Formdrill Process Uses Friction Heat To Drill

The Formdrill process uses a special carbide tip to drill through thin materials such as sheet metal using friction, removing the need for nuts and bosses. The Formdrill process involves a carbide conical tip (Formdrill) that heats up the material by friction into a super-plastic state, enabling the Formdrill to push through and form the hole and displace the material into a bushing that generally triples the material thickness.

This additional wall surface is then threaded, eliminating the need for welded nuts, bosses or inserts. This bushing is also used as support for brazing or as a bearing wall in rotating shaft applications. It can be used on most drill presses, milling machines or CNC systems. The only parts required are a tool holder, a collet and the Formdrill. Each Formdrill will perform from 8,000 to 10,000 cycles in mild steel, a little less in stainless steel, and more in aluminum and copper.

This process is claimed to have the ability to reduce costs from 50 per cent to 90 per cent when compared to conventional methods. The savings come from the fact that overall cycle times are reduced and consumable costs are almost eliminated. There is virtually no post-process cleanup. The joints created are said to have exceptional torque and pull-out strength values that equal or excel the welded nut equivalents.

Autodrill Develops Structural Steel Drill

Autodrill has designed a drill that uses annular cutters and a positive plug ejection system for structural steel operations. By automating the stroke and retract sequences, the operator of the equipment is kept at a safe distance from the machine and any debris created during the process.

Environmentally safe cutting fluids and materials can be incorporated into the process for drilling holes in beams, channel, tube and most other flat- or curved-surface structural products. The units are also capable of drilling in aluminium, stainless steel, plastics and other materials. All the equipment is rated for continuous duty production work.

Hardcore Drill Boosts Output At Young Touchstone

Stellram has developed a drilling tool design, which has boosted productivity and has reduced costs at Young Touchstone, a manufacturer of industrial heat exchangers. Stellram Hardcore technology has transformed a machining operation at the company's plant in Tennessee, US, by doubling the average number of holes achieved per drill and delivering a 59 per cent saving on tool costs.

Young Touchstone, part of Wabtec Corporation, turned to Stellram for help on its project, which involved drilling approximately 1,000 holes, 13mm x 16mm deep, in 1,018 CR steel plates used for a variety of cooling applications. Patrick Cann, ATI Stellram's solid carbide specialist, said: 'The challenge was to identify areas for improvement that would help increase productivity and decrease tool costs.

'Under the existing operation, the drill cost per hole was high and tool life varied greatly. 'The Stellram product development team recommended the use of Hardcore technology drills as part of a series of changes designed to further improve the control of cutting conditions and tool life. 'A feed and speed was established that not only gave the required production rate, but also longer tool life.

'As the tool life was substantially increased, the average holes per drill increased from 15,000 to 30,000 and, as a consequence, the cost per hole was also reduced, achieving a saving of 59 per cent compared to the previous method,' he added.

Chad Copeland, ATI Stellram's sales engineer, said that the patented Hardcore technology combines two optimum grades of carbide in one tool, removing the problems usually associated with switching between tools with different carbide grades. He said: 'This new technology helps extend tool life, eliminate chipping and resolve durability or production speed issues.

'While one of the carbide grades is designed to withstand the high speed of the tool's outer diameter, the robust characteristics of the other grade easily handle the slow speed of the tool centre,' added Copeland. Hardcore drills are available in sizes ranging from 3mm to 16mm in diameter and capacities up to five times the diameter.