Even in deep drilling with single-lip drills, both when boring and drilling, the trend is moving towards tools with indexable inserts. The range of advantages is vast compared to soldered tools, with improvements in bore quality and performance being particularly noticeable.
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For holes with depths starting at about 20 x D, single-lip drills are clearly superior to other drilling tools. The gradients are lower, the surfaces of significantly better quality. These are important reasons why this type of tool is often used for applications with less deep bores, but the highest quality requirements. Experts refer to this as “precision drilling.” The quality can be increased even further if single-lip drills with indexable inserts are used. This fact often remains unknown because indexable inserts are not nearly as common in deep drilling as, for example, in milling, turning or short-hole drilling.
“Single-lip drills with indexable inserts have both performance and quality benefits,” says Dr. Thomas Bruchhaus, tool expert at TBT Tiefbohrtechnik in Dettingen/Erms. “If only one of these aspects is important to the user, we recommend indexable inserts with single-lip drills. And this is happening more and more often, because the cost pressure and the demands on the quality of the cutters are constantly increasing.”
While the quality of the bore is of less importance than machining time for cooling or lubricating bores in the field of mould-making or the automotive industry, the plastics industry, for example, attaches great importance to extremely smooth surfaces. Both requirements can be fulfilled very well by the insert-type single-lip drill.
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As a full-service provider for deep drilling, TBT has continued to expand its tool range in recent years. Single-lip drills with indexable inserts for full boring are currently available from a diameter of 12 mm. With small diameters, there is no space to clamp the indexable inserts and guide strips; as such, these are still manufactured exclusively with soldered cutting edges. Drilling with single-lip drills is a less common type of machining; the tools are almost always made by TBT according to customer requirements.
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Indexable inserts are an important component of indexable tools, providing multiple cutting edges that can be easily replaced or repositioned. Compared to welded and integral tools, indexable tools offer significant advantages. In this article, we will delve into the concept of indexable tools, explore their characteristics and highlight their advantages over welded tools.
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Basic concepts of indexable tools:
An indexable tool is a tool that uses mechanical clamping to securely clamp a pre-machined polygonal insert with multiple cutting edges to the tool body. When one cutting edge becomes dull during use, the clamping is released, allowing the insert to be indexed or replaced. By positioning the new cutting edge in the working position, the tool can continue to be used after re-clamping.
Features of indexable tools:
Compared to welded and integral tools, indexable tools have two main features:
a) Multiple cutting edges: The insert mounted on the tool body has at least two pre-machined cutting edges available for use. This feature allows efficient use of the tool, as when one cutting edge becomes dull, it can be indexed or replaced while maintaining the same geometrical parameters.
b) Fixed cutting edge position: The position of the cutting edge on the tool body remains constant after indexing of the insert. This stability ensures consistent cutting performance and eliminates the need for readjustment, saving time for tool changes and increasing machine availability.
Advantages of indexable inserts over welded tools:
Indexable inserts offer several distinct advantages over welded tools:
a) Enhanced cutting performance: Indexable inserts provide better cutting performance as a separate functional element. Thanks to the variety of insert materials available, the optimum selection can be made depending on the material being machined, maximising cutting efficiency.
b) Process flexibility: The mechanical clamping of indexable inserts eliminates the limitations of the welding process. This makes it possible to utilise inserts made from different materials, further improving cutting performance and efficiency.
c) Time savings: The fixed spatial position of the cutting edge relative to the tool body eliminates the need for time-consuming adjustments to the tool during insert indexing. This results in a reduction in auxiliary time and an increase in overall productivity.
d) Cost-effectiveness: Indexable tools are economically efficient due to their high cutting efficiency and reduced auxiliary time. The reusability of the tool body keeps steel and manufacturing costs to a minimum. In addition, the specialisation and standardised production of indexable tools drives the entire manufacturing process of cutting tools.
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