Monday, February 22, 2021

Ra to Rz - Industrial Engineers and Their Achievements - Productivity Improvement

 


Rahul Panchal 

Senior Process Engineer at Whirlpool Corporation

India


Experience

Whirlpool Corporation

Senior Process Engineer

Dates Employed: Since Jul 2019 

Education

Industrial Engineering

Vishwakarma Institute Of Technology

Graduation2016

https://www.linkedin.com/in/rahul-panchal-10103295/

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Aa to Az - Industrial Engineers and Their Achievements - Productivity Improvement

 

Alejandro Arroyo

Senior Industrial Engineer

Mexico 


Electrolux

Title: Senior Industrial Engineer

Dates Employed: From Sep 2017 

Location: Juarez, Chih. Mexico


Accountability of industrial engineering department in charge of three engineers, eight process technician and six welding technician.

Responsible of labor productivity, efficiency and utilization, budget, cost reduction projects and over time (KPI’s).

Head count calculation according to the customers demand to guarantee the safety, quality, cost and deliveries metrics.

Supporting the production lines where there are 600 direct labors and 4 lines call washer, dryer, fabrication and painting.

Following up and implementation of engineering change notice (ECN’s).

Working directly with maintenance, facilities, quality, materials, safety and production to solve problems in the production lines.

Equipment and machinery installation assistance and purchasing.

Knowledge and development of continuous improvement methodology and six sigma tools.


Industrial Engineer

Full-time

Dates Employed: Oct 2016 – Aug 2017

LocationJuarez Chihuahua Mexico

Support to the production line with 400 employees like an Industrial Engineer with two industrial technician and four welders in charge.

Responsible of the 3K metal cars and rack to maintenance in optimal condition to move the raw material.

Implemented & developed the lean manufacturing tools such as PDCA, 5 S’s, 7 wastes, standard work, visual factory, problem solving, 5D build in Quality, KPI’s, Data analysis, Line balance, SMED, PFEP, Process mapping, Leveling production system, KAIZEN workshop to continuously improve upon our own records.

Implemented & developed manufacturing tools such as time study, PFMEA, MOST, Poka yoke design, Flow Diagram, Ergonomic analysis, labor map, Poka Yokes design.

Production tooling purchasing order placing. Cost reduction projects leading. Pilot run & new models launch introduction.

Facility design as work station, static rack, dynamic rack, gravity conveyors, production lines, isolations areas and utility carts with Pipe Racking System.

https://www.linkedin.com/in/alejandro-arroyo-91b66256/

https://www.linkedin.com/in/mudassir-ali-57920217a/


https://www.linkedin.com/in/alan-reyes-869297163/


https://www.linkedin.com/in/amit-pangerkar-542b8810/


https://www.linkedin.com/in/avinash-gudmewar-1b97a596/

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Saturday, February 20, 2021

Drilling Machines - Specifications

 

AKN Hydraulic Automatic Deep Hole Drilling Machines

For mild steel or medium hard materials.

Brand AKN

Type of Drilling Machine Pillar

Motor HP 1-3 HP


Model H-90-150 H-70-150 H-60-150 H-50-100


Model                  H-50-100  

Max. Drilling Capacity Ø 10mm 

Spindle Travel  100mm

Spindle Speed (RPM)  3 speeds - 830.1670.2500 

https://www.aknindia.com/drilling-machines.html



Radial Drilling Machine - HMT

http://www.hmtmachinetools.com/product/108/radial-drilling-machine.htm


Specifications :

                      RM 62     RM 63         RM 65  

Drilling Capacity 


In Steel     mm                      dia 100 (At 60 rpm with 0.5 mm/rev.)

 


 In Cast Iron mm                dia.125 (at 60 rpm with 0.62 mm/rev)                              



Spindle speeds rpm 12:40-1800 32:10-1545

Spindle feeds no:mm/rev 6:0.125-1.25 18:0.075-4

Machine 1

http://www.hmtmachinetools.com/product/108/radial-drilling-machine.htm

Automatic drilling machine tool specifications

Description (All dimensions are in mm)

Model: P4/38

Drilling capacity in steel 38

Morse taper in spindle      4

Spindle traverse          178

Pillar diameter           139.7

Distance between center of spindle and column front 311

Maximum distance between spindle and Table 555

Maximum distance between spindle and base 1000

Table: Working surface 368 (Dia)

Base: Working surface 368*330

Number of spindle feeds 10

Number of power feeds 3

Range of feeds (mm/rev) 0.095, 0.190 and 0.285

Power of the spindle drive motor 2HP, 960 RPM, 400/440 volt A.C 3phase, 50 cycles

Space occupied (height*width*length) 2000*660*1110

Net weight of the machine 850 kg



Available spindle speeds

At MOTOR 720 RPM   MOTOR 1440 RPM

340                            680

245                            490

180                            360

125                            250

85                              170


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Machine Shop Cost Reduction News up to 2014 - Metal Working - Cost Reduction Opportunities

Machining Time Reduction - Productivity Improvement News


2014
Four Cost-Cutting Tips for CNC Machining
Daniel Clark
JUL 31, 2014
https://www.americanmachinist.com/shop-operations/article/21898592/four-costcutting-tips-for-cnc-machining


ORIGINAL ARTICLE
Published: 29 June 2014
Development of a smart machining system using self-optimizing control
Hong-Seok Park & Ngoc-Hien Tran 

2013

Productivity Technology in Metal Cutting - 2013

Manufacturing Systems Conference 2013 Papers - Bibliography

11. A study on the heating process for forging of an automotive
crankshaft in terms of energy efficiency
http://cms2013.ceni.pt/wp-content/uploads/2013/05/11_paper.pdf

42. An approach for a cloud-based machine tool control
http://cms2013.ceni.pt/wp-content/uploads/2013/05/42_paper.pdf

49. A Study of Automatic Determination of Cutting Conditions to
Minimize Machining Cost
http://cms2013.ceni.pt/wp-content/uploads/2013/05/49_paper.pdf

57. Beyond Lean and Six Sigma; Cross-Collaborative Improvement of  Tolerances and Process Variations - A Case Study
http://cms2013.ceni.pt/wp-content/uploads/2013/05/57_paper.pdf

62. Current State of Standardized Work in Automotive Industry in
Sweden
http://cms2013.ceni.pt/wp-content/uploads/2013/05/62_paper.pdf

64. Manufacturing of Twist-Free Surfaces by Hard Turning
http://cms2013.ceni.pt/wp-content/uploads/2013/05/64_paper.pdf


2012



30 November 2012
Complementarity and Cost Reduction - 1997 paper on Automobile Industry

Cost Effective Machining of Brass, Copper and Its Alloys

Cost Reduction of a Chassis and Cover by switching to Die Casting - Alexander Machine and Tool Company Cases - Cost reduction to $210 per piece frm $300

Emerging Titanium Cost Reduction Technologies

Impression Die Casting Projects - Cost Reduction Achievements - There is crank shaft case also.

Metal Injection Molding - Cost Reduction opportunities for small components with more than 10,000 parts per month and above

Ready for Six Sigma - 2006

Reduction in machining cost of crank shaft die by using a different tool

Setup Time Reduction in Machine Shop


Taking the pain out of  Machining ISO P25 Grade of Steel 
Multicapable insert tackles one of the toughest ISO classified turning areas.


JAN 26, 2006

2004
Richards Industries in Cincinnati, Ohio, - setup reduction
In January 2002, average setup time of CNC machines was 50 minutes. In two years, it was brought down to  average of 27 minutes.  The goal is 20 minutes, by the end of this year. The machine shop has  CNC lathes and mills, about 30 machines in all. In 2001, Richards Industries invited productivity consultants from TechSolve,  a Cincinnati-based firm to help them.
"setup reduction events" have four steps:

Document the current changeover.
Determine what setup steps can be done while the machine is still running.
Streamline setup steps that must be done while the machine is not running.
Put the basics in place for workplace organization and visual control.

The company set out to apply this process systematically, one machine at a time, starting with those machines that had the longest setups. Each "setup reduction event" took about a week. The first was held in February 2002.

As part of the exercise, an efficient workplace was created which has tools, parts etc. that are required in properly place positions so that there is no time waste in locating them.  

Shell Molding Process produces cost savings

Single piece design instead of 5 items - Forging

The Cost of Machine Tool Ownership

Tips on designing for cost effective machines parts

Use  Cold forming in place of machine - Reduce cost

Use continuous casting instead of machining

Use hard turning instead of grinding - Feb 2003


5-axis machining will reduce fixture costs and setup costs

Latest Trends in Machining - Full Book - Drishtikon Book


Machining cost reduction - Google Search Results

Operating A CNC Powered Machine Shop: Roadmap for Efficiency
http://home.earthlink.net/~cadcamcnc/data/Operating%20A%20CNC%20Powered%20Machine%20Shop.pdf


9/1/2001 
Boosting Multi-Spindle Productivity
Here's a look at some of the ways Delta Faucet is taking advantage of off-the-shelf technology to improve multi-spindle screw machining productivity.

















Updated on 19 August 2020
30 November 2012
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Friday, February 19, 2021

Drilling - Process and Machine - Evolution

Rotary cutting tool having PCD cutting tip

Abstract
A rotary cutting tool with an elongate body disposed about a longitudinal axis, the elongate body including a helical flute and a polycrystalline-diamond cutting tip. The cutting tip comprises an inner portion having an inner point angle and an outer portion having an outer point angle different from the inner point angle.
2019-06-25
Publication of US10328536B2
Inventor: L Karthik Sampath,  Armin Zimmerman, Steve George; Current Assignee: Kennametal Inc
https://patents.google.com/patent/US10328536B2/en

Deep hole drilling methods as well as tools for deep hole drilling machines

Abstract
The present invention relates to a deep hole drilling method for manufacturing a pipe having an inner profile having at least one recess spirally extending along the inside of the pipe, the deep hole drilling machine comprising: a basic body extending along a longitudinal axis And at least one cutting edge arranged on the outer periphery of the base body, wherein the tool is pulled through the interior of the pipe while the cutting edge is rotated around the longitudinal axis such that the cutting edge completes the cut along the spiral curry line on the inside of the pipe; Pushed.
2019-08-06
Publication of KR20190091438A
https://patents.google.com/patent/KR20190091438A/en


Drill head for a deep hole drilling tool for bta deep hole drilling, and deep hole drilling tool


A drill head (100) for a deep hole drilling tool for BTA / STS or ejector hole drilling, comprising a main body (101) of a drill head, a cutting edge (109), and guide pads (110, 111) (101) is rotatable about an axis of rotation (113) and has a hollow conduit (107) with a chip collection orifice (106) on the perforated side (160) and the perforated side (160) 109 are arranged on the upper side and have a ridge 114 of the main cutting edge and a ridge 115 of the minor cutting edge and the minor cutting edge is arranged on the outer side in the radial direction of the cutting edge,
2018-02-13
Publication of KR101829079B1
https://patents.google.com/patent/KR101829079B1/en


Drills: Science and Technology of Advanced Operations
Viktor P. Astakhov
CRC Press, 08-Apr-2014 - Science - 888 pages

In a presentation that balances theory and practice, Drills: Science and Technology of Advanced Operations details the basic concepts, terminology, and essentials of drilling. The book addresses important issues in drilling operations, and provides help with the design of such operations. It debunks many old notions and beliefs while introducing scientifically and technically sound concepts with detailed explanations.

The book presents a nine-step drilling tool failure analysis methodology that includes part autopsy and tool reconstruction procedure. A special feature of the book is the presentation of special mechanisms of carbide (e.g. cobalt leaching) and polycrystalline (PCD) tool wear and failure presented and correlated with the tool design, manufacturing, and implementation practice. The author also introduces the system approach to the design of the drilling system formulating the coherency law. Using this law as the guideline, he shows how to formulate the requirement to the components of such a system, pointing out that the drilling tool is the key component to be improved.

Teaching how to achieve this improvement, the book provides the comprehensive scientific and engineering foundations for drilling tool design, manufacturing, and applications of high-performance tools. It includes detailed explanations of the design features, tool manufacturing and implementation practices, metrology of drilling and drilling tools, and the tool failure analysis. It gives you the information needed for proper manufacturing and selection of a tool material for any given application.
https://books.google.co.in/books?id=3wwNAwAAQBAJ

Drills - Materials
https://books.google.co.in/books?id=3wwNAwAAQBAJ&pg=PA228#v=onepage&q&f=false



The invention also relates to a method of drilling composites by means of a ceramic drill bit of the type described above, in which method the drill bit has a peripheral cutting speed of between 600 and 1000 m/min.

Advantageously, the drill bit is advanced at between 0.05 and 0.20 mm/revolution.

Ceramic drill bit for high-speed drilling of composites


The ceramic drill bit has a particular geometry and is very advantageously applicable to the very high-speed drilling of parts made of a composite, especially a carbon-fiber composite having an epoxy resin matrix. The invention also relates to a method for the high-speed drilling of composites.

2009-01-29 Publication of US20090028654A1
2012-06-26 Application granted
2012-06-26 Publication of US8206067B2
Status Active
2031-04-26 Adjusted expiration
InventorL Claude Turrini; Current Assignee:  Safran Aircraft Engines SAS


6/15/1998 

The Fast Track To High Speed Drilling
Drill more productively by making a few strategic changes to the process. Those same changes may also let you drill dry.

Peter Zelinski, Editor-in-Chief, Modern Machine Shop


The Morse Twist Drill and Machine Co ...
[Catalogue]

Corporate Author: Morse Twist Drill & Machine Co., New Bedford, Mass.
Language(s): English
Published: New Bedford, 1912.
https://catalog.hathitrust.org/Record/100493266?type%5B%5D=title&lookfor%5B%5D=drilling%20machine&ft=

Modern drilling practice

A treatise on the use of various type of single- and multiple-spindle drilling machines, including their application to standard and special operations, the relation of speeds and feeds to intensive production, and the different types of tools and fixtures utilized in progressive machine shops for increasing the range and efficiency of machines of this class [by] Edward K. Hammond
Main Author: Hammond, Edward K., b. 1885.
Published: New York, The Industrial Press; [etc., etc.] 1919.
Edition: 1st ed.
https://babel.hathitrust.org/cgi/pt?id=uc2.ark:/13960/t06w97384&view=1up&seq=7


Suggested unit course in drill press work for beginners in machine shop practice ...
Corporate Author: New York (State).
Related Names: Witzel, Ewald L.
Language(s): English
Published: [Albany] : The University of the state of New York, the State education dept., Bureau of industrial and technical education, 1940.

https://catalog.hathitrust.org/Record/009211727?type%5B%5D=title&lookfor%5B%5D=drilling%20machine&ft=

Modern drilling practice, Hammond, Edward K

Published: New York, The Industrial Press; 1919.
Edition: 1st ed.
https://babel.hathitrust.org/cgi/pt?id=uc2.ark:/13960/t06w97384&view=1up&seq=7

Drilling machines which find the most general application in American manufacturing plants may be roughly divided into three general classes, as follows:
1. Vertical drilling machines. 2. Radial drilling machines. 3. Multiple-spindle drilling machines.

Each of these general classes is capable of further subdivision, so that drilling machines are finally classified under the following headings:

1. Vertical or " upright " drilling machines. 2. Vertical sensitive drilling machines. 3. Vertical high-duty drilling machines. 4. Radial drilling machines. 5. Multiple-spindle drilling machines of straight-line type. 6. Multiple-spindle drilling machines of cluster type. 7. Automatic drilling machines. 8. Turret-type drilling machines.

In addition to the eight preceding types of machines, a great deal of useful work is done by special machines built to meet the requirements of individual cases. Such machines are generally of the multiple-spindle type, but they are especially designed for specific classes of work.


Vertical or Upright Drilling Machines.


The vertical or up-right machine is the most commonly used type of " drill press " employed in the machine shop. It is usually equipped with power feed, and a tapping attachment is often provided, which may be engaged to provide for handling work in which holes have to be tapped. The term " sensitive " is applied to those types of light drilling machines which are equipped with hand feed, so that the opera tor is able to judge the amount of feed pressure with which the drill is being driven into the work. These machines are usually adapted for drills from the smallest sizes up to from f to J inch in diameter. They are used on a great variety of work, and for handling small parts in quick-acting jigs or fixtures they are capable of giving very satisfactory results. One advantage of the hand feed is that an experienced operator may use his judgment in releasing the feed pressure, if he finds that the drill has struck a hard spot in the work. This is the means of saving the breaking of drills. Machines of this type are now being built for operation at speeds which were unheard of a few years ago. For instance, some types of sensitive drilling machines are built for operation at speeds ranging from 10,000 to 15,000 revolutions per minute.

Vertical High-duty Drilling Machines.


As their name implies, high-duty drilling machines are adapted for the performance of heavy work, and they are commonly employed for using a range of drill sizes running from the maximum capacity of sensitive drilling machines up to the largest sizes in which drills are made. In addition to the performance of drilling operations, high-duty drilling machines are used for a great variety of other classes of work, including such operations as hollow-milling, spot-facing, facing, counterboring, threading, tapping, etc. In general, machines of this character may be employed to advantage wherever it is desired to use a rotating tool on stationary work under conditions where heavy cuts are to be taken. To meet the requirements of such severe service, the high-duty drilling machine is equipped with power-driven feed, and the rates of feed are commonly much greater than that employed on sensitive drilling machines, while the speed at which the drill is operated is correspondingly reduced, owing to the greater diameter of the drill. There are various forms of mechanisms used on these machines, but in all cases provision is made for obtaining any of a range of speed and feed changes suitable for the work on which the machine is engaged.


Radial Drilling Machines.


On the familiar type of radial drilling machine the spindle head is carried on an arm, which may be swung around the column of the machine, and the spindle head may also be moved back and forth along the arm. This combination of movements makes it possible to locate the spindle of a radial drilling machine at any desired point over work which comes within this range of movement. Radial drilling machines are commonly classified according to the length of arm, i.e., a 6-foot radial drill has an arm 6 feet in length. Sizes in which these machines are generally built run from about 2 to 6 feet. Obviously, the size of the work which can be handled with a machine of this type is governed by the length of arm and vertical adjustment of the arm on the machine column. Radial drilling machines are generally employed for handling those classes of work where there are a number of holes to be drilled and where the work is either too heavy or too large to be conveniently set up on multiple-spindle drilling machines.


Multiple-spindle Drilling Machines.


A great many parts that have to be drilled require holes of different diameters, and other operations, such as counterboring, reaming, or counter- sinking, are frequently necessary. When work of this class is done in a machine having one spindle, considerable time is wasted in removing one drill and replacing it with a different size or with some other kind of tool. For this reason, drilling machines having several spindles are often used when the work requires a number of successive operations. The advantage of the multiple spindle or " gang " type as applied to work of the class mentioned is that all the different tools necessary can be inserted in the various spindles, and the drilling is done by passing the work from one spindle to the next. Drilling machines of the multiple-spindle type are also commonly used for drilling a number of holes simultaneously. The arrangement of these machines is varied considerably to suit different kinds of work, but they may be divided into two general classes; namely, those having spindles which remain in the same plane but can be adjusted for varying the center-to- center distance, and those having spindles which can be grouped in a circular, square, or irregular formation. The first class referred to is used for drilling rows of bolt or rivet holes in steel plates, etc., and the second type is adapted to the drilling of cylinder flanges, valve flanges, or similar work.

CHAPTER IV

SPEEDS AND FEEDS FOR DRILLING


The proper speed at which a drilling operation should be performed is that speed at which the most desirable balance is obtained between cutting down of production through lowering the drilling speed and loss of time through the necessity of more frequently stopping the drilling machine to grind drills, where higher drilling speeds are employed. The following recommendations made by different authorities should prove of interest and practical value.

H. 'M. Norris, chief engineer of the Cindnnati-Bickf ord Tool Co.: occasionally a drill is found which is capable of standing up satisfactorily at a cutting speed of 150 feet per minute in either cast iron or steel, but it is seldom desirable to drive anything but very small drills at speeds in excess of 100 feet per minute. Under average conditions of operation, the best results will be obtained with a cutting speed of 80 feet per minute in cast iron, while, for steel, a speed of "7+76 feet per minute will give satisfactory results. Where this rule is used, the cutting speed will be decreased from 100 feet per minute for a |-inch drill to 80 feet per minute for a 3-inch drill. In explaining the rule, attention is called to the fact that, while cast iron is cut dry, a lubricant is required for drilling steel and a volume of lubricant sufficient to keep a J-inch drill cool at 100 feet per minute will only be sufficient to cool a 3-inch drill at 80 feet per minute.

Cleveland Twist Drill Co.:  It is well to start carbon steel twist drills under the following conditions of speed and feed until more definite data are available as to the maximum speed and feed which can properly be employed for the operation under consideration.

When drilling machine steel, use a peripheral speed of 30 feet per minute; for cast iron, use a speed of 35 feet per minute; and for brass, use a speed of 60 feet per minute. In each case, a feed of from 0.004 to 0.007 inch per revolution should be employed for drills up to i inch in diameter, while for larger sizes the feed should be from 0.005 ^^ ^-^^ 5 ^^^ P^^ revolution. In the case of high-speed steel drills, the preceding rates of speed should be increased from 100 to 125 per cent, while the same rates of feed are employed.

The Standard Tool Co. recommends starting high-speed steel drills at a peripheral speed of from 50 to 70 feet per minute for wrought iron or steel, and from 60 to 80 feet per minute for cast iron, or at 140 feet per minute for brass. The feeds recommended are 0.004 i^ch per revolution for a y^5-inch drill in wrought iron or steel, 0.005 inch per revolution for a J-inch drill, 0.008 inch per revolution for a ^-inch drill, o.oio inch per revolution for a i-inch drill, and 0.015 i^ch per revolution for a i^-inch drill.

Starting with any of the preceding speeds and feeds which have been recommended by different authorities, the operator carefully notes the condition of the drill after it has been working for some time. If the drill shows a tendency to wear away on the outside, it is running too fast, while if it breaks or chips on the cutting edges, the feed is probably too heavy for the work required. A little careful experimenting in this way, making changes gradually according to indications which are shown after working for some time, will usually result in securing a combination of speed and feed which will be the means of obtaining something approaching the maximum possible production.  It will, of course, be obvious that, to obtain a given peripheral cutting speed, the number of revolutions per minute must differ according to the size of the drill which is being used. This is the reason for running very small drills at extremely high speeds in order to have them working under conditions which approximate the required cutting speed for the material that is being machined. For the convenience of users of twist drills and other rotary cutting tools, tables are available which show the number of revolutions per minute at which a given size of drill should be run in order to obtain the required cutting speed. In Tables 1 and 2 the diameters of drills are given in the left-hand column, while peripheral cutting speeds in feet per minute are noted at the top of the table. By finding the intersection of horizontal and vertical lines through the given drill diameter and the required cutting speed, the number of revolutions per minute at which the drill must be run in order to obtain this speed will be found. Table 3 gives the decimal equivalents of nominal sizes of drills, and will be found useful when calculating the peripheral cutting speed of drills of various sizes; this table also shows the relation of the different sizes of drills, which are designated by letters and numbers, as compared to the fractional sized drills.

Critical Drilling Speeds. — In experimenting to determine the number of revolutions per minute at which a drill will have the greatest productive capacity, some interesting results are secured. Researches which were made at the plant of Baker Bros., with the view of securing data required in connection  with the design of their drilling machines, showed that there are certain critical speeds at which a twist drill will have a satisfactory rate of production, while there are other speeds — often lying between two rates of speed where the production is satisfactory — at which the drill will fail to give anything approaching satisfactory results. This condition is clearly shown by Fig. 3, which is plotted with data taken from original tests. These investigations were made several years ago, so that, while the condition shown by this set of curves is an established fact, the rates of speed and feed are lower than would be used in conducting similar tests at the present time. The point brought out by this diagram is the remarkable increase in production which can be secured by increasing the speed. The curves are plotted for the maximum feed at which the stock was successfully drilled without destroying the drill; at the next higher feed the drill would be destroyed. Curve No. 2 shows that the drill would give a far greater production without failing at 2CX) revolutions per minute than it would at 250 revolutions per minute, and also that it would give a much greater production if the speed were still further increased to 4cx) revolutions per minute.

Recently a well-known manufacturing establishment had an investigating committee working for over two years on the development of a table of speeds and feeds for use in connection with different sizes of drills working in various materials. The result of this investigation is presented in Tables 4 and 5, and although it is not claimed that the data presented can be followed without modification, it is claimed that the thousands of tests which were made during the period over which these data were secured have led to results which may safely be regarded as an average maximum of the rate of speed and feed under which a drilling machine may be operated. These tables are copyrighted by the Henry & Wright Mfg. Co., and the tests were made on a special drilling machine built by this company.


In starting to work on a new job the operator of the drilling machine will use the speed and feed shown in these tables, but should he find that the drill shows a tendency to wear around its periphery or that there is a considerable amount of chipping along the cutting edges of the drill, it indicates that the speed or feed is too heavy, and so the required adjustment of operating conditions must be made. In the plant where these data were obtained, the investigating committee reported that the installation of machines capable of operating under these conditions of speed and feed would represent a saving of $30,000 a year. The speeds recommended are rather high, and if twist drills are unable to stand them, the drill manufacturers should be notified, as it is claimed that any responsible maker can furnish suitable drills for use under these conditions if he is required to do so. The speeds are also too high for machines equipped with plain bearings, but properly constructed machines with ball bearings will easily stand up under such conditions of operations.

The best advice which can be given to the man who is trying to improve conditions in his drilling department is to adopt the method of experimenting with trial speeds and feeds — adopting those trial speeds and feeds recommended in the preceding discussion — until he has found the conditions
of speed and feed which give the most satisfactory results on his work.

High Speeds of Modem Drilling Machines. — Machine tool builders are now making drilling machines fully equipped with ball bearings so that they are adapted for operation at speeds which would have been utterly impossible of attainment a few years ago. For instance, the Leland-Gifford Co. builds a ma-
chine which is adapted for operation at speeds of from 11,000 to 15,000 revolutions per minute, and the same speeds are recommended for use on a bench drilling machine recently brought out by the Fenn Mfg. Co. Other machinery builders are making high-speed drilling machines. Driving twist drills at such
speeds means that the drilling operation is practically instantaneous; in fact, the speed at which holes may be drilled is often equal, if not in excess, of the speed at which the same work could be done on a power press. It is this constant increase in the speed of drilling, with the constant reduction of the ratio between " drilling time " and " setting-up time," which has emphasized the fact that, in order to approach the maximum rate of production, the user of high-speed drilling machines must design his work-holding fixtures in such a way that work may either be set up in indexing fixtures while the drilling operation is being performed, or, if this is not feasible, the clamping devices on fixtures must be so made that a minimum amount of time is consumed in securing the work in place ready to be drilled.

Several important advantages are secured through drilling at high speed, and this is particularly the case with small sized drills, which are likely to break, and also with high-speed steel drills. The reasons for this are as follows: In the case of small drills operated in sensitive drilling machines equipped with hand feed, running the drill at high speed makes it improbable that the operator will impose an excessive feed on the drill, because, in the case of a drill which is running at from 10,000 to 15,000 revolutions per minute, it would be necessary to pull the feed-lever down extremely fast in order that the feed for any one revolution of the drill would be sufficient to impose a stress in the steel which would be in excess of the maximum that the strength of the drill is capable of withstanding. A further explanation for the increased strength of a drill when running at high speed is that where an excessive amount of feed pressure tends to bend the drill slightly when running at high speed, the length of time that any set of fibers in the drill is subjected to stress is so short that the danger of breaking may be less than if the load remains on such fibers for a greater length of time. This is, of course, an unsettled question and is advanced in the form of a hypothesis rather than a statement of fact; in V any case, the question is an interesting one.

A series of tests was conducted on this machine by Paul Bedell Starr and John Millard Marsh to secure data for a thesis presented at the time these men took the degree of Bachelor of Science in mechanical engineering at the Case School of Applied Science. The object of this investigation was principally to determine the feed pressure required to drive different sizes of drills under various conditions of speed and feed. That very little reliable data were available on this subject was shown by the fact that, when the special drilling machine was first built by a firm of wide experience in the design and construction of equipment of this type, a pressure gage reading up to 3000 pounds was provided. At the first test, using a i-inch drill at a normal rate of feed, the range of this gage was shown to be entirely inadequate; therefore, a gage reading up to 15 tons was substituted, which proved suitable for the service required of it, this difference in gages showing conclusively that the knowledge concerning the magnitude of feed pressures was not at all definite.

Coolants and Lubricants used for Drilling. — For drilling operations, satisfactory results can usually be obtained through the use of one of the soluble oil coolants, for all classes of work where the length of chips produced is not very great; but in cases where long chips are formed, there is a rubbing action produced by the chips sliding over the lips of the drill, which produces a condition analogous to that of a machine bearing, thus making it necessary to apply a fluid which serves the combined purpose of lubricant and coolant. The following is an outline of lubricants and coolants recommended for drilling operations in various classes of material, and the lubricants used are recommended in the order in which they are named. In this list " cutting compound '' refers to any satisfactory brand of soluble oil mixed with water, in accordance with the manufacturer's instructions; and " mineral lard oil " is a mixture of lard oil and light petroleum oil. The proportions of this mixture vary according to the work, but one part of lard oil to two parts of petroleum gives a mixture that is well suited to the requirements of many average drilling operations. For drilling high-carbon or alloy steel, use mineral lard oil or turpentine; low-carbon steel, mineral lard oil or cutting compound; cast iron, dry or compressed air; wrought iron, cutting compound or mineral lard oil; malleable iron, cutting compound; brass, dry; bronze, cutting compound or dry; copper, mineral lard oil; aluminum, kerosene, beeswax, or tallow; monel metal, cutting compound; and glass, solution of camphor in turpentine.


Updated  19 Feb 2021
Published on 27 April 2020






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Deep Hole Drilling - Technology and Productivity News and Developments

https://www.ctemag.com/   



Drilling - Process and Machine - Evolution

2011 - 2020 Drilling Operation Elements - News and Information for Industrial Engineering

2000-2010 Drilling Operation Elements - News and Information for Industrial Engineering

1991-2000 Drilling Operation Elements - News and Information for Industrial Engineering




Automotive components requiring deep hole drilling: 

Rackbars, Pinion Shafts, Cylinder Head, Engine Blocks, Valve Guides, Transmission Shafts, Connecting Rod, Input Shaft, Output Shaft, Gear Shaft, Camshaft, Crankshaft, Rocker Arm Shaft, Crank Case, Shock Absorbers, Piston Pin, Pump Barrel, Common Rail, and Nozzle.


Automotive deep hole applications - Available Solutions

Cam Shaft Deep Hole Drilling Solution

Engine Connection Rod Deep Hole Drilling Solution

Engine Valve Deep Hole Drilling Solution

Engine Valve Guide Drilling Solutions - Valve Guide Gundrilling

Fuel Injection Parts Deep Hole Drilling Machine

Gear Shaft Deep Hole Drilling Solutions

Oil pump injectors gun drilling machine

https://www.deepholemachines.com/special-purpose-deephole-machines/automotive-deep-hole-applications

______________________

https://www.youtube.com/watch?v=sN3F6W3J5Uc

_____________________


Deep hole drilling  - Fundamentals

_____________________


https://www.youtube.com/watch?v=1FmNqL_0dOE

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2021

https://www.americanmachinist.com/machining-cutting/media-gallery/21153554/customized-deephole-drilling-suhner-industrial-products

Search deep hole drilling - Interesting results


Widia TDMX indexable insert drilling line has been extended.

Deep hole drilling line extended

05.01.2021

1.5XD and 12XD drill bodies got added to the existing 3XD, 5XD and 8XD. 

The new 1.5XD addition will enhance the productivity, rigidity and stability when drilling shallow holes whereas the 12XD range will enable manufacturers to enjoy the benefit deep hole drilling. The TDMX drill body incorporates polished flutes, through coolant channels and margin lands on the entire body length to ensure straightness and increased hole quality.

2020

Going deep and cellular

Published December 8, 2020 

Deep-hole drilling systems, which can produce holes that exceed a 20-1 depth-to-diameter ratio, are a unique class of manufacturing equipment.

Unisig a multiple-spindle machine, the UNI25HD. It had the power and controls necessary to apply indexable gundrilling tools, significantly improving feed rates.

https://www.ctemag.com/news/articles/going-deep-and-cellular


BTA deep hole drilling machine

Patent
Publication of JP6746311B2: 2020-08-26

Drilling system and methods for deep hole drilling

Abstract

A deep hole drilling system and methods provide stability and cutting performance to produce deep holes having desired straightness. The system may include a replaceable cutting head provided with a center cutting member and first and second side cutting inserts. The tool provides a major diameter with the OD cutting margins on the replaceable side inserts, as well as possibly cutting margins on the center cutting member. Adjustment mechanisms are provided to adjust the center cutting member and/side cutting inserts.

2020-02-25: Publication of US10569347B2

Inventor: L Paul, W. Best, Salvatore D. Deluca, Lucas S. Dummermuth, David J. Carlisle, Current AssigneeL Allied Machine and Engineering Corp

https://patents.google.com/patent/US10569347B2/en



2018


Selection Of Deep Hole Drilling Parameters Under Cycle Time Requirement Based On Tool Wear Analysis And Life Estimation

Cong Liao, Haiyan Henry Zhang, and Yueen Li

Journal of Multidisciplinary Engineering Science and Technology (JMEST)

Vol. 5 Issue 10, October - 2018


Deep hole drilling process  investigated

9.9 mm diameter and 202 mm depth (the L/D ratio is more than 20). The tool is solid carbide twist drill bit coated with TiCrN and the workpiece is SAE1045.

Cutting parameters and conditions: 

SFM – 262(2570rpm), feed – 0.23mm/rev, 

coolant pressure – 725 psi, coolant concentration – 6~8%. 

Observed that the severe tool wear occurred at the periphery of the cutting edge in the early stage of  usage under the cutting condition of depth of 202 mm, diameter of 9.9mm, speed of 2570 rpm, and feed of 0.23 mm/rev. The surface speed at the outer spot of the cutting edge is estimated of 79.9 m/min.

Experiments reported

V (m/min)           f (mm/rev)                        tcycle (min) 

79.9                           0.23                              0.3149 

65.3                           0.27                              0.3563 

65.3                           0.225                            0.4276 

The paper gives the formula for calculating drilling time.

It also gives tool life formula for deep hole drilling in terms of cutting speed, feed and hole length.

2017

https://www.fabricatingandmetalworking.com/2017/12/deep-hole-drilling-of-diesel-engine-components-transmission-shafts-and-more/

2015

https://www.americanmachinist.com/machining-cutting/article/21898952/seven-axes-one-setup-for-deephole-drilling

https://www.americanmachinist.com/machining-cutting/media-gallery/21898953/automated-deephole-drilling-for-custom-shaft-production

2014


Going deep with holemaking

Christopher Tate

Published October 1, 2014


Uniform nomenclature for long/deep drills. Drill length is specified as a function of the diameter, it is common to see the drill length called out as 15D, 20D and so on. For example, 20D means the drill can produce a hole 20 diameters deep. Therefore, a ½ "-dia., 20D drill can produce a 10 "-deep hole.

2013

Effective Parameters For Improving Deep Hole Drilling Process By Conventional Method - A Review

L. Francis Xavier and D. Elangovan 


2008

Water-Cooled VW Performance Handbook: 3rd edition


Greg Raven, Chad Erickson

Motorbooks, 15-May-2011 - Transportation - 208 pages


Turn your VW into a high-performance machine. Chad Erickson explains everything from low-buck bolt-ons to CNC-machined mods. Learn how to choose, install, tune, and maintain performance equipment for Golfs, GTIs, Jettas, Passats, and more. This book will help improve your VW’s engine, transmission and clutch, ignition, carburetion/fuel injection, suspension and handling, brakes, body, and chassis. In its 3rd edition, Water-Cooled VW Performance Handbook is now updated to include new engines, body styles, and modifications for the 1986–2008 model years.

1999

Process for drilling oil-holes in crankshafts

Abstract

A process for drilling oil holes in a crankshaft at various positions lengthwise and widthwise about a longitudinal axis of the crankshaft, where the oil holes are perpendicular to and have angled directions with regards to the longitudinal axis. The process includes the sequential steps of placing the crankshaft in a horizontal position in a crankshaft holding unit and maintaining the crankshaft in a horizontal position through the drilling process. The holding unit is then rotated on a vertical axis until the crankshaft faces the drilling unit. The crankshaft is next rotated along the longitudinal axis of the crankshaft to position the crankshaft in a position for drilling a hole. The drill tool is then moved on a second and third axis until the drill tool is situated in order to drill the hole in the crankshaft.

Application US09/756,669 events 

1999-04-19

Priority to ES9900797

2002-11-26

Publication of US6485401B2

2019-07-23

Anticipated expiration

Status

Expired - Fee Related

https://patents.google.com/patent/US6485401B2/en


Updated 19 Feb 2021

Published on 15 Feb 2021



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Wednesday, February 17, 2021

Kubernetes - Cloud Computing - Cost Reduction and Cost Control

 

12 Feb 2021

Tame Kubernetes Costs with Percona Monitoring and Management and Prometheus Operator


More and more companies are adopting Kubernetes for cost benefit. But after some time they see an unexpected growth around cloud costs. Auto-scalers are set up, but the cloud bill is still growing.  Percona Monitoring and Management (PMM) can help you with monitoring Kubernetes and reducing the costs of the infrastructure.

https://www.percona.com/blog/2021/02/12/tame-kubernetes-costs-with-percona-monitoring-and-management-and-prometheus-operator











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