We're running 12L14 on a Daewoo chucker lathe.
Need to drill 0.063" hole, 0.550" deep (ok, 9x deep)
Diameter +0.002/-0 TIR over the length of the hole is 0.002" max. OD is turned in the same setup, before hole is drilled. Need 3,000 holes/month.
Currently using Metal Removal carbide drills with a low helix and split point. We do not have high pressure through coolant.
Currently running 5krpm, 0.001"/rev, 0.030" pecks with full retract (G83 Fanuc) on a spotted hole. Using a Cheap 'n Cheeful ER20 holder/ collets in a boring bar VDI tool block, we're getting very poor results. Even when drill is centered to 0.0003". Worse results as machine warms up and drill drifts 0.0015 off center. Drill life is about 150 holes and concentricity is not stable within our tolerances, even when the machine is warm and the drill is new.
Possible options:
-Invest in $800 holder which can be adjusted in x and y (we don't have y-axis) and its angle can be adjusted. Made by Gyro
-Go with HSS vanadium OSG 1100-series drills. Tool rep says no pecks, good runout, good size. About $20 each (which is fine, if they work)
-We were thinking of building a floating holder which will ride on three ball bearings so it can "actively" float in x and y (only about
0.003 in any direction). Also adjustable in angular alignment along z.Any thoughts? It looks like carbide is not recommended for this type of application. We've had good success with parabolic flutes in other applications. Would it help here?
We are currently outsourcing these parts to a lathe job shop who knows what he's doing, but we're eager to bring them in house.
Thanks for any thoughts.
Regards,
Robin