soldered connection 22 8 1Steel up to 700 N mfntensile strength 8 2 Non ferrous metals with the excep tion of brittle material like CuZn40Pb2 8 3 Aluminium with less than 596 Si 8 4 Stainless steel acid resistant steel In some cases it is desirable to test the suitability of the Flowdrill system In particular in case of zinc coated mate rials f HT M20 mm 23 9 1 Flowdrills are made of specially 9 10 Flowdrill temperature should not developed carbide This will maintainexceed dark red colour its strength at high temperatures but is sensitive to thermal stress LocaB 11 Speed and axial force should be cooling should be avoided adjusted optimally under observation of the temperature of the FD indicated by 9 2 Flowdrills cannot withstand high dark red colour mechanical shock They should not be dropped and hard impact onto th 12 Ho
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