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.

Colletvs chuck

However, it would be best to exercise caution when using carbide-tipped drills since they can be brittle despite being the hardest. Because of their great strength, they are extensively employed in industrial applications. They can cut through concrete, masonry, tile, and hardened steel.

Placed in a chuck, a collet forms a collar around the tool to be held. The standard ER collet is the most widely used tool-clamping option for machining applications. Commonly used to hold endmills, drills, taps and reamers, ER collets exert clamping force when tightened with a nut.

Milling cutter held by its shank that cuts on its periphery and, if so configured, on its free end. Takes a variety of shapes (single- and double-end, roughing, ballnose and cup-end) and sizes (stub, medium, long and extra-long). Also comes with differing numbers of flutes.

Hardened steel is used in energy,  transportation, general mechanical engineering components, and many other applications. Axles, arbors, driving pinions, camshafts, and Cardan joints are examples of hardened steel components.

“When you have a larger amount of collapsibility, there is more room for runout to be introduced and quite a bit more room for instability or chatter,” Moon said. “So for high-performance applications, especially being a milling guy, I generally do whatever I can to steer people away from an ER collet chuck.”

If you are short on time, the best drill bits for hardened steel are carbide-tipped bits. They are the most suitable drill bits for hardened steel due to their robust and heat-resistant properties. However, there are other options such as titanium and cobalt.

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

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.

Cobalt drill bits are not made of pure cobalt. Instead, they are made of steel combined with a small proportion of cobalt, often between 5 and 7 percent, and the remaining part steel.

In addition, shop personnel should visually inspect the collet and chuck while a toolholder is out of a machine and disassembled.

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A problem with ER collets in this regard is what gives an edge in flexibility to them over competitors: their compressibility.

For better protection, use safety glasses that wrap around the sides of your face. Eye protection is required to ensure that a tiny metal fragment does not cause significant eye injury.

Inside these chucks is “just a straight bore,” Miller said. “So you need a tightly toleranced straight cylinder to go inside these holders.”

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If you are in the process of drilling hardened steel, maybe for one of the reasons mentioned above, or potentially something completely different, why not take a look at the drill bits we have available for metal. Our range is designed for high end performance and is suitable for those drilling hardened and normal stainless steel.

Collettypes with pictures

Cobalt has a high melting point of 1495°C, making it ideal for high heat drilling applications like hardened steel. The most common are M35, a 5% alloy, and M42, a 7% alloy.

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For shops set on using ER collets, he said the best way to optimize performance is to closely match collet size with tool shank diameter.

Drill through-hardened steel metal at the recommended speed using a drill bit, preferably carbide bits. Larger drill bits require even slower speeds.

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If you've worked with hardened steel before, you'll know that a regular drill bit won't cut through. Your best bet is to use the carbide bits because they are the hardest drill bits available.

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Hardened steel types include ATS34, CPM440V, Z60CDV14,  Sandvic, and 12C27. Carbon steel must go through a succession of heat treatments, quenching, and reheating to become hardened steel.

But even when customers come in with relatively light milling applications, Moon said, “if we can get them to move to a hydraulic, milling or shrink-fit chuck or even a side-lock holder, they can double their tool life because the tool isn’t moving around as much in the chuck and you don’t get the chatter.”

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On the downside, Miller said ER collets fall short compared with other toolholding options when it comes to gripping strength. As a result, he said, ER collets are not well suited for high-torque cutting. So his company mostly recommends them for finish milling, drilling and reaming applications.

Flexible-sided device that secures a tool or workpiece. Similar in function to a chuck, but can accommodate only a narrow size range. Typically provides greater gripping force and precision than a chuck. See chuck.

“Our collets have a minimal amount of flexibility, following ISO H6-H9 standards,” Doiron said. “They are designed to fit one specific tool diameter.”

Other recent developments involve collet designs that depart from conventional shapes. Most traditional collets have a taper. As the toolholder nut is tightened, this taper is forced into a matching one in the toolholder. Hydraulic chucks, however, lack this taper.

The company recently expanded its line of FPC collet chucks to include Slim Line models. Available in 2 mm to 14 mm sizes, the slim design and tapered shape of these models eliminate problems caused by a toolholder when trying to access work in confined areas or negotiate challenging angles.

Make sure the piece of metal is in a flat and secure area. Holding the metal with one hand while running the drill with the other is not a good idea. It is better to secure the metal with a clamp.

While shrink-fit and Weldon flat toolholders accommodate only one tool size, hydraulic and milling chucks allow the use of straight reduction collets to change tool sizes, Miller said. But he added that the presence of reduction collets in these chucks hurts their performance, resulting in increased runout and/or decreased clamping force.

With the other options, “you’re really locked in to one size toolholder for a specific-size cutting tool,” he said. “But with collets, one holder size can hold a wide variety of cutting tool shanks. Especially for smaller shops, that versatility will make things easier.”

ColletChuck

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To extend the reach of a tool an extra 12.7 mm (0.5"), “people will push that tool out to the very end of the holder,” he said. “It’s as if you were holding a stick with the very tips of your fingers versus holding it with your hand.”

For hydraulic chucks, BIG KAISER Precision Tooling has introduced straight reduction collets. One type, which is called Perfect Seal, seals the cutting tool shank so coolant can flow through drills at high pressure. The other, which is named Perfect Jet, lacks a seal but reduces the clearance between the collet and cutting tool to improve coolant delivery along the tool shaft.

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Titanium nitride (TiN) is a very strong ceramic substance that protects the steel bit and allows it to last longer, especially when drilling hardened steel.

Workholding device that affixes to a mill, lathe or drill-press spindle. It holds a tool or workpiece by one end, allowing it to be rotated. May also be fitted to the machine table to hold a workpiece. Two or more adjustable jaws actually hold the tool or part. May be actuated manually, pneumatically, hydraulically or electrically. See collet.

“If you need to hold on to a 1⁄8" endmill or drill, you want to use a 1⁄8" collet even though there is some flexibility in that size,” Moon said. “The more the collet compresses, the more runout you’re going to introduce.”

As an example, Miller pointed out that an ER32 collet chuck can hold tool shanks ranging from 3.175 mm (0.125") to 19.05 mm (0.75") in diameter with different collets. ER systems, he explained, include different collets for every 1 mm (0.04") increment in tool shank diameter at a minimum, so it would take at least 17 collets to cover the 3.175 mm to 19.05 mm shank diameter range.

Carbide drill bits are typically harder than cobalt drill bits, although both are suitable for drilling stainless steel and other hard metals. However, Carbide drill bits retain their sharpness for a longer period than cobalt drill bits. They can also be utilized at a faster cutting rate and withstand higher temperatures than cobalt drill bits.

The PJC straight collet is a reduction sleeve for small-diameter cutters with peripheral coolant supplies. Image courtesy of BIG KAISER Precision Tooling

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Runs endmills and arbor-mounted milling cutters. Features include a head with a spindle that drives the cutters; a column, knee and table that provide motion in the three Cartesian axes; and a base that supports the components and houses the cutting-fluid pump and reservoir. The work is mounted on the table and fed into the rotating cutter or endmill to accomplish the milling steps; vertical milling machines also feed endmills into the work by means of a spindle-mounted quill. Models range from small manual machines to big bed-type and duplex mills. All take one of three basic forms: vertical, horizontal or convertible horizontal/vertical. Vertical machines may be knee-type (the table is mounted on a knee that can be elevated) or bed-type (the table is securely supported and only moves horizontally). In general, horizontal machines are bigger and more powerful, while vertical machines are lighter but more versatile and easier to set up and operate.

Colletin jewellery

Collettypes

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

Measure and mark the hole, then use a center punch and hammer to make a slight indentation. Drill bits tend to wander when they first start drilling. Therefore the dimple helps the drill bit become more steady. The dimple also serves as a reference for where to drill your hole.

When drilling through hardened steel, you must ensure that your drill bit is made from tougher materials. Carbide bits are the strongest drill bits material and can cut through hardened steel. But if they are not available, titanium and cobalt drill bits can also be used. However, drilling with either of these bits will take longer than drilling with a carbide drill bit.

Titanium drill bits are high-speed steel bits with a titanium nitride (TiN) coating, whereas cobalt drill bits do not have a coating; the entire bit is constructed of alloy steel that contains 5 to 8% cobalt.

Lubricant should be applied to both the drill bit and the drilling surface. To reduce the temperature, repeat this step between drillings.

Doiron cited another bad but fairly common practice: overextending a tool held by a collet to make the tool reach a little farther, thereby sacrificing critical gripping force.

On the other hand, shrink-fit holders are sized based on tool shank diameter, said Dan Doiron, milling product manager at Emuge Corp., West Boylston, Massachusetts. This means that a shop would need a different shrink-fit holder for each tool diameter. In addition, he said, a shop using shrink-fit holders needs a heating unit to install tools in the holders, adding more cost to that option.

Titanium drill bits are high-speed steel bits with a titanium nitride covering. Titanium-coated drill bits provide many advantages over ordinary steel bits, including the ability to endure greater temperatures, increased wear resistance, and higher durability.

Rockwell hardness testing is a standard method for determining the  hardness of metals and polymers. Rockwell hardness is measured with a device known as a Rockwell hardness tester. The tougher the steel is, the higher the number on the RC scale. The higher the RC number, the slower the drill speed should be.

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Carbide drill bits are the toughest drill bits available and best for drilling hardened steel. Carbide is a  compound made from tungsten and carbon. Carbide drill bits are typically composed of steel that has a carbide tip.

Shops that want to use collets but don’t want the compressibility of the ER type may want to consider FPC collets sold by Emuge.

Carbide drill bits are used for drilling broken bolts, safes, studs, bearing races, taps, and knives made from hardened steel. They are designed to allow the quick dissipation of heat and prevent chipping.

FPC Slim Line collet chucks are designed to make it easier to use cutting tools in confined work areas. Image courtesy of Emuge

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.

Therefore, cobalt drill bits have a longer life and are more heat resistant than titanium drill bits. Which means cobalt drill bits are typically better since they are much more durable than titanium-coated bits and can drill holes through the hardest metals.

The drill speed is critical for drilling hardened steel. Drilling at high speeds causes high temperatures, which will damage your drill bit. Therefore, drilling hardened steel should be done at a low RPM and feed rate. Feed rates are typically at least 50% lower than for lesser hardness steel. Speeds generally are 30% of that of a non-hardened material.

Other well-known toolholding alternatives include shrink fit and Weldon flat — also known as side lock — as well as hydraulic and milling chucks. Compared with these, the biggest advantage of ER collet systems is their versatility, said Alan Miller, engineering manager at BIG KAISER Precision Tooling Inc., Hoffman Estates, Illinois.

Generally about 152.4 mm (6") long, spanner wrenches for ER collet nuts “are designed to keep you from imparting a giant amount of torque to those things,” he said. “But shops get into trouble when somebody torques down (the nut) by hand and then grabs a hammer and gives the wrench a couple of hits just to make sure the nut is really tight.”

In computing for the RPM, for example 1"-diameter tool must run at 30 sfm. Based on the equation above, at 30  sfm: (30 × 3.82) ÷ 1 = 114.6, this means you have to use 115 RPM to drill a 1 inch Rockwell C 40 to 45 steel.

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There are many other things to consider when choosing the right drill bit for hardened steel. This post will cover what you need to know about drilling hardened steel and provide you with some suggestions on the best drill bits that will work well for your needs.

Torque wrenches aren’t used to tighten collet nuts in most cases, Moon said. But shops can get satisfactory results using a spanner wrench.

Collets are among the items most commonly found at machine shops. But people who routinely use these toolholding mainstays probably don’t have all the important facts about them.

That’s because there’s a lot to know about collets — in a number of different areas. These include how collets stack up against other toolholding options and the latest in collet technology, as well as how to choose and use collets to extend their lives and get better results with machining.

What is a collet used forin lathe

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.

Besides the versatility of the ER collet system as a whole, users get the toolholding flexibility of the individual collets in the system. This is due to the slotted ER collet design, which allows a good deal of compression and therefore can accommodate different tool shank diameters, explained Andy Moon, product manager for milling and toolholders at Guhring Inc., Brookfield, Wisconsin. He added, however, that this flexibility is limited to a small range, which can be anywhere between 0.5 mm (0.02") and 1 mm.

When using collets, the things that shops do — and don’t do — can make a big difference in how collets perform and how long they last. One common mistake made with collets is over-tightening the collet nut.

Collettypes and sizes

“People get the idea that tighter is better, but that’s not the case,” Moon said. “When you over-tighten, you’re over-stressing the nut and collet, and the metal starts to yield and bend at some point.”

Some effective practices for getting the most from collets are easy and obvious. For example, Moon recommends taking out and thoroughly cleaning a collet and collet chuck every time that a tool being held is changed out. Simply blowing off chips and any other debris with an air hose is all that’s required. He said if cleaning isn’t done regularly, debris will cause wear on the outside of a collet and the inside of a toolholder.

When comparing the carbide, both cobalt and titanium drill bits are better than regular steel drill bits due to their added components, as well as their resistance to heat and wear. However, in terms of hardness and longevity, the carbide drill bit is better than both of them.

For best results, he recommends the use of a torque wrench for tightening. He said shops today can find tightening torque recommendations for different ER collet sizes.