A roll-forged drill bit

Abstract: A roll-forged drill bit 1 comprising a shank 3 for insertion in a chuck of a drill, the shank 3 including an helically twisted web 7 defining a cutting tip 9, the cutting tip 9 including a central chisel edge 11 and a cutting edge 15 defining the maximum diameter of the cutting tip 9, wherein the cutting tip 9 is formed after the shank 3 has been roll-forged and includes a pair of faces 13 defining the chisel edge 11 and a pair of upturned flats 17 defining the cutting edge 15. A roll-forged drill bit 1 according to the present invention provides a significant improvement in cutting speed over known prior art roll-forged drill bits.

Description: This invention relates to roll-forged drill bits, and in particular to a roll-forged drill bit having a featured, or non-standard, tip. Roll-forged drill bits are considered to be of lower quality than "cut-from-solid" drill bits. Accordingly, roll-forged drill bits tend to fill the lower end of the market and professional workmen always look to obtain cut-from-solid drill bits, where possible. Document DE-A-1918587 discloses a rolling mill for roll-forging helical grooves into workpieces. As will be appreciated, cut-from-solid drill bits result in significant wastage of material (up to about 30%) and are, therefore, expensive. However, the application of "featured" tips to drill bits has, to the present day, been seen only in this sector. Document EP-A-0137898 discloses a drill bit according to the preamble of claim 1. In general, roll-forged drill bits have a cutting tip or point defined by accepted standards which includes a central chisel edge and flats extending from the chisel edge to the outside of the drill bit tip. The included angle between the opposing flats is usually in the region of 118°. In view of the foregoing, the present invention aims to improve upon the prior art roll-forged drill bits by producing a roll-forged drill bit including a featured cutting tip. Furthermore, a drill bit according to the present invention has improved performance over prior art roll-forged drill bits. The present invention is defined in claim 1. There is provided a drill bit comprising a shank for insertion in a chuck of a drill, the shank including a helically twisted web defining a cutting tip, the cutting tip including a central chisel edge defined by a pair of faces each having an inner cutting edge , each of the faces having an associated upturned flat having an outer cutting edge, wherein the inner and outer cutting edges meet at a line which defines a sudden change of angle of the cutting tip between the faces and flats, characterised in that the drill bit is roll-forged and the outer cutting edges define the maximum diameter of the cutting tip. As a result, a drill bit according to the present invention is a marked improvement over prior art roll-forged drill bits and is likely, therefore, to attract much interest from potential customers and users. By including upturned flats defining the cutting edge, the axial distance between the chisel edge and the cutting edge tends to be shorter than in prior art roll-forged drill bits, thereby enabling thin workpieces to be cut more accurately because the chisel edge does not break through the workpiece before the cutting edge has engaged the workpiece. The faces define an angle of between about 121° and about 127°, preferably approximately 124°. This angle results in the faces being flatter to the workpiece, during use, than is the case with prior art roll-forged drill bits. The complete length of the faces therefore engages a workpiece more quickly than is the case with prior art roll-forged drill bits, which results in quicker holes being produced by the drill bit. Each flat makes an angle of between about 3° and about 9°, preferably approximately 6°, with a plane perpendicular to the axis of the shaft. By including the upturned flats, the cutting edges defined by the flats at the edge of the cutting tip help to produce a neat edge to the hole during drilling. The angle of inclination of the flats is, however, small, thereby insuring that the complete length of the flats comes into contact with a workpiece quickly. This arrangement, once again, assists in cutting holes quickly. The web tapers from the shank towards the cutting tip to a greater extent than is usual, thereby creating a thinner web at the tip. This feature assists in reducing "walking" of the drill bit during use and increasing the ease with which the bit drills. Additionally, by including a tapered web, debris is removed from a work site more quickly and efficiently. In a preferred embodiment, the web has a thickness at the cutting tip which is approximately 30% of its maximum thickness. A specific embodiment of the present invention is now described, by way of example only, with reference to the accompanying drawings, in which:- Figure 1 is a side view of a roll-forged drill bit according to the present invention; Figure 2 is a cross-sectional side view of the shank of a roll-forged drill bit showing diagrammatically the tapering of the web; Figure 3 is an enlarged view of the cutting tip of the roll-forged drill bit shown in Figure 1; Figure 4 is a view of the cutting tip of Figure 3 rotated through 90°; Figure 5 is a plan view of the cutting tip of Figures 3 and 4; and Figures 6 to 8 are graphs comparing the life and speed of cut of 3mm, 6mm and 10mm diameter respectively roll-forged drill bits according to the present invention with known prior art roll-forged drill bits. With reference to the drawings, a roll-forged drill bit 1 according to the present invention comprises a shank 3 including a solid end 5 for insertion in a chuck (not shown) of a drill, during use, and an helically twisted web 7 defining a cutting tip 9. As shown in Figure 2, the web 7 tapers from the solid end 5 towards the cutting tip 9, so that the web 7 has a thickness at the cutting tip 9 which is less than 30% of its thickness where it joins the shank end 5. As a result, during use, "walking" of the drill bit is reduced and debris is removed from a work site in a quick and efficient manner. With reference to Figures 3, 4 and 5 of the drawings, the cutting tip 9 comprises a chisel edge 11 defined by two faces 13 inclined rearwardly from the chisel edge 11. The faces 13 define an angle therebetween of approximately 124°, which is a slighty larger angle than in most prior art roll-forged drill bits. Cutting edges 15 are defined by upturned flats 17, as shown in Figures 3-5 of the drawings. The cutting edges 15 make an angle of approximately 6° with a plane perpendicular to the axis of the shank 3. As a result, the outermost part of each cutting edge 15 produces a neat and clean cut in a workpiece, during use. As can be seen in Figure 3 of the drawings, the faces 13 defining the chisel edge 11 meet the flats 17 at a line 19, which defines a sudden change in the angle of the cutting tip 9. Once again, this is a substantial departure from the cutting tip arrangements known in prior art roll-forged drill bits. By providing a roll-forged drill bit according to the present invention, a significant improvement in the performance of the drill bit 1 is produced. In this regard, as can be seen from Figures 6-8 of the drawings, drill bits 1 according to the present invention, are shown compared against a number of other roll-forged drill bits currently in the market place. As can be seen, for drill bits having diameters of 3mm (Figure 6), 6mm (Figure 7) and 10mm (Figure 8), the drill bits according to the present invention are significantly quicker at drilling holes in workpieces without sacrificing a loss in life expectancy of the drill bit. Thus it will be appreciated that a roll-forged drill bit according to the present invention is a marked improvement over those known from the prior art.

Claims: A drill bit (1) comprising a shank (3) for insertion in a chuck of a drill, the shank (3) including a helically twisted web (7) defining a cutting tip (9), the cutting tip (9) including a central chisel edge (11) defined by a pair of faces (13) each having an inner cutting edge, each of the faces (13) having an associated upturned flat (17) having an outer cutting edge (15), wherein the inner and outer (15) cutting edges meet at a line (19) which defines a sudden change of angle of the cutting tip (9) between the faces (13) and flats (17), each outer cutting edge (15) defining an angle of between 3° and 9° with a plane perpendiculaar to the axis of the shank (3), and wherein the axial distance between the chisel edge (1) and the outer cutting edges (15) is shortened due to the upturned flats (17) defining the outer cutting edges (15) wherein the faces (13) define an angle of between 121° and 127°, wherein the outer periferal surface of the drill bit tip is of uniform diameter about the axis of the drill bit (1) so that any part of such perifery is equidistant from the axis, whereby the outer cutting edge (15) of the cutting tip (9) intersects the outer periferal surface of the drill bit (1) at an acute angle substantially between 87° and 81° characterised in that the said web (7) is tapered from a solid end (5) of the shank to the cutting tip (9) and in that the drill bit (1) is roll-forged and the outer cutting edges (15) define the maximum diameter of the cutting tip (9). A drill bit as claimed in claim 1 in which said web thickness tapers to a thickness at the cutting tip (9) which is less than 30% of its thickness where it joins the solid end (5).

Inventors: JUNGWIRTH RUDOLF, MULROY MICHAEL, RIEDL JOHANN, JUNGWIRTH, RUDOLF, MULROY, MICHAEL, RIEDL, JOHANN
Applicants: BLACK & DECKER INC, BLACK & DECKER INC.
Application year: 1996
Main classification: B23B51
IPC codes: B23B51