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One of the most important tools in any metalworker's arsenal is the drill bit. Drill bits are cylindrical cutting tools that are used to create holes in various materials such as metal, plastic, wood, ceramic tile, and concrete. But not all drill bits are made the same, and choosing the wrong one can lead to disastrous results.

When it comes to using drill bits, mistakes are not uncommon. These are some of the most common mistakes that you should avoid to ensure safety:

Flutes are the grooves that run spirally along the length of a drill bit. They serve to remove chips and debris from the hole as the bit cuts into the material. They are also typically wider and deeper on larger diameter bits. Flute design can greatly affect the performance and efficiency of a drill bit.

Cobalt (HSCO) drill bits are made from high-speed steel with added cobalt, which enhances their strength and heat resistance. They can withstand higher temperatures and are less prone to dulling. Cobalt drill bits are ideal for drilling through hard metals, such as stainless steel, cast iron, and titanium.

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Using the wrong bit can result in damage to the material, decreased efficiency, and even injury to the user. Therefore, it's essential to understand the various types of drill bits available and their unique features, including materials, coatings, point angles, and lengths.

The drill point angle refers to the angle at which the cutting edge of the drill bit is ground. It is measured in degrees and can range from 90 to 150. A 118-degree angle is the most common, but other angles, such as 135 degrees and 90 degrees, may be more suitable for specific materials or applications.Common Drill Point Angles

Black oxide is a coating made by blackening the surface of the drill bit to enhance rust resistance and reduce friction. It is made from iron oxide and magnetite. They are best used for drilling soft metals such as aluminum, copper, brass, and mild steel.

Boring tool performance depends greatly on the Length-to-Diameter (L:D) Ratio of the application. While this is a straightforward calculation, the Length and Diameter values to be used may not be clear.   Given the application image shown above, the part L:D ratio is given by the calculation 6.7/2.75=2.4. For reference, most ratios under 4 are considered optimal, which means that maximum cutting conditions can be applied based on the part material and insert grade.

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When it comes to drilling, there are various types of drill bits designed for specific materials and applications. Here are some of the most common types:

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The drill point length refers to the distance from the tip of the drill bit to the beginning of the flute. There are three types of drill point lengths: standard, jobber, and long.

To choose the best drill bits for metal and other materials, you should consider the design features that affect their performance. These are the three key design features of drill bits:

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A gray-colored coating that is harder than TiN. It is made by depositing a layer of titanium carbonitride on the surface of the drill bit. They are best used for drilling abrasive materials like high-silicon aluminum, fiberglass, and carbon composites.

A gold-colored coating that provides heat resistance and hardness. It is made by depositing titanium nitride on the surface of the drill bit.They are best used for drilling hard materials such as stainless steel, cast iron, and titanium.

High-speed steel (HSS) is a type of tool steel that is highly resistant to heat and wear. It contains tungsten, molybdenum, chromium, and vanadium, which provide increased strength and durability. HSS drill bits are suitable for drilling into soft metals, such as aluminum and brass, as well as wood and plastic.

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Whether you're a seasoned metalworker or just starting, this guide will equip you with the knowledge you need to make informed decisions and achieve the best results.

A bare metal finish with no coating. It is the most common type of drill bit. They are best used for drilling plastic, wood, and soft metals.

Each type of drill bit has its own unique features, suitable applications, advantages, and disadvantages. Choosing the right type of drill bit is essential for achieving accurate and efficient results in drilling.

Born in the Philadelphia area and raised in Houston by a family who was predominately employed in heavy manufacturing. Herb took a liking to factory processes and later safety compliance where he has spent the last 13 years facilitating best practices and teaching updated regulations. He is married with two children and a St Bernard named Jose. Herb is a self-described compliance geek. When he isn’t studying safety reports and regulatory interpretations he enjoys racquetball and watching his favorite football team, the Dallas Cowboys.

In more extreme cases of this type of application, there are other options that can be chosen to increase productivity such as carbide extensions, or damped components which minimize vibration at higher cutting parameters than standard steel components.

The material provided in this article is for general information purposes only. It is not intended to replace professional/legal advice or substitute government regulations, industry standards, or other requirements specific to any business/activity. While we made sure to provide accurate and reliable information, we make no representation that the details or sources are up-to-date, complete or remain available. Readers should consult with an industrial safety expert, qualified professional, or attorney for any specific concerns and questions.

Carbide (Carb) drill bits are made from tungsten carbide, which is a dense and durable material that can resist high temperatures and wear. They are ideal for drilling through hard materials, including ceramics, glass, and masonry, as well as hard metals like stainless steel and cast iron.

When we look at the boring tool being used, however, the ratio is much different. For the boring tool, the calculation is 7.126/1.535=4.6, which falls into the critical category, where cutting speeds and feeds may need to be reduced in order to produce an acceptable bore. The tool’s L:D ratio is the one that needs to be considered when determining cutting parameters. In order to reduce the ratio, and therefore increase the productivity of the operation, the boring tool may need to be tweaked.   In this example, an extended range insert holder is being used. This could be explained by borrowing in-house components from another application and just replacing the insert holder to reduce the tooling investment for this part, which is a great idea for small batch sizes. However, when production volumes increase, cycle times need to be reduced. This tool would likely need to be replaced with an assembly using a larger modular connection size and boring head, which would help in two ways: