Drill with coolant channels and method for its manufacture

Abstract: A spiral drill and a method to manufacture a spiral drill with two indexable inserts and two coolant channels (23, 24) wherein the coolant channels located in the holding shank part extend either parallel to the center line at different distances from said center line, or extend conically in relation to said center line, where the middle portion has been twisted while in heated condition to form spirally curved coolant channels (17, 18) and where the exit channels at the tip have been drilled after twisting, and where the exit openings (21,22) are located at different distances from the center line.

Description: The present invention relates to a spiral drill with indexable inserts comprising a holding shank, a nose portion with insert pockets for the receipt of a central insert and a peripheral insert and a spiral part which comprises two spirally curved ribs with a coolant channel provided into each such rib. The invention relates also to a method for manufacture of drills according to the precharacterising part of claim 6. A basically similar method is known from WO-A-9413422 representing the closest prior art. In spiral drills it is possible to supply liquid through coolant channels to openings near the cutting edges, which facilitates chip formation and lowers friction in the flutes. In order not to lower the torsion stiffness and give an undesirable coupling between axial force and torsion angle, the drill can often be made with two spiral coolant channels as shown in the patents SE 335 111 and EP-A-118 035, located between the flutes in the ribs where they are least detrimental to the strength. Those patents also show how a drill can be made from a such a spiral part joined to a separately made shank part with different location of coolant channels. It is also known through patent SE 194 706 to make drills with indexable carbide inserts in pockets on a steel body, where it has been made possible to utilize a limited number of insert sizes for a large number of drill diameters by using two or more unsymmetrically located indexable inserts, one of which is a center insert close to the center line of the drill and one of which is a peripheral insert close to the periphery of the drill. According to the invention there is provided a spiral drill and a method for manufacturing such a drill as defined in claim 1 and claim 6 respectively. According to the invention straight coolant channels are drilled in a cylindrical drill blank from the shank part but not through to the tip end such that said channels are located at different distances from the centre of said blank. The blank is then locally heated and twisted a predetermined angle. After twisting, the flutes, the insert pockets, the cutting tip and straight exit portions are machined, said exit portions being provided to meet the coolant channels whereby at least one of the exit portions of the cooling channels is drilled as a conical channel. During this machining the cooling channels in the shank part are used as angle reference. This makes it possible to locate the exit openings at optimal positions relative to the insert pockets without regard to the spiral channel location in the cross-section. In accordance with one embodiment of the invention the cooling channels are drilled mutually parallel but located at different distances from the central line in the cylindrical drill blank that is subjected to twisting whilst heated at a predetermined angle. In accordance with an alternative embodiment the cooling channels are drilled at an oblique angle in relation to the central axis of the drill blank such that they terminate at different distances from the central axis at their exit openings. The insert pockets are unsymmetrically located, one near the center and one near the periphery. In order to achieve the best effect of the coolant, the exit openings should be located at same position as the following insert and thus one exit opening should be located closer to the center and one closer to the periphery, which is accomplished by drilling the exit channels in connection with the machining of the insert pockets. The invention is described in detail with reference to the figures; where figure 1 shows a drill according to the invention; figure 2 a cross-section of the drill; figure 3 a drill blank prepared for twisting; and figure 4 a drill blank, before twisting, according to an alternative embodiment of the invention. A drill according to the invention comprises a shank part (15), a spiral part with two ribs (11, 12) separated by two flutes (29, 30) and a tip where one center insert (13) and one peripheral insert (14) are fastened with screws to pockets machined at the ends of the ribs (11,12). To give the drill a well defined axial position when mounted in a machine, it can be made with a flange (16) between the shank part and the spiral part. Within each rib (11, 12) there is a coolant channel (17, 18) spirally curved with the same curvature as the rib, and continuing in the shank part (15) as a straight channel (23, 24) extending parallel with the center line whilst at varying distances R 1 and R 2 from the center line all the way to the end face (31) of the shank part. In accordance with an alternative embodiment these channels (23, 24) have a straight extension whilst diverging towards the drill tip at an angle (α) all the way to the end face (31) of the shank part. The size of said angle (α) ought to vary in the range 1,5-4,0° for drills of the diameter 30-60 mm, and 0,3-2,5° for the diameter 13-30 mm. The spiral coolant channels (17, 18) end at terminal points (19, 20) within the ribs (11, 12) near the tip. In accordance with one embodiment of the invention conically extending exit channels lead to exit openings (21, 22) in the tip end face behind the inserts. The exit openings are not symmetrically located, but the exit opening (21) on the rib (11) carrying the center insert (13) is located radially farther from the center line to cool and lubricate the following peripheral insert (14). Preferably the exit channel in the rib carrying the center insert is made with a larger cross-section than the other exit channel. Alternatively it could be advantageous in some cases to provide the exit channel on the rib carrying the center insert with a smaller cross-section than the other exit channel. A drill according to one embodiment of the invention is manufactured from cylindrical drill blank with two straight parallel axial channels to be made into coolant channels (23, 24) running at different distances from the center line (CL) of the drill blank. The method of manufacture is thereafter the same as already disclosed in Swedish patent 9203716-7 (corr. WO 94/13422) which is hereby incorporated. The drill blank is mounted in two chucks, one of the chucks (27) holding what is to be the shank part (15) and the other chuck (28) holding a part of the blank near the end (25) to become the tip end. The drill blank is heated between the chucks by an induction coil (26) or other suitable means, whereupon the drill blank is twisted a predetermined angle with the chucks. The grip of the chucks must be stable enough to avoid any twisting of those parts of the drill blank held within the chucks. The portions of the channels (17, 18) located between the chucks will become spirally curved, and the position of the terminal points (19, 20) will be well defined relative to the straight channel parts (23, 24). After twisting the drill blank is reduced to its final diameter, and the flutes (29, 30) are machined. By using the channels (23, 24) as a reference, it is ensured that the spiral flutes will not be located in too close proximity from the cooling channels (17, 18). The pockets for the inserts (13, 14) are then machined and conically extending exit channels are drilled from the exit openings (21, 22) to the terminal points (19, 20), with the exit openings (21, 22) located at different radial distances from the center line. In accordance with an alternative embodiment the cooling channels (17, 18) could, for certain drill diameters, be allowed to be terminated directly at the drill tip end portion. Thanks to the above outlined arrangement of having the cooling channels located at different distances from the center line of the drill blank it becomes easier to locate the cooling channels and their exit openings such that more space can be provided for the chip flutes (29, 30). This enables greater flexibility so as to adapt the location of the holes for various types of chips depending upon which type of material in the workpiece to be subject of machining. In accordance with one embodiment the size of one of the cooling channels could be larger than the other one when there is a need for enlarged coolant supply such as in the proximity of the centrally located insert.

Claims: Spiral drill with indexable inserts, comprising a shank part (15), a tip with pockets for a center insert (13) and a peripheral insert (14), and a spiral part with two spirally curved ribs (11, 12) with a coolant channel (17, 18) in each rib, said coolant channels being spirally curved with the same curvature as the ribs, where each coolant channel communicates with exit channels terminated by exit openings (21, 22) at the drill tip where said exit openings are located at different distances from the center line and where each coolant channel (17, 18) continues in the shank part as a straight channel (23, 24), characterized in that the coolant channels (17, 18, 23, 24) in the shank part in each rib are located at different radial distances from the center line (CL). Spiral drill according to claim 1, characterized by the exit channel of the exit opening (21) on the same rib (11) as the center insert (13) having a larger cross-section than the exit channel of the exit opening (22) located on the same rib (12) as the peripheral insert (14). Spiral drill according to claim 1, characterized in, that the exit channel associated with the exit opening (21) located in the rib (11) carrying the central insert (13) has a smaller cross-section than the exit channel associated with the exit opening (22) located in the rib (12) carrying the peripheral insert (14). Spiral drill according to any of the claims 1-3, characterized in, that the coolant channels of the shank part (15) comprise two straight channels (23, 24) which diverge towards the drill tip under a cone angle (α) that amounts to 0,3-4,0°. Spiral drill according to claim 1, characterized in, that the coolant channels (23, 24) extend mutually parallel in relation to the central line (CL) of the drill. Method for manufacture of spiral drills with coolant channels and two indexable inserts, according to claim 1-5, whereby drilling in a cylindrical blank two straight channels (23, 24) extending from one end (31) of the cylindrical blank to terminal points (19, 20) within the blank near its other end; heating at least the middle portion of the blank; gripping both end portions (15, 25) of the blank with chuck devices; applying torque to the chuck devices to twist said middle portion a predetermined angle to form said parallel channels within the middle part into spirally curved coolant channels (17, 18); machining spiral flutes, tip end face and insert pockets with the parallel channels (23, 24) at the end face (31) as an angle reference; and finally drilling exit channels from exit openings (21, 22) as aforesaid characterized in that the two straight channels (23, 24) are drilled at different distances from the center line. Method according to claim 6, characterized in, that the exit channel located in the rib (11) carrying the central insert (11) is drilled to a larger diameter than the exit channel located in the other rib (12). Method according to claim 6, characterized in, that both coolant channels (23, 24) are drilled parallel with the central axis (CL) of the drill blank. Method according to claim 6, characterized in, that both the coolant channels (23, 24) are drilled such that they extend at conical relation from one another under an angle (α) in the range of 0,3-4,0° for drills having a diameter of 13-60 mm. Method according to claim 6, characterized in, that the exit channel located in the rib (11) carrying the central insert (13) is drilled with smaller diameter than the exit channel located on the rib (12) carrying the peripheral insert (14).

Inventors: TUKALA TOMMY, TUKALA, TOMMY
Applicants: SANDVIK AB, SANDVIK AKTIEBOLAG
Application year: 1996
Main classification: B23B51
IPC codes: B23B51, B23P15