HEATEXCHANGERS
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I N D U ST RY SO LUT I O N - HE AT EXCHA NG ERS

2Heat Exchangers play an importantrole in moving heat from one
medium to another and are used
in a wide variety of industry
segments.
Tungaloy has the knowledge andskill to provide solutions for Heat
Exchangers in the Oil and Gas,
Nuclear Energy, Power Generation,
Water Waste Treatment, andAerospace industries.
Heat Exchanger producers insuch business segments enjoy thebeneﬁt of creating reliable productswith Tungaloy’s innovative toolgeometries and grades for theirdrilling, turning, milling, and grooving operations.
Plate Heat Exchangers and Shell
and Tube Heat Exchangers are
the major types; this brochure will
focus on the Shell and Tube Heat
Exchangers as they are known tobe more versatile than the Platetype.

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I N D U ST RY SO LUT I O N - HE AT EXCHA NG ERS

4

tube sheets
Drillmeister
the ultimate drilling solution

ba f f l e pl ates
connections
internal grooving & CHAMFERING
SUCCESS STORIES

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I N D U ST RY SO LUT I O N - HE AT EXCHA NG ERSTUBESHEETs
Large inserts with CNMG/M or SNMG
geometries and 19/25 sizes arecommonly used for turning operations
on tube sheets, and excellent chip
control is required to handle ﬂuctuations
in D.O.C. Grades with high chipping
resistance are greatly recommended toassure productive machining processes
and to avoid sudden fractures.

Stainless
Steel

Nearly unbreakable CVD series for improved
machining efficiency

APPLICATION AREA
400

t9205

200t9215
t9225
t9235

0Continuous

6SteelCVD grades with outstanding
productivity especially for steel
turning

Cutting speed Vc (m / min)T U RNIN Gt9200

LightInterrupted

Heavy
Interrupted

t6200ah6200

Stainless
Steel

Highly reliable CVD & PVD
grades for stainless steel
turning

ah8000

PVD grades for heat-resistantalloysComplete grade line up for stainless steel turning

Incredible reliability in turning of heat-resistantalloy due to Nano-multi-layered AlTiN coatingwith high Al content

APPLICATION AREA

APPLICATION AREA
120

t6215
150

ah6225
ah6230

0Continuous

LightInterrupted

Heavy
Interrupted

Cutting speed Vc (m / min)300

Cutting speed Vc (m / min)Superalloys

ah800560

ah80150

Continuous

LightInterrupted

Heavy
Interrupted

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I N D U ST RY SO LUT I O N - HE AT EXCHA NG ERSTUBESHEETsDRILLIN G
Single tube sheet contains hundreds
and thousands of holes, which makes
high productivity, long tool life, and highrepeatability mandatory in machining
operations.

Improves productivity andreliability in heavy drilling withunique drill head and clamping
concept

SMP

8

Exchangeable head drills forunparalleled tool life andmachining performance

DMPDMCDMHTIDCF chamfer adaptor to performchamfering operations and drilling in
one shot
Chamfer inserts with 30o, 45o and
60o can be mounted in the same
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I N D U ST RY SO LUT I O N - HE AT EXCHA NG ERS

the ultimate
solution fordrilling tube
sheets andbaffle plates
Exchangeable head drill
system for superior drilling
performance and long tool life
Tool inventory and management costs are signiﬁcantly
reduced as there is no need for regrinding.
Drill bodies are offered in a wide range of sizes and styles,
allowing optimal tool assembly for secure and productive
drilling.
Drill bodies:
TID-F, Flange type:
Available in 1.5×D, 3×D, 5×D, and 8×D
TID-R, Cylindrical shank type:
Available in 3.5×D, 6×D, 8×D, and 12×D
TID-C:
Available in 3×D and 5×D suitable for use with TIDCF chamfer holders.
TIDCF chamfer holder: Available with 3 types of inserts inchamfering angles of 30°, 45°, and 60°

10A wide product lineup tocover all of your drillingneeds
Each drill body capable ofworking with 10 different
drill head sizes

DMPDMC

Drill dia.:ø4 - ø25.9 mm

Drill dia.:ø4 - ø25.9 mm(ø.157" - ø1.02")(ø.157" - ø1.02")

General purpose drillinghead ideal for various drilling
applications

High precision drilling headwith double-margined drill
periphery and self-centeringchisel edge

DMH
Drill dia.:ø6 - ø25.5 mm(ø.236" - ø1.004")
General purpose head withenhanced cutting edge

DMF
Drill dia.:ø6 - ø25.9 m(ø.236" - ø1.02")
180° flat edges forcounterboring and flatbottoms

MarginHelicalpolished
flute design
Frontal coolant hole close to
the cutting edge for increased
tool life
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I N D U ST RY SO LUT I O N - HE AT EXCHA NG ERS

clad material
Drilling procedures for tube sheets and stacked baffle plates
made of clad materials (L/D>5)
Step 1: Drilling a pre-hole
Drill body: DrillMeister 1.5xD
Drill head: DMP/DMC
Drill head diameter:19.3 mm (.760")
25.7 mm (1.012")
The pre-hole should penetrate into
the second material by 1mm (.04")
Parameters to suit Clad material

Step 2: Drilling through hole
Drill body: DrillMeister 5xD, 8xD,12xD
Drill head: DMP/DMC
Drill head diameter:19.27 mm (.759")
25.67 mm (1.011")
Drilling Procedure:- Rotate the drill at 100RPM to enter
the pre-drilled pilot hole
- Increase RPM to 100%, about2mm (.08") above the bottom of thepilot hole
- Apply 80% feed to start drilling into
the material for 2mm (.08") depth- Finish drilling with 100% feed until
the drill head passes through thework-piece by 2 mm (.08")

12

Clad material
ExoticLow
CarbonSteel
AISI/SAE 266 orAISI/SAE A516 Gr.70

ExoticLow
CarbonSteel
AISI/SAE 266 orAISI/SAE A516 Gr.70

non-clad material
Drilling procedures for uniform tube sheets and stacked
baffle plates (L/D>5)
Step 1: Drilling a pre-hole
Drill body: DrillMeister 1.5xD
Drill head: DMP/DMC
Drill head diameter:19.27 mm (.759")
25.67 mm (1.011")
Pre hole depth: 6mm (.024")

Step 2: Drilling through hole
Drill body: DrillMeister 5xD, 8xD,12xD
Drill head: DMP/DMC
Drill head diameter:19.27 mm (.759")
25.67 mm (1.011")
Drilling Procedure:- Rotate the drill at 100RPM to enter
the pre-drilled pilot hole- Increase RPM to 100%, about
2mm (.08") above the bottom of thepilot hole
- Apply 80% feed to start drilling into
the material for 2mm (.08") depth

Low
CarbonSteelAISI/SAE 266 or
AISI/SAE A516 Gr.70

Low
CarbonSteel
AISI/SAE 266 or
AISI/SAE A516 Gr.70- Finish drilling with 100% feed until
the drill head passes through thework-piece by 2 mm (.08")

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I N D U ST RY SO LUT I O N - HE AT EXCHA NG ERSTUBESHEETs
DEEP D RILLIN G
The hole-making process of tube
sheets can be performed with 3 typesof tools: indexable gundrills, indexable
BTA tools, and brazed BTA tools.
Each type has its own advantages, andTungaloy offers machining solutions
with all 3 types of tools to meet theneeds of each customer.

14

Wide range of chipbreakers andgrades for maximum
machining efficiency with thehighest accuracy

BTA heads with indexable
inserts and guide pads

FBM/FBH

Indexable gun drill with exceptional efficiency

TOHT

LOGT

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I N D U ST RY SO LUT I O N - HE AT EXCHA NG ERSbaffle
pl ates
DRILLIN G
Drilling baffle plates involves complex
machining operations. To maximize
productivity, several baffle plates areusually stacked together to be drilled in
one shot; tools with excellent chip control
and low cutting forces are required to drill
in and out of several material layers inthe same operation.
Tungaloy’s DrillMeister andDrillForceMeister series overcome
these challenges and maximize
productivity as well as efficiency evenin such demanding processes.

16

Exchangeable head drills forunparalleled tool life andmachining performance

DMPDMCDMHDMF

Improves productivity andreliability in heavy drilling withunique drill head and clamping
concept

SMP

SMF

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I N D U ST RY SO LUT I O N - HE AT EXCHA NG ERSCONNECTIONSDRILLIN G & Mi l l i n g
Machining connection parts requires
low cutting forces for both hole-making
and milling operations.
Tungaloy’s TungSix-Drill series offers
6 cutting edges per insert and helps
customers reduce not only cutting
forces but also tooling costs in theirdrilling processes.
Tungaloy’s DrillForce-Meister is also
an excellent tool for producing connection parts as it excels in maximizing
productivity for heavy drilling operations.

18For roughing face milling operations,
MillQuadFeed cutters are ideal dueto their tough cutting edges and ability
to change entry angles on workpiecematerials.
For ﬁnishing operations, TungEight-Mill
series offers economical and efficientsolution with 8 cutting edges on aninsert.

Indexable drill with economical 6
cutting edged insert

DJDS

Improves productivity andreliability in heavy drilling withunique drill head and clamping
conceptSMF

SMP

A new generation of versatile,
high-feed milling cutter

SWMT

Face milling cutter with economical
8-edged inserts that reduce cutting
forcesOWMT
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I N D U ST RY SO LUT I O N - HE AT EXCHA NG ERSINTERNALGROOVING &chamfering
Tungaloy’s TungMeister series provides
an efficient solution for machining innergrooves used for ﬁtting pipes in tube
sheets and baffle plates.

The special TungMeister headcapable of creating two grooves in
one shot, which improves efficiency
and productivity of the machining
process20

For internal slitting of small grooves.
Unique chatter free design for improved
material removal rate and low vibration.

Endmill with exchangeablechamfering heads for reduced
tool replacement time andimproved productivity

VCWVDS

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I N D U ST RY SO LUT I O N - HE AT EXCHA NG ERS

successstories+75% better tool life and +90% better productivity have been achieved against the existing exchangeable
drill due to combination of self-centering geometry and AH9130 grade.
Baffle platePart:
AISI/SAE A516 .70
Material:
Through - Horizontal M/C BT50
Operation:TID190F25-5
Drill Body:
DMC1927
Drill Head:
19.27 mm (.759")
Diameter:
38.1 mm (1.500")
Depth:
AH9130
Grade:
Cutting Conditions:
Vc = 120 m/min (394 sfm)
Vf = 595 mm/min (23.4 ipm)
f = 0.3 mm/rev (.012 ipr)

+150% better tool life has been achieved against existing exchangeable drill due to high wear resistant grade
AH9130.
Baffle platePart:
SUS304 (X5CrNi18-10)
Material:
Through - Horizontal MC BT40
Operation:
TID125F16-5
Drill Body:
DMP128Drill Head:
12.8 mm (.504")
Diameter:
52 mm (2.05")
Depth:
AH9130
Grade:
Cutting Conditions:
Vc = 50 m/min (164 sfm)
Vf = 186.6 mm/min (7.35 ipm)
f = 0.15 mm/rev (.006 ipr)22

+33% better tool life and +38% better productivity have been achieved against the existing exchangeable
drill due to combination of self-centering geometry and AH9130 grade.
Tube sheet
Part:
AISI/SAE A516 .70
Material:
Through - MC BT50
Operation:
TID250F32-5
Drill Body:
DMC2567
Drill Head:
25.67 mm (1.011")
Diameter:
101.6 mm (4")
Depth:
AH9130
Grade:
Cutting Conditions:
Vc = 115.2 m/min (378 sfm)
Vf = 428.8 mm/min (16.8 ipm)
f = 0.3 mm/rev (.012 ipr)

+300% better productivity has been achieved against the existing brazed carbide gundrill with Tungaloy’s
indexable gun drill.
Tube sheet
Part:
AISI/SAE A516 .70
Material:
Through hole - BTA machine
Operation:
TRLG22.45X800-A62X
Drill Body:
TOHT110405-NDJ
Drill Head:
22.45 mm (.884")
Diameter:
200 mm (7.874")
Depth:
AH9130
Grade:
Cutting Conditions:
Vc = 90 m/min (295 sfm)
Vf = 102 mm/min (4.02 ipm)
f = 0.08 mm/rev (.003 ipr)

+30% better productivity has been achieved against the existing brazed carbide gundrill.
Tube sheet
Part:
SA508 Gr.3 Cl.2 + Inconel 690
Material:
Through hole - BTA machine
Operation:
Brazed Drill
BTU-002BA 19.28 1132
Head:
19.27 mm (.759")
Diameter:
300 mm (11.81")
Depth:
1132
Grade:
Cutting Conditions:
Vc = 50 m/min (164 sfm)
Vf = 33.03 mm/min (1.3 ipm)
f = 0.04 mm/rev (.002 ipr)

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