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Reamers are finishing tools designed to enhance the precision of a pre-drilled hole while creating a smooth surface finish. Both cylindrical and tapered holes can be produced with reamers. Reamed holes are required for precision applications such as tool and die making, combustion engine parts, airframe fastener holes, and firearms.

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Tapered reamers are conical in shape with a specific angle. Tapered reamers are used to create a slight taper in pre-drilled cylindrical holes. Tapered holes are usually required to fit tapered pins for locating purposes or tapered shafts with Morse tapers, a standard taper used for tooling.

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Hand reamers are designed to be used manually without the aid of a machine, so not with CNC machines. The rear end of the reamer shank is square so it can  engage with a tap wrench or spanner. The reamer is slightly tapered at the front to allow it to self-align in the hole, making it easier to use. Hand reamers are ideal for light-cutting jobs and are not as precise as machine reamers due to the potential for human error; therefore, they are not recommended for applications requiring tight tolerances.

In terms of technique, it shouldn't matter much. However, in terms of maintenance, a metal flute is much easier than wood flute.

A ring or shell reamer is ideal for high-production-volume reaming of large-diameter holes. Create your free Fictiv account and request a CNC machining quote today — we machine complex parts at ridiculous speeds!

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Reamers can be made from HSS (High-Speed Steel), carbide, and high-alloy steel. Hole reaming is considered a finishing process.

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This type of reamer typically has multiple cutting bits attached around the periphery of a ring,  resembling a face mill. Ring reamers are utilized at high speeds, mostly for larger diameter holes. Limited expansion, a key design feature of most ring reamers, limits tool wear, resulting in higher accuracy and extended longevity.

This article will describe what reamers are, how they work, the different types of available reamers, and how to use them to achieve unparalleled precision effectively.

A shell reamer usually has a hollow cylinder geometry and straight flutes and is utilized on both CNC and manual machines. Helical and twisted flutes are also utilized. The internal diameter of the reamer is sized to fit over an arbor. Quick replacement benefits shell reamers versus standard reamers, as only the cutting edges need to be replaced, not the entire shank. Spinning during reaming is prevented due to the slots on the rear of the reamer, enabling lug engagement on the arbor.

When a hole is needed in a part, it is usually cut with a drill. However, drills do not produce precisely sized holes, as their primary function is to remove large amounts of material as quickly as possible. Drills are ideal for holes that do not need precise sizes and smooth surface finishes, for example, holes for fasteners.

You can use a tap to cut threads in a hole drilled in metal, such as steel or aluminum, so you can screw in a bolt or screw. The process of tapping a hole is actually pretty simple and straightforward, but it’s important that you do it right so your threads and hole are even and consistent. Choose a drill bit and a tap that fits the screw or bolt you want to use by making sure they’re the same size. For safety, it’s also important that you steady the item you’re drilling and you use the right drill bits.

Choosing the correct reamer for your application can be challenging as it depends on several factors. A straight-fluted hand reamer will be ideal if a one-off reamed hole is required. However, a machine reamer is better suited for maximum precision and productivity.

Insert the tap into a T-handle and add drilling oil to the hole. Fit the end of the tap into the hole pointing straight down and aligned with the hole. Rotate the T-handle clockwise using smooth rotations. Don't apply much pressure; allow the tap to thread the hole on its own.

Expansion reamers are designed to increase their diameter by turning a screw, which then displaces the cutting edge radially outwards. This expansion allows tool wear compensation and fine control of different hole diameters. The modular design of these reamers, which are not as rigid as standard reamers, can only remove relatively small amounts of material. This means they do not last as long.

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Reamers are typically only used on metals and are not compatible with plastics. The plastic will deflect away from the reamer, resulting in an inaccurate hole diameter.

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A drill reamer, also known as a reaming drill, allows for drilling and reaming in the same operation, saving time. A reaming drill is best suited for through-holes. It must be noted that if extremely precise holes are required, a drilling operation with a separate reaming operation is preferable. But, this type of reamer can provide cost savings and streamline the machining process if the precision requirements aren’t too stringent.

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Reamers, conversely, are used to enlarge an existing drilled hole to a precise size with a tight tolerance. Reamers are only designed to remove a small amount of material and typically have straight or helical flutes. Reamed holes can be produced manually or with a machine. Machine-produced reamed holes are preferred if maximum precision is required.

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An alignment reamer is a powerful reaming tool commonly used in the manufacturing industry to improve holes’ accuracy. It works by enlarging and aligning holes, ensuring they are straight and parallel, which is essential for many mechanical components to function correctly. Due to its precision, the alignment reamer is widely used in machinery and equipment manufacturing, where even the smallest inaccuracies could lead to significant problems. By using an alignment reamer, manufacturers can ensure their products are of the highest quality and meet the strictest standards.

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Shell reamers are best suited for holes larger than 0.75” in diameter.  Left-hand spiral flutes should be utilized for blind holes.

These reamers are the most commonly used and have either a straight or Morse tapered shank. Chucking reamers are sometimes also called machine reamers. The flutes on chucking reamers can either be straight or helical. These reamers are often fixed into a CNC or manual drill press, lathe, mill chuck, or collet, hence the name. The tip of the reamer typically has a 45-degree chamfer. A chucking reamer is utilized to increase the size of an existing drilled hole, to a more precise dimension with tighter tolerances.

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