User Guide • We recommend using CHAMDRILL in rotating or
Contents
1. Burrs on Exit 1 Reduce the feed rate by 30 50 during exit 2 Replace the worn head 3 Check the adaptation Use hydraulic clamping chuck MAXIN power chuck or side clamping systems GCLWDRILL user cupe Machining Data for DCM Tensile Strength Hardness Material Material Condition N mm2 HB No lt 0 25 C Annealed 125 1 Non alloy steeland gt 0 25 C Annealed 190 2 cast steel free cut lt 0 55 C Quenched and tempered 250 3 ting steel gt 0 55 C Annealed 220 4 Quenched and tempered 300 5 P Low alloy steel and Annealed 200 6 cast steel 275 7 less than 5 of Quenched and tempered 300 8 alloying elements 350 9 High alloyed steel cast steel Annealed 680 200 10 and tool steel Quenched and tempered 1100 325 11 ferritic martens 200 12 Stainless steel and martensitic 240 B cast steel austenitic 180 14 Cast iron nodular GGG SOLES pearitic 180 1 Pearlitic 260 16 Grey cast iron GG Fermitic 160 17 Pearlitic 250 18 Malleable cast iron F emie 130 Wo Pearlitic 230 20 Aluminum Not cureable 60 21 wrought alloy Cured 100 yy Ani lt 12 Si Not cureable 75 23 uminum cast Cured 90 24 alloyed gt 12 Si High temperature 130 25 gt 1 Pb Free cutting 110 26 Copper alloys Brass 90 27 Electrolitic copper 100 28 A Duroplastics fiber plastics 29 Nonimealk Hard rubber 32. 2 Increase coolant pressure Ww N U A Deviation of Hole Tolerance 1 gt D nominal 0 15mm Check the runout and make sure it is within 0 02 mm T I R radial and axial cutting points Reduce feed rate Check the chisel point runout and make sure that it is within 0 02 mm T I R Wrong cutting edge Replace head Increase workpiece chucking force Check the adaptation 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 0 02 mm T I R radial and axial 2 Check the stability of the machine spindle tool and workpiece clamping rigidity 3 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 0 02 mm T I R Ww U A Surface Finish Too Rough 1 2 In case of chip jamming increase the E 1 1 Z 1 E E si 1 1 Check the runout and make sure it is within 0 02 mm 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 0 02 mm T I R Use pecking cycle
3. 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 GAY DRILL user cue Machining Conditions Internal Coolant Pressure Recommended Cooling Pressure and Flow Rate Coolant Flow Rate liter min A 30 gt Drill Diameter 25 D mm Drill diameter gt D mm 6 8 12 16 25 x For special drills more than 8xD it is recommended to use higher coolant pressure 15 70 bar 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 the drill is then required for 2xD max GAY DRILL user cue Troubleshooting Cutting Edge Chipping 1 Check the stability of the machine spindle tool and workpiece clamping rigidity 2 Reduce feed rate increase speed 3 If the drill vibrates reduce cutting speed and increase feed rate 4 When drilling ro
4. 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 2 mm 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 22 to 825 9 DCM oD Pocket Drilling Range L Designation d d L L Size Key Heads 22 0 22 9 66 MIENE 25 32 951 56 22 K DCM 22 23 0 23 9 69 25 32 995 56
5. 0 High temp alloys Fe based Annealed 200 31 Cured 280 32 Annealed 250 33 S Super alloys Ni or Co based 350 34 Cast 320 35 Titanium Ti alloys EEO y Alpha beta alloys cured RM 1050 37 Hanienedercel Hardened 55 HRC 38 Hardened 60 HRC 39 Chilled cast iron Cast 400 40 Cast iron Hardened 55 HRC 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 GaLW DRILL user cupe Cutting Speed Vc m min 50 130 100 120 90 110 90 120 70 90 Feed vs Drill Diameter mm rev D 6 8 10 9 0 12 0 2 D 11 12 9 0 15 0 25 D 13 14 9 0 2 0 3 D 15 16 9 0 25 0 35 D 17 20 9 0 25 0 45 D 21 25 9 0 25 0 45 80 130 70 110 60 90 40 70 50 80 40 70 20 50 90 140 80 130 100 180 90 160 90 160 80 120 90 160 30 50 20 40 0 12 0 2 0 12 0 2 0 08 0 14 0 2 0 3 0 2 0 35 0 05 0 1 0 15 0 25 0 12 0 22 0 12 0 22 0 25 0 35 0 25 0 4 0 08 0 13 0 2 0 3 0 15 0 25 0 12 0 15 0 3 0 4 0 3 0 45 0 1 0 15 0 25 0 35 0 2 0 28 0 14 0 20 0 35 0 45 0 35 0 5 0 12 0 18 0 25 0 33 0 16 0 24 0 4 0 5 0 4 0 6 0 12 0 2 0 25 0 35 0 15 0 28 0 4 0 6 0 4 0 65 0 12 0 22 20 50 20 50 0 06 0 12 0 06 0 12 0 09 0 15 0 09 0 15 0 12 0 18 0 12 0 1
6. 23 K DCM 23 ipi 24 0 24 9 72 25 32 103 6 56 24 K DCM 24 25 0 25 9 75 DCM 250 075 25A 3D 7s 32 109 0 56 25 K DCM 25 Hole tolerance D 0 05 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 22 to 925 9 DCM oD Pocket Drilling Range L Designation d d L L Size Key Heads 22 0 22 9 110 MIERES 25 32 1391 56 22 K DCM 22 23 0 23 9 115 D 2 e 23 K DCM 23 DI 24 0 24 9 120 DYSIPZUSPIRIED 25 32 1516 56 24 K DCM 24 25 0 25 9 125 EOAR 25 32 159 0 56 25 K DCM 25 Hole tolerance D 0 05 in average conditions however it can be higher or lower according to machine and tooling conditions Drilling Heads for DCM Drills IDI D Range Pocket S s Size ig 22 22 9 9 3 22 0 e 23 23 9 9 8 23 0 e 24 24 9 10 0 24 0 e 25 25 9 10 6 25 0 e Heads are available in increments of 0 1mm SK heads for drilling cast iron available in IC 908 Ordering examples for 913 3 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 Drilling Head Mounting Procedure GAL DRILL user cupe Power Force Requirements Drilling Limitations Drilling can be done on 6 maxi mum a
7. 8 0 15 0 2 0 15 0 2 0 15 0 23 0 15 0 23 0 15 0 25 0 15 0 25
8. User Guide e We recommend using CHAMDRILL in rotating or stationary applications with a maximum of 0 02 mm 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 0 02 Angular Adj 1 Radial Adj D2 0 e 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 We
9. ngular surface Regrinding of drill head is not recommended it may cause drill malfunction Power Force Requirements KW Net Power ATL a Pe eae ee si vg ke Diameter mm Material SAE 4340 Speed 100 m min Feed 0 2 mm rev Values change for different materials and drilling conditions es ee Diameter mm HWDRILL user Gumpe Indications of a Drilling Head Wearing Out Wear Limit eS Power Restriction 1 New drilling head 2 Worn out drilling head Diameter Change O Surface Finish Declines gt D nominal 0 15mm D nominal 2 lt D nominal 0 03mm GAY DRILL user cue CHAMDRILL Unlocking Change in Torque Typical Unlocking Torque Range Torque N cm Dia 17 25 9 mm Dia 11 16 mm Dia 7 5 10 5 mm gt 10 12 14 16 18 20 22 24 26 28 30 No of Indexes The number of indexing changes according to machine clamping rigidity machining 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
10. ugh hard or sloped surface up to 6 reduce the feed rate by 30 50 during entrance and exit 5 Check cooling lubricant Increase coolant pressure In case of external coolant supply improve jet direction and add cooling jets Chisel Area Chipping 1 Reduce feed rate 2 Increase coolant pressure 3 Check the adaptation Use hydraulic clamping chuck MAXIN power chuck or side lock systems 4 Increase workpiece chucking force Excessive Flank Wear 1 Check that the correct geometry is used 2 Reduce cutting speed 3 Increase internal coolant pressure Excessive Flute Land Wear 1 Check that the correct geometry is used 2 Check the runout and make sure it is within 0 02 mm T I R radial and axial 3 Reduce cutting speed When drilling rough hard or sloped surface up to 6 reduce the feed rate by 30 50 during entrance and exit 5 Increase coolant pressure Check the chisel point runout and make sure it is within 0 02 mm T I R Increase workpiece chucking force stability and rigidity 8 If there is low pocket gripping force replace drill body A e2 N CLWIDRILL user cupe gt Troubleshooting p os 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
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