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FIGURE 24.2
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Drill bit geometry.
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The result of increasing the land mass and the web is a smaller flute area. Less flute space implies reduced amounts of available area to remove drilling debris, which again raises the drilling temperature. It is important to understand that some drill designs that are meant to increase strength (particularly in smaller-diameter drill bits, with the intent to reduce breakage) may include what are referred to as partial margin reliefs (see Fig. 24.3). What this means is that when the drill bit is viewed from the point, a relieved margin is seen. However, viewing
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FIGURE 24.3
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Drill tip attribute nomenclatures.
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this type of design drill bit from the side reveals that the relief extends only part of the way, typically about one-fifth of the total flute length The major drawback of this particular design is that it increases drilling temperatures (documented to be as much as 25 percent or more), resulting in increased heat-related drilled hole defects (such as smear) and drill breakage due to packed margins. 24.2.2.4 Flute Length. Minimum flute length must equal total drilled depth (total laminate thickness + entry thickness + backup penetration depth) plus at least 0.050 in of unused drill flute remaining above the stack at the bottom of the drill stroke to allow debris to be removed by the vacuum system. If debris cannot be removed from the drill flutes during and between drill strokes, the results are extensive hole quality defects and drill breakage. 24.2.2.5 New Drill Bits. It is not necessary to inspect incoming orders of drill bits 100 percent. A procedure proved to be effective is to inspect drill bits according to an acceptable quality level (AQL) method (such as MIL-STD-105). This type of sampling plan allows the user to determine the percentage of drill bits that are inspected to judge an entire lot of drill bits to a predetermined quality level. Using this method, finding a defined quantity of drill bits that do not meet the specification is cause to return all received drill bits to the vendor; if the selected quantity of inspected drill bits meets specification, the entire lot of drill bits is accepted. Inspection criteria might include point geometry defects (refer to Fig. 24.4), damage (chips), diameter (drill and shank), and flute length, as well as correct ring set distance and size imprint (matching both the actual diameter and that labeled on the box). 24.2.2.6 Repointed Drill Bits. Drill bits are typically repointed for reasons of economics. The cost of repointing a tool may be as low as 15 percent of the cost of a new tool. The number of times a drill is repointed varies anywhere from 1 to as many as 10 times or more and typically depends on the drill diameter. The smaller the drill, the fewer times it is normally repointed. The reason is that smaller-diameter holes are more critical and require better hole quality. There are two methods used to repoint tools. 1. The first is to specify a certain number of times the tool is to be repointed before being discarded. This number typically varies between one to three for smaller-diameter tools depending on hole quality experienced after repointing. 2. The second is to specify a minimum overall length of the tool at which it is discarded. Minimum overall length is determined by calculation based on minimum remaining flute length required to drill the required total drilling depth. This method does not allow determination of how many times a drill is actually repointed because stock removal during each regrind may vary from 0.002 to 0.005 in or more. Repointed drill bits cannot be expected to perform as well as new drill bits because only the points are refurbished to a quality that may be as good as a new drill bit while the rest of the drill bit, including the critical margin, is not. The condition of the margin is very important because it is the part of the drill bit that finishes the hole wall. A rough margin results in a rough hole wall surface. When inspecting repointed drill bits, examine the sides of the drills for margin damage and/or fused or packed drilling debris remaining from previous use. These drill bits contaminate holes from the very first one drilled and may cause run-out due to an imbalanced condition of the drill bit resulting from the buildup. Drill bits must be repointed to the same point geometry specifications as those that apply to new drill bits. Point inspection criteria, therefore, is the same for repointed drill bits as for new drill bits.
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