Mattedroom
Cast Iron
- Joined
- Jan 18, 2006
- Location
- Detroit
I have to drill 20,000 .406 (-.002 +.007)holes in A36 material. The part is .75 thick and it's a thru hole. We have ran this job a couple of times, but the quantities where smaller. All I did was use a spot drill and a 13/32 drill. Drill was just HHS with a feed of 6.4ipm, peck every .150 and 1800rpm. Good enough tool life, about 500 pcs before resharpening. We had to deburr the back side of the part from where the drill broke thru. Operator did this, amongst other things while the machine was running. But there is a lot of other things to deburr, so I'd really like to eliminate this task.
Since it is such a high quantity, I decide to call Allied tool and see what they have in the means of a spade drill with coolant thru and something that could deburr the back side and top. I was hoping not to spot drill and not have to deburr the backside of the part. (save time). We quoted it the same way we had ran it before, but I figured I'd try to improve on the process. I imagine that this will save about 15 or 10 seconds per part. That's a guess. The machine is a mid 90s Leadwell MCV 1000 vertical machining center. I hooked up a coolant inducer that can make it to about 500psi, the specs say 900psi, but it's lying. Since it is a coolant inducer, I use a special 40 taper holder that I can only go from 1.125 down to 5/8 dia tools. Easy enough with a spade drill holder, I'll just get one with .75 shank.
Allied called me back and wants $480 bucks for the custom spade drill holder with a 45 degree chamfer tool on it. Plus 80 bucks for the custom spade drill so I can move off center when I break thru and chamfer the back side of the hole. Sure, when you do the math it's worth it, sounds good. But what happens when the operator forgets to tighten the vise and destroys my $560 drill. That's just a little too steep. I can imagine I talk the boss into this and some kid kills the drill on the second cycle. It's my rearend that gets kicked. Imagine that we break 2 of these drills, that's $1120, but we are still in the profit.....just sounds crazy.
Anybody have any thoughts on this? Maybe a cheaper way to do what I want. I really can't fool proof the work holding, because we don't have automatic vises or anything like that. I can stress to the operator to tighten the vise and double check himself. Maybe another company besides Allied that sells something that can drill and deburr both sides of these holes with the specs that I want. Or just a carbide drill that I can eliminate the spot drilling with, but I still have deburr the backside, which is ok, it's an improvement. Thanks for reading, hope I explained it well enough.
Since it is such a high quantity, I decide to call Allied tool and see what they have in the means of a spade drill with coolant thru and something that could deburr the back side and top. I was hoping not to spot drill and not have to deburr the backside of the part. (save time). We quoted it the same way we had ran it before, but I figured I'd try to improve on the process. I imagine that this will save about 15 or 10 seconds per part. That's a guess. The machine is a mid 90s Leadwell MCV 1000 vertical machining center. I hooked up a coolant inducer that can make it to about 500psi, the specs say 900psi, but it's lying. Since it is a coolant inducer, I use a special 40 taper holder that I can only go from 1.125 down to 5/8 dia tools. Easy enough with a spade drill holder, I'll just get one with .75 shank.
Allied called me back and wants $480 bucks for the custom spade drill holder with a 45 degree chamfer tool on it. Plus 80 bucks for the custom spade drill so I can move off center when I break thru and chamfer the back side of the hole. Sure, when you do the math it's worth it, sounds good. But what happens when the operator forgets to tighten the vise and destroys my $560 drill. That's just a little too steep. I can imagine I talk the boss into this and some kid kills the drill on the second cycle. It's my rearend that gets kicked. Imagine that we break 2 of these drills, that's $1120, but we are still in the profit.....just sounds crazy.
Anybody have any thoughts on this? Maybe a cheaper way to do what I want. I really can't fool proof the work holding, because we don't have automatic vises or anything like that. I can stress to the operator to tighten the vise and double check himself. Maybe another company besides Allied that sells something that can drill and deburr both sides of these holes with the specs that I want. Or just a carbide drill that I can eliminate the spot drilling with, but I still have deburr the backside, which is ok, it's an improvement. Thanks for reading, hope I explained it well enough.