Deep Hole Drilling into Ladder Frame out of AlSi12Cu1 with  KOMET  KUB®  Drillmax, Solid Carbide Drill

Challenge

Material:
Aluminium with 12% silicon

Part:
Ladder frame

Drill hole:
Ø 4,0, 40×D long, entrance and exit under an angle

Machine:
Vertical machining centre

Coolant:
Minimum Quantity Lubrication (MQL) 10 bar (145PSI)

Situation:
No safe process with competitor's tool, tool life 2.500-6.000 drill holes

KOMET-Solution

KOMET  KUB®  Drillmax 4,0 40×D MQL Special Pilot hole 18 mm deep Cutting data:
v_c = 100 m/min
SFM = 7.950 r.p.m.
f = 0,23 mm (.0090")/rev.

Entering pilot hole (Z-14 mm = .55“)
with 100 r.p.m and 3.000 mm (118“)/min

Start drilling down to Z-25 mm = .98“ with
v_c = 50 m/min (164 SFM) and
f = 0,23 mm (.0090“)/rev.

Deep hole drilling with vc 100 m/min
(328SFM) at f = 0,23 mm (0.0090“)/rev.
to final depth Z-87mm = 3.42“

Withdraw drill out of the finished hole
with 100 r.p.m. and F = 5.000 mm (197“)/min

Customer's Benefit

• Tool life > 6.000 holes (522 m = 1.712 ft) have been manufactured safely
• 30% faster than competition. At the same feedrate f = 0,23 mm/rev (.0090") the cutting speed could be increased from v_c = 55 (180 SFM) to 100 (328 SFM)