The steel block was initially run with an HSS twist drill and required three separate operations to complete each hole. First, each hole had to be spot drilled. Next, a 13¼32" pilot hole was drilled through. Finally, a 1" HSS twist drill was used to complete the roughing operation.

Metric drill speed chart

But today, many drill manufacturers offer a broad range of carbide grades for specific uses in high-performance applications. Many grades are custom-designed to machine a specific material or family of parts. Indexable-drill manufacturers may offer as many as 12 carbide grades, and in some cases they may even offer polycrystalline-diamond-tipped inserts for the high-speed drilling of aluminum.

Usually, before a shop purchases a new kind of tool, it tests the tool under the most challenging machining conditions the shop has to offer. Progressive Tool Co., Waterloo, IA, offered such a challenge to a new indexable carbide drill.

Condition of vibration involving the machine, workpiece and cutting tool. Once this condition arises, it is often self-sustaining until the problem is corrected. Chatter can be identified when lines or grooves appear at regular intervals in the workpiece. These lines or grooves are caused by the teeth of the cutter as they vibrate in and out of the workpiece and their spacing depends on the frequency of vibration.

When HSS tooling was used, Progressive Tool had to use a peck drilling cycle to break up the chips. The operator had to remain dedicated to a single machine to be sure the cycle ran properly. With the indexable drill, the chips are small and manageable. The operator does not have to monitor the cycle as closely and therefore is free to run another machine as well. Also, the smaller chips are safer for the operator to handle.

Progressive Tool noted several advantages of the indexable drill. It replaced three separate operations using three separate tools with a single operation requiring only a single tool. This reduced setup time and tool and hardware inventory. In addition, the feed rates were increased from 2.0 ipm with HSS drills to 3.6 ipm with indexable drills.

Secures a cutting tool during a machining operation. Basic types include block, cartridge, chuck, collet, fixed, modular, quick-change and rotating.

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Machining operation in which metal or other material is removed by applying power to a rotating cutter. In vertical milling, the cutting tool is mounted vertically on the spindle. In horizontal milling, the cutting tool is mounted horizontally, either directly on the spindle or on an arbor. Horizontal milling is further broken down into conventional milling, where the cutter rotates opposite the direction of feed, or “up” into the workpiece; and climb milling, where the cutter rotates in the direction of feed, or “down” into the workpiece. Milling operations include plane or surface milling, endmilling, facemilling, angle milling, form milling and profiling.

Main body of a tool; the portion of a drill or similar end-held tool that fits into a collet, chuck or similar mounting device.

HSS drillspeedsandfeedschart pdf

To prevent these maladies, check all indexable drills for location with an indicator while in the machine tool. If the location varies by more than ±0.005" TIR, then repositioning is necessary.

When through-the-spindle coolant delivery is not possible, consider using coolant collars. These collars fit around the tool shank and have been engineered to operate within the drill’s speed guidelines. Always follow the manufacturer’s guidelines when installing a coolant collar, and make sure the external adaptation to the collar, either a pipe or a hose, is not binding the collar. Collar binding can cause premature failure or leakage. When using coolant collars, spindle speed should not exceed 3000 rpm and coolant pressure should not exceed 90 psi. The coolant must be well filtered, and the collar shouldn’t run dry.

The roughing operation was completed in 1 min., 18 sec./hole using the indexable drill. Multiply this by 180 holes, and the total time for this operation was 3.9 hr., compared to 25 hr. using the HSS drill. That’s an 85% cycle-time reduction.

Progressive Tool was aware of indexable carbide drills’ capabilities and decided to test the tool on the troublesome production piece so that engineers could directly compare the HSS and indexable drills.

The chief advantages of using indexable drills are higher permissible speeds and greater versatility. Indexable drills can be run at machining rates approaching those of turning and milling. The higher cutting speeds indexable drills can muster translate into faster holemaking rates than possible with solid twist or spade drills. And, unlike solid drills, indexable drills can be used as nonrotating tools for applications on lathes and as rotating tools on machining centers and transfer machines.

Tangential velocity on the surface of the tool or workpiece at the cutting interface. The formula for cutting speed (sfm) is tool diameter 5 0.26 5 spindle speed (rpm). The formula for feed per tooth (fpt) is table feed (ipm)/number of flutes/spindle speed (rpm). The formula for spindle speed (rpm) is cutting speed (sfm) 5 3.82/tool diameter. The formula for table feed (ipm) is feed per tooth (ftp) 5 number of tool flutes 5 spindle speed (rpm).

Most of today’s manufacturers offer four or more chipbreaker configurations for machining various materials. There are two basic chipbreaker styles - standard and dimple.

The following tables are starting parameters only. Every application is different and may require varying feeds and speeds from this chart.

HSS drillspeedsandfeedsmetric

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Machining operation in which material is removed from the workpiece by a powered abrasive wheel, stone, belt, paste, sheet, compound, slurry, etc. Takes various forms: surface grinding (creates flat and/or squared surfaces); cylindrical grinding (for external cylindrical and tapered shapes, fillets, undercuts, etc.); centerless grinding; chamfering; thread and form grinding; tool and cutter grinding; offhand grinding; lapping and polishing (grinding with extremely fine grits to create ultrasmooth surfaces); honing; and disc grinding.

Fluid that reduces temperature buildup at the tool/workpiece interface during machining. Normally takes the form of a liquid such as soluble or chemical mixtures (semisynthetic, synthetic) but can be pressurized air or other gas. Because of water’s ability to absorb great quantities of heat, it is widely used as a coolant and vehicle for various cutting compounds, with the water-to-compound ratio varying with the machining task. See cutting fluid; semisynthetic cutting fluid; soluble-oil cutting fluid; synthetic cutting fluid.

The operation required 180 1"-dia. through holes. Tolerances and surface finish were not critical, because this was strictly a roughing operation. Progressive Tool’s concern was to remove material more quickly and more efficiently than its current process allowed.

Hardness is a measure of the resistance of a material to surface indentation or abrasion. There is no absolute scale for hardness. In order to express hardness quantitatively, each type of test has its own scale, which defines hardness. Indentation hardness obtained through static methods is measured by Brinell, Rockwell, Vickers and Knoop tests. Hardness without indentation is measured by a dynamic method, known as the Scleroscope test.

Most common type of drill, having two or more cutting edges, and having helical grooves adjacent thereto for the passage of chips and for admitting coolant to the cutting edges. Twist drills are used either for originating holes or for enlarging existing holes. Standard twist drills come in fractional sizes from 1¼16" to 11¼2", wire-gage sizes from 1 to 80, letter sizes A to Z and metric sizes.

U drillspeedsandfeedsChart

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1. Ability of a material or part to resist elastic deflection. 2. The rate of stress with respect to strain; the greater the stress required to produce a given strain, the stiffer the material is said to be. See dynamic stiffness; static stiffness.

Group of carbon steels designated by American Iron and Steel Institute numerical classification as AISI 1005, 1006, 1008, etc., up to AISI 1026, for a total of 16 grades. They are softer and more ductile than other carbon steels. Composition of low-carbon steels is 0.06 to 0.28 percent carbon, 0.25 to 1.00 percent manganese, 0.040 percent (maximum) phosphorus and 0.050 percent (maximum) sulfur. See high-carbon steels; medium-carbon steels.

Almost all of today’s carbide inserts for indexable drills are pressed to form the general shape and then finish-ground to final size. Because of advances in pressing technology, an almost limitless variety of pressed-in chipbreaker shapes is possible.

Because of the importance of high-volume coolant delivery to the point of cut when using indexable drills, all indexable drills are manufactured having the largest coolant holes possible for a given drill diameter. This ensures that maximum coolant volume can be delivered to the cutting edge.

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Groove or other tool geometry that breaks chips into small fragments as they come off the workpiece. Designed to prevent chips from becoming so long that they are difficult to control, catch in turning parts and cause safety problems.

On the disk or hole bottom, there is a stub surrounded by four distinct rings for double-insert drills. The outer two rings are generated by the outboard insert, while the inner two rings and the stub (ideally measuring 0.02" in diameter and 0.01" high) are created by the inboard or center-cutting insert.

The key to preventing tool deflection when using an indexable drill is to balance the cutting forces on each of the opposing inserts. The use of trigon inserts in indexable drills helps to ensure this balance. The trigon insert geometry stabilizes the drill in the cut, reducing tool deflection and improving penetration rates. Drills equipped with trigon inserts also are more versatile than those with conventional insert shapes. As illustrated in Figure 2, trigon-insert drills perform well in interrupted cuts and on a variety of workpiece surfaces, including flat, convex, concave, sloped, and irregular. Additionally, these tools can drill from solid, drill holes that are larger than the drill diameter, core drill, bore, and turn and face outer diameters when applied on a lathe.

A trigon-insert indexable drill leaves a well-defined pattern or "footprint" at the bottom of a blind hole or on the disk that is ejected from a through hole. This pattern is generated by the insert shape and the position of the drill. Examination of this footprint can reveal much about the drill’s performance.

In rough-drilling applications, drills equipped with indexable carbide inserts can create short holes faster and for less money than HSS and solid-carbide twist drills and spade drills can. Indexable drills, which range in length from 1 to 4 diameters, can make any hole up to 4 diameters deep, provided an adequate machine tool is employed.

Outside of these specific circumstances, indexable drills represent a highly efficient and versatile drilling technology, offering the advantages of carbide at a reasonable cost.

To help combat chip recutting, drill manufacturers are now offering indexable drills with two grooves on the end of the drill connecting the coolant holes to the drill flutes. Older drills that do not have this feature may have to be hand-ground. When grinding the grooves, make sure they aim at each insert as shown in Figure 5. The grooves should be half as deep as they are wide and should feature a full radius. The grooves will direct the coolant at the inserts, flushing the chips off the cutting edge as they are generated.

As a general rule, it’s not a good idea to use indexable drills to make holes deeper than 4 diameters. Starting a long indexable drill in the cut is difficult, because the drill lacks rigidity, evacuating chips is a problem no matter what coolant system is used, and the tool is more likely to deflect. These factors add up to poor hole finishes.

This inordinate amount of machining time, along with inadequate tool life, made the HSS tool’s performance unsatisfactory. Progressive Tool had to look for an alternative method of performing the roughing operation.

Machining grooves and shallow channels. Example: grooving ball-bearing raceways. Typically performed by tools that are capable of light cuts at high feed rates. Imparts high-quality finish.

The majority of Progressive Tool’s business is in the design, machining, and assembly of precision stamping dies for a variety of industries. One of the firm’s jobs, a mold for a major customer, was causing great difficulty. The workpiece was a 4"-thick block of A-2 tool steel, which has a hardness of Rc 30. A-2 tool steel’s stringiness makes it difficult to machine.

Space provided behind a tool’s land or relief to prevent rubbing and subsequent premature deterioration of the tool. See land; relief.

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An indexable drill should not be applied to radial- or post-type drilling machines. Also, applying an indexable drill halfway up column-type machines can cause a severe loss of rigidity in the column, making it less able to resist axial thrust forces and torque forces generated when using indexable drills. Never apply the drill more than halfway up the column.

Some applications approach the limits of what indexable drills can do. Special care must be taken in these instances to ensure a successful operation. For instance, when applying indexable drills in deep-hole operations (greater than 4 diameters) or when entering a very rough or uneven surface, it may be necessary to halve the feed rate until the drill penetrates the workpiece to a depth of about 0.1". This allows the drill to generate its footprint in the workpiece and create a clean, straight hole, and it helps eliminate insert chipping. The feed rate should also be halved when the drill exits surfaces that are uneven or rough to help prevent insert chipping.

Drill speed chart for steel

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Many machine tool builders supply high-pressure, pulsating coolant systems with new machines. These coolant systems can generate pressures up to 300 psi, but they are limited to very low gpm ratings, usually a maximum of 5 gpm. At first glance, these systems, when combined with indexable tooling, appear to be highly efficient, but there are some disadvantages to consider:

As the degree of taper increases, you may have to use the large diameter provided to calculate the appropriate RPM, instead of tip size. This usually isn’t necessary until seven degrees. At that time, the tip size would be used to calculate the needed feed per tooth. Tapered end mill usage can be tricky if the proper settings are not adhered to. Please follow these endmill usage charts as closely as possible.

Although an indexable drill generates approximately 30% fewer axial thrust pounds of force than a conventional HSS twist drill does, it still requires a very rigid machine tool and fixturing. If the spindle is not tight and properly adjusted, the drill will not perform as designed. The drill will cut off-center, resulting in oversize holes, poor hole finishes, and, in some cases, insert chipping. Similarly, an inadequately fixtured workpiece will render indexable drills ineffective, resulting in higher horsepower requirements and excessive axial thrust forces.

Workpiece is held in a chuck, mounted on a face plate or secured between centers and rotated while a cutting tool, normally a single-point tool, is fed into it along its periphery or across its end or face. Takes the form of straight turning (cutting along the periphery of the workpiece); taper turning (creating a taper); step turning (turning different-size diameters on the same work); chamfering (beveling an edge or shoulder); facing (cutting on an end); turning threads (usually external but can be internal); roughing (high-volume metal removal); and finishing (final light cuts). Performed on lathes, turning centers, chucking machines, automatic screw machines and similar machines.

As per standard procedure, the speeds and feeds were turned down to 60% as the test began. When the tool first made contact with the test block, it seemed to run roughly. On successive holes, the speeds and feeds were gradually increased. The indexable drill ran more smoothly as the overrides were increased. Finally, at 150% of the programmed speeds and feeds, the drill ran smoothly and consistently through the entire 4" cut.

Overall, these three operations resulted in a cycle time of 8 min., 15 sec./hole. Multiply that by 180 holes, and the total is 25 hr. of machining time for a simple roughing operation.

Value that refers to how far the workpiece or cutter advances linearly in 1 minute, defined as: ipm = ipt 5 number of effective teeth 5 rpm. Also known as the table feed or machine feed.

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In indexable drilling, it is imperative to remove the heat generated in the chip during the machining process, because indexable drills generate more heat than HSS or solid-carbide drills do. However, in drilling, the heat zone is a confined area at the bottom of the hole. Therefore, coolant acts as a carrier to transport both heat and chips from the bottom of the hole to the mouth of the hole through the flutes. For this reason, running indexable drills larger than 1 diameter without liquid coolant usually leads to drill failure. A full-flow water-base or synthetic coolant is generally recommended.

The finish of the rings also offers clues about the tool’s performance. At optimum speeds and feeds, the outer two rings cut by the outboard insert will be bright and the inner two will be dull.

"There is almost no load put on the spindle," notes Progressive Tool foreman Bruce Erpelding. "The load meter barely moves off its idle reading. When we used HSS drills, it was common to run the load meter to 60% and kick out the overload." The reduction in spindle load saves wear and tear on the spindle and bearings.

Drill SPEED CHART pdf

Indexable drills require the inboard insert to cut past the centerline of the tool. As a result, the inboard insert experiences little or no sfm, which in turn heightens the compressive forces of the feed. For this reason, the inboard insert must be a tougher carbide grade than is required for its outboard counterpart. This means that two different carbide grades are required in most applications. Luckily for end users, there are plenty of grades available for indexable drill inserts.

Angle of inclination between the face of the cutting tool and the workpiece. If the face of the tool lies in a plane through the axis of the workpiece, the tool is said to have a neutral, or zero, rake. If the inclination of the tool face makes the cutting edge more acute than when the rake angle is zero, the rake is positive. If the inclination of the tool face makes the cutting edge less acute or more blunt than when the rake angle is zero, the rake is negative.

Chatter marks may also be present on the footprint, indicating that speeds and feeds should be modified. In most cases, increasing feed rates will eliminate chatter.

If there is no stub at all, it means the drill is either misaligned or deflecting oversize radially or axially, or a combination of the two (Figure 3b). When this happens, the inboard insert will probably chip at the drill’s centerline. This situation can be corrected by modifying the feed rate or realigning the drill.

Tool life was improved as well. The inserts lasted for 25 holes before they required indexing. The indexable drill went through 100" of A-2 tool steel before the operation had to be stopped, as compared to 60" with the HSS drill (not including the pilot drill). Even then, it was a quick and easy task to index the inserts and restart the run.

Number derived from the net increase in the depth of impression as the load on the indenter is increased from a fixed minor load to a major load and then returned to the minor load. The Rockwell hardness number is always quoted with a scale symbol representing the indenter, load and dial used. Rockwell A scale is used in connection with carbide cutting tools. Rockwell B and C scales are used in connection with workpiece materials.

Pressed double-ended inserts for External, Internal, Face machining with Grooving and Turning. TCLAMP(PARTING&GROOVING)

Also avoid using indexable drills to generate holes in laminated or stacked materials. Remember, all standard indexable drills produce a disk as the drill exits the hole, or in this case, as the drill exits one layer and enters the next. This disk becomes trapped between layers and causes severe tool damage or complete failure of the drill. The latter is more likely.

WARNING: All cutting tools can shatter and break during use. Government regulations require that safety glasses be worn during use. We also recommend wearing a simple respiration mask.

The stub is created because the inboard insert station is positioned below center by 0.01" radially. This positioning allows the inboard insert to cut past the center. If the stub measures 0.02" in diameter, the drill is cutting to its designed diameter with little or no deflection (Figure 3a).

When applying indexable drills on high-pressure coolant systems, first try to push the coolant volume above 10 gpm. (If you can’t, you may need to peck-feed the drill.) Then reduce or discontinue the pulsator and run only with straight, constant pressure. Finally, reduce the pressure to 100-150 psi if possible.

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Substances having metallic properties and being composed of two or more chemical elements of which at least one is a metal.

When first introduced, indexable-insert drills were available with a limited selection of carbide-insert grades. Many drill manufacturers offered three grades of carbide: an uncoated C-1 grade for steel, coated C-7 for steel, and uncoated C-2 for nonferrous materials.

Once the chip has been broken, the next challenge is to get it out of the hole. Poor chip evacuation can cause chip recutting, insert chipping, and even drill failure. The efficiency of chip evacuation depends upon chip control, coolant pressure, coolant volume, and hole depth. Figure 4 offers coolant guidelines for achieving optimum chip-evacuation efficiency.

Cone-shaped pins that support a workpiece by one or two ends during machining. The centers fit into holes drilled in the workpiece ends. Centers that turn with the workpiece are called “live” centers; those that do not are called “dead” centers.

Studies indicate that about 60% of all drilling applications involve the production of short holes. It’s becoming clear that indexable drills are uniquely qualified to handle such operations.

Stainless steels possess high strength, heat resistance, excellent workability and erosion resistance. Four general classes have been developed to cover a range of mechanical and physical properties for particular applications. The four classes are: the austenitic types of the chromium-nickel-manganese 200 series and the chromium-nickel 300 series; the martensitic types of the chromium, hardenable 400 series; the chromium, nonhardenable 400-series ferritic types; and the precipitation-hardening type of chromium-nickel alloys with additional elements that are hardenable by solution treating and aging.

All indexable drills have one effective cutting geometry regardless of the number of inserts in the tool (usually two or four). Though both the inboard and outboard inserts seat in a neutral attitude in the drill, they have a 12° positive rake, which gives the drill a positive cutting geometry. The drill body’s 2 helical flutes evacuate chips efficiently and help prevent deflection of the drill. The flute helix angle on standard drill lengths varies with each drill size to provide the highest possible bending moment opposing the cutting forces. This increases drill stiffness, thereby minimizing chatter and deflection. Figure 1 depicts a cross section of a typical indexable drill.

Turning machine capable of sawing, milling, grinding, gear-cutting, drilling, reaming, boring, threading, facing, chamfering, grooving, knurling, spinning, parting, necking, taper-cutting, and cam- and eccentric-cutting, as well as step- and straight-turning. Comes in a variety of forms, ranging from manual to semiautomatic to fully automatic, with major types being engine lathes, turning and contouring lathes, turret lathes and numerical-control lathes. The engine lathe consists of a headstock and spindle, tailstock, bed, carriage (complete with apron) and cross slides. Features include gear- (speed) and feed-selector levers, toolpost, compound rest, lead screw and reversing lead screw, threading dial and rapid-traverse lever. Special lathe types include through-the-spindle, camshaft and crankshaft, brake drum and rotor, spinning and gun-barrel machines. Toolroom and bench lathes are used for precision work; the former for tool-and-die work and similar tasks, the latter for small workpieces (instruments, watches), normally without a power feed. Models are typically designated according to their “swing,” or the largest-diameter workpiece that can be rotated; bed length, or the distance between centers; and horsepower generated. See turning machine.

Along with improvements in carbide grades, indexable drills have undergone advances in chipbreaker geometries developed to better control chips. Chip control is crucial to a successful drilling operation. The size and shape of a chip affects tool life, hole size, hole finish, and even the life of the drill body itself.

Available in two major types: tungsten high-speed steels (designated by letter T having tungsten as the principal alloying element) and molybdenum high-speed steels (designated by letter M having molybdenum as the principal alloying element). The type T high-speed steels containing cobalt have higher wear resistance and greater red (hot) hardness, withstanding cutting temperature up to 1,100º F (590º C). The type T steels are used to fabricate metalcutting tools (milling cutters, drills, reamers and taps), woodworking tools, various types of punches and dies, ball and roller bearings. The type M steels are used for cutting tools and various types of dies.

1. SFM + FPT (For Material) 2. Find RPM at intersection of SFM + Diameter 3. Calculate Feed IPM = FPT x Number of Flutes X RPM

Grooves and spaces in the body of a tool that permit chip removal from, and cutting-fluid application to, the point of cut.

If an overly large stub is present, it may mean that the inboard insert is being pulled off centerline radially or being pushed further behind center axially (Figure 3c). This condition will result in undersize holes and can be more damaging to the drill and inserts than if no stub were present.

Standard chipbreakers are designed for general-purpose drilling in short-chipping materials such as cast iron and in materials in which controllable chips can be produced by adjusting speeds and feeds. The standard chipbreaker is recommended for all steels with a hardness of Bhn 250 or higher, aluminum, all stainless steels, cast iron, and high-temperature alloys.

When used in lathe or screw-machine operations, this process separates a completed part from chuck-held or collet-fed stock by means of a very narrow, flat-end cutting, or parting, tool.

If changing parameters doesn’t result in controllable chips, you should try a dimple-style chipbreaker, which is designed to control chip formation in soft low-carbon steels, low-Brinell-hardness stainless steels, and any material that tends to create long, stringy chips with little or no color. (Colorless chips are the toughest to break.) The dimple form produces a chip that has ridges, which increase its brittleness. The ridges allow the chip to break more easily in softer materials.