Hi and welcome to this knowledge session about solid round tools. This is a film in a series with application tips and strategies for solid round tools and today we will look at drilling with solid carbide drills. But as always, safety first. Safety is our top priority at Sandvik Coromant, so we kindly ask you to make sure you are in a safe place, know the safety routines in case of an emergency. My name is Antti Wikström, I work as a training specialist and with me I have Henrik. Hello, my name is Henrik Liliby and I am a solid round tools driver. And looking at drilling, we have three main designs for drills. We have the solid carbide drills, we have the exchangeable tip drills and we have indexable drills. And looking at how these drills position to each other, looking at diameters, we have solid drills from 0.3 mm in diameter up to 20 mm. The exchangeable tip drills are from 9.5 mm to 33 mm in diameter. And indexable drills from 12 to 84 mm in diameter. And as you see there is overlaps in some of the diameters. For instance diameter 14 where we have all three drill types available. But looking at the reach or the length of the drill, it also differs a bit between the types. Indexable drills reach up to 7 times the diameter in length. Exchangable tip drills up to 12 times the diameter in length. And solid carbide drills all the way up to 30 times the diameter in length. This all depends a bit on what diameter you are at and what product family you are in. But a rough picture there. Also on tolerances we have differences between the three types of drills. Indexable drills possible to reach approximately H12, H13 in hole tolerances. Whereas exchangeable tip drills can reach H9, H10. And solid carbide drills you can expect to reach H8, H9 in tolerance. Looking a bit closer at the positioning for solid carbide drills. We have two main areas. We have the versatile area with the core drill 460 XM. And we have the optimized area with the core drill 430 for cast iron and non-ferrous metals. And the versatile, the core drill 460 XM allows for more instability and a wide application in different materials. You will not be able to cover every alloy within the material groups but you have a broad coverage. So if you have the other materials you can go to the core drill 460 XM, H6, H6, H6, Gm, if you have slightly better stability you can go with this one and cover most materials. But then if you are working in one specific material for instance and would like to optimize for that you have different options in the dedicated geometries and grades. So looking at H60GM, can you tell us a bit more about that and what is it that makes it special and what's it all about? Yes, as Antti mentioned, H60 is part of our optimized assortment but still it's versatile in its application area in which material we can cover with them. So we will go through the H60GM a bit more now in this session and this is our newest solid drill at Sandwich Cormant. Right. First of all in the H60GM we have a completely new grade and the grade is a combination between the carbide substrate and also which kind of coating but also what kind of edge preparation and everything. Which you will see in the next picture we have the coating only on the tip but the flute itself is polished so we have many benefits of that. The ship flute is designed in a different way that we have compared to other drills. It's actually a smaller volume and this is to have a more secure ship evacuation. Within drilling compared to turning, milling, ship evacuation, ship control is crucial because the cutting edge is going into the material and we need to evacuate the ships in a secure way. It sounds a bit contradictory that we have a smaller ship flute and get better ship evacuation. How does that come together? The effect we have of this together with the polishing and the design in the ship flute, the ship will not so to say compete with each other. Right. They are lined up in a good way so we have a secure ship evacuation. And another benefit with the smaller ship flute volume is that we also have a better strength in the drill. It's more rigid since we have more carbide left in the drill then. Right. And but as you can see also the tip itself is coated then. Yeah. And that's because that's where we have the wear. Yeah. Basically that is a cutting zone. Yeah. Yeah. We also have some other features in this drill which we don't have a standard in other drills. One of them is the corner chamfer. The corner on the drill is the area where we have the 100 percent cutting speed and also the highest temperature. So we protect the corner with this corner chamfer. The chamfer also gives us a better hole quality when it comes to through holes and we have maybe materials which are difficult to have with the bursts at the exit which this corner chamfer avoids in a good way. Of course depending on what kind of material. Right. Another benefit we have is also the double margin. Double margin is something that we have benefit of with if we have an inclined exit or we have cross holes that will give the drill a better balance and better control when we have hole configuration such as that. Right. Another feature which is very important in drilling is the center and the chisel edge. Within solid drills it's really important that we have a balanced drill entry. And this comes from of course less the smallest possible run out on the drill but also how the tip geometry is designed. And with this kind of geometry we have a very distinct chisel edge which helps the drill entry to be balanced. Right. Also the clearance side on the drill which you can see to the right also have a different kind of geometry but also the surface quality is improved so we have less cutting forces due to that. Another feature on the margins is something that you might not see with your eyes. It is an extra protection chamfer on the margin which this is an area where it can easily be a located area for wear or maybe shipping. This is sharp corner there but we have protected that with an extra chamfer. As we mentioned about the edge preparation this is also something that is really important for all cutting tools to have a secure and very high quality edge line. That is what gives the predictable tool life. And also in solid carbide tools when you have grinding we can remove any micro defect that comes from the grinding maybe. So that is also something that is improved in this new H60 EGM. And reinforcing the margins like this actually helps both stability and whole quality. Yes. A predictable tool life. Looking at industry segment and material as we mentioned this is a drill where we cover most materials. We shouldn't say all materials but the main materials within P, M and K. But we also see a good function in hardened steel in aluminum for example. And of course depending on components in these industrial segments we cover most of them of course. Right. And looking at the drilling applications also here we cover many of them but when it comes to inclined entry cross holes we of course have the benefit of the double margins. Also if you have like the convex concave surfaces also helps with the drill entry in the tip design as we saw. And also the double margins will help us here. And you see the also the chamfer step and chamfer we have an assortment at standard where we can cover these holes. But also in tailor made we have more flexibility to design whatever the step and chamfer configuration is. Yeah. And the assortment as Henrik mentioned we have the single diameters and we have the step and chamfer. For the single diameters we have three to eight times the diameter in length. It's 438 articles in standard assortment. Diameter between three and sixteen millimeters in diameter and both for external and internal coolant. For the step and chamfer we have the three times diameter in length. It's 26 standard items and it's between three and fourteen millimeters in diameter both for internal and external coolant. But as you mentioned we have the tailor made as well. Yeah. And there you can define any specific diameter you need or any specific lengths you need. Yeah. And you also have that on the web. Yeah. So if you have a login and username in our website you can design the drill by yourself and a CAD drawing, DXF file, price delivery time in a couple of minutes depending on type of drill. And you can start from a standard drill and modify that or you can start from scratch. Yeah. Yeah. Full freedom. Yeah. Looking at a bit of cases and what you can expect from the 860GM. Here is a case in stainless steel. It's in 360L against the competitor. And as you can see we ran the same data as the competitor drill. And even with the exact same data not optimizing for the 860GM we reached a plus 100% tool life. Different case here in cast iron. It's a 21 millimeter through hole at 6.6 millimeter in diameter. And here we actually increased the cutting data a lot. We increased both the cutting speed and the penetration rate. And besides reaching a much greater tool life we also then improved productivity. And by that we could reduce cost per part by a lot. Very good. We can also see how that we had the performance also after reconditioning. Yeah exactly. And here we also managed to remove the pecking cycle. So instead of having 5 millimeter pecks we could do this the hole straight away. So. And yet a different case. Here it's a 40 millimeter drilling depth and it's a 9 millimeter in diameter. In this case we actually lowered the cutting speed from 56 meters per minute to 50. But we compensated that by increasing the penetration rate and the feed per revolution. And with that we could improve the tool life by 167%. Also here we could remove the pecking. And then perhaps we should look at the 860SM. Yeah. Just a few words on that one. This is also one of the newest drill in the optimized family. We can see here that the naming is SM which stands for ISO-S. So this is an optimized drill for ISO-S materials, both titanium and nickel alloys. Yep. Yep. This is a drill that is replacing or have replaced the 846 which were our previous drill for this. So this is like an optimized, refined, more performance, new grades compared to that one. So it's a new drill for those kind of materials. Right. Right. But what we also would like to mention here is that many tools have secondary areas where they perform really well. But it can be a bit maybe tough to find recommendations or find it on the website or a catalog. But we would like to take the opportunity to mention that the 860SM is also a really good drill for hardened steel. And that comes from the rarest resistance grade and also this strong geometry which we can see here in the picture. We have convex cutting edges and with that we protect the corner and it's a really strong design. That is why we can drill up to 63 Rockwell with a good function. Maybe not the most common drilling application but sometimes you need it. And it can be good to know that we have a really good product for this. Start value is around 35-40 meters in cutting speed and the feed is one hundredths of a millimeter per diameter. So diameter 8 for example, 0.8 in feed as a start value. And in most cases it works really good. Really good. Right. And talking about secondary application areas for stainless steel for instance, duplex stainless. Would the SM be a choice also there if the MM is not working? Yeah, it can be. Of course the MM is the first choice but sometimes stainless steel can have variation within the spec and it's tough to machine. So the SM is of course an alternative also in stainless steel. Right. So it can be a good choice. And looking at the assortment, we have a single diameter in the standard assortment here. It's length between two to five times the diameter in length and it's three to sixty millimeters in diameter. And here we only have an assortment for internal coolant. And why is that? This kind of materials you need to have coolant of course. So we haven't any options with the external. No. Will not work any good. Will not work anyway. No. But you also have the tailor-made option here. And S with 860 GM you can there define any specific lengths or diameters you would need. You should also advertise a bit on CurvePlus tool guide where you can find good starting recommendations for all your drilling. Now we will have a quick look at some troubleshooting and optimization. And talking about troubleshooting, we have to read the wear. Wear is always present on our cutting tools. But there are different types of wears. And different remedies for different types of wears. If the drill looks like this, if it's either broken or if it has a cutting edge as in the right of the picture, it's gone far too far to be able to determine what cause the wear. Anything could actually cause this. And anything would eventually lead to a breakage. So if you end up in this situation, you have to back it up a bit, trace it back, and find out what was the cause of the wear you ended up with like this. So what can we say about wear? Yes, as all cutting tools you would like, you prefer one type of wear, flankwear. Yeah. That is a control wear and you can easily measure it and you can like adjust your cutting data to have the preferable wear. So but within drilling it's a bit different if you compare how to adjust cutting data to get to the preferred wear. So we will go through this, why it is a different thing compared to other tools and what if you have a certain problem, what can you do to solve it? Right. So if we are having flankwear but we are not really satisfied with the tool life, what can we do? Well, sometimes you need to accept that the tool life isn't longer what it is, depending on material. Some materials are difficult to machine. But usually if you have a flankwear that comes too quickly and it is on the periphery, the diameter, more flankwear in that area, then it is probably too high cutting speed. If it is in the center, then the feed is probably too high. So you should try to adjust the cutting data so the flankwear is nice and even, from the outer diameter into the periphery. Then you have a good balance between cutting speed and feed. Looking at the size, a rule of thumb is 4% of the diameter. Then it is time to replace the dill, send it for reconditioning. So that is a good indicator that drill is worn out. Yeah. And what happens then if you run it too long? Drill breakage. The cutting forces will go up in the roof and you will have a drill breakage. Yeah. Or you can also affect the hole quality when you maybe should tap the hole afterwards. You can have problems in tapping which are caused by the drilling. Yeah. And then chisel wear. What can we do about that? Many problems within drilling starts with maybe a too high run out. A solid drill is really crucial when you do the drill entry with the chisel that the drill is balanced. If you have some kind of run out or unbalanced then you will affect the chisel and you can have shipping. It can also be too high feed. You have too much feed rate which affects the center. And I would say the main things are either run out, some instability or too high feed. Right. And talking about chipping, what can we do about chipping? Again, as always within drilling, I can't say that too many times, check the run out. Is there anything that is also here? Something is unstable, not in balance, then you will of course get shipping. And it can be unbalanced or instability both in component and in tools setup? Yeah, it can be fixture tooling, component, anything around that. It can also be that the shipping comes from built up edge. Built up edge can come and go, come and go and when it gets loose from the carbide, the tool, and then it can take some carbide with it. Right. And that can be the root cause for shipping. Maybe not instability, it can be also built up edge. Okay. And drill breakage? Yep. What can we say about drill breakage? If you come into drill breakage, then as you mentioned before, you need to start look early. Follow the wear. What is it? Is it chipping? Is it built up edge? Is it whatever it is, but you need to start more look more frequently and look early. If you come to drill breakage, then you have waited too long to follow the wear. You mentioned built up edge and that it can cause chipping. But what can we do about the built up edge then? Well, we can do many things and within drilling, it is depending on where it sits on the drill. Is it at the periphery or is it in the center? And again, sometimes you just need to accept this material will give you a built up edge. Then you need to place the built up edge with the help of cutting data in the best area, so to say. Yeah. So, but it's depending on where it sits, how to adjust. Right. And normally with turning or milling, you would increase the speed to get out of the built up edge. Yep. Because with increased heat, you can get away from the built up edge area. But if we do that in drilling. Yep. If we would increase the cutting speed when the built up edge are on the corners in the periphery, what will happen then is that we will just move the built up edge closer to the center. Because if we have here 100 in cutting speed on the diameter, and that is a built up area in that zone. If we then increase to 120, well then 100 is closer to the center. So we will just move the built up edge. Right. Right. The solution here, if it sits on the corners, is to lower the cutting speed. Then the built up area comes outside of the drilling diameter. Right. Right. But of course, if we have built up edge closer to the center, then you can increase cutting speed to get it out outside the drill diameter. But as we mentioned, sometimes it can be really tough to remove it and then try to adjust the speed cutting data. So we place it in the middle of the main cutting edge. That is where the drills are strongest and you don't want to have it in the corners. There we have 100% cutting speed, heat, highest temperature. We don't want to have the built up edge in the center. You know, we need to drill entry, balance. We don't want to have a clean edge there. So if it's this kind of material, try to put it in the center of the cutting edge. Yeah. And as always, monitor the coolant flow and the coolant pressure. Of course. Everything around. You need to take away the run out and everything first. Then you can trim the cutting data. Yeah. And talking about ship evacuation. Besides run out, what we talked about, as we mentioned in drilling, the ship evacuation is crucial. So this is something that you need to also pay attention to, of course. Both look at the chips, clean the machine, wash away the coolant and other ships. Take the ships, have a look at them. Are they in the right shape? Are they in the right size? Also, ships, if they are wrong, you can also hear on the sound. If there is a good sound, then you know it is a good ship evacuation. If you have like a bad sound, then you can suspect that the ships are in a wrong shape or size and you have difficulties with the ship evacuation. And there are certain ways also to adjust to if they are too hard broken or curled or of they are long. You have certain things to adjust to cutting data to solve that. Yeah. And both if they are over broken or if they are too long, it might affect ship evacuation and whole quality. Yes, really important. One other thing besides the normal drill ships, you can also check the start ship. This is something that you can be mistaken that this ship that comes from the drilling operation, which can cause problems. But the the starting ships, which look like on the on the picture right now, they will always occur. You can't remove them and they almost never cause any problems. But by looking at the start ship, you can see something. If you have the needles with the the picture showing, then you can say you have something that is not balanced. Either run out a component that is unstable, fixturing, or maybe the surface where the drill entry is, it's not maybe not machined. So something is not in balance, then you will have these needles. So this is something that you would not like to see. No, but but looking at it, you can see if they set up and everything is okay. But you might need a microscope to see this clearly. And then if you look at the other ships, drill ships, so to say, this is from a case where the the surface finish in the hole wasn't like visually perfect. The surface finish value when we measured it was okay. Yeah, but this was like a gray surface, which was not acceptable. But then we looked at the ship in the Microsoft and we saw that it was like scratch marks. So in this case, we had to high feed. The sound was good, but the the size of the ship was too big. So it is like metal to metal in the ship evacuation and it scratches the hole and the wall in the hole. So what we did lower the field a bit, increase the cutting speed. So we remain with the with the penetration rate. And then the surface finish was okay. And that was the end of today's session. So we would like to thank you for taking time. And if you're interested in more application tips on solid round tools, keep an eye open for next session. If you would like to more information on what we talked about today, about solid carbide drilling, or if you would like to us to contact you, either follow the link by the QR code or by the web address on the screen. Thank you.