High-Productivity Drilling Tools Materials, Metrology, and Failure Analysis

Cover
Half Title
Title Page
Copyright Page
Table of Contents
Preface
Acknowledgments
Author
Chapter 1 Metrology of Drilling Tools: Tolerances, Inspection, and Representation in Tool Drawings
	1.1 Introduction
	1.2 Tolerances on Drills and Drilling Tools’ Critical Features and Their Representation on Tool Drawings
		1.2.1 Drilling Tool Diameter
		1.2.2 Shank Diameter
		1.2.3 Overall Length/Flute Length/Shank Length
		1.2.4 Runout
		1.2.5 Point Angle and Lip Height
		1.2.6 Web Thickness and Centrality (Symmetry) of the Web
		1.2.7 Flute Spacing
		1.2.8 Chisel Edge Centrality
		1.2.9 Back Taper Tolerance
		1.2.10 Margin Width Tolerance
		1.2.11 Helix, Rake, and Clearance Angles
		1.2.12 Surface Roughness
		1.2.13 Tool Balancing Tolerances
	1.3 Fundamentals of Inspection/Measurements of Drilling Tools
		1.3.1 Basic Definitions
		1.3.2 Dimensional Inspection (Metrological) System
		1.3.3 Important Fundamental of Tool Optical Inspection/Measurement
	1.4 Gages and Microscopes for Drilling Tool Measurement/Inspection
		1.4.1 Legacy Gages
		1.4.2 Comparators
		1.4.3 Advanced Drilling Tool Measuring Devices
	Note
	References
Chapter 2 Tool Materials
	2.1 Introduction
	2.2 Basic Properties of Tool Materials
		2.2.1 Tensile and Compression Strengths
		2.2.2 Modulus of Elasticity
		2.2.3 Toughness
		2.2.4 Wear Resistance
		2.2.5 Hardness
		2.2.6 Red Hardness
	2.3 High-Speed Steels
		2.3.1 Why HSSs?
		2.3.2 Short Historical Development
		2.3.3 Common Grades of HSS
		2.3.4 Factors Affecting Intelligent Grade Selection of HSS
		2.3.5 Formation of Properties
		2.3.6 Components in HSS
		2.3.7 Heat Treatment of HSS
		2.3.8 Cryogenic Treatment of HSSs
		2.3.9 Coating of HSS
	2.4 Cemented Carbide
		2.4.1 What is CC?
		2.4.2 Grade Classification
		2.4.3 Properties of CCs
		2.4.4 Carbon Content
		2.4.5 Non-destructive Testing of Carbide Properties Using Magnetic Measurements
		2.4.6 Cryogenic Treatment of CCs
		2.4.7 Trends in Development
		2.4.8 Carbide Blanks
		2.4.9 Coating
	2.5 Tool Materials: Words of Wisdom
	Note
	References
Chapter 3 Metalworking Fluids (MWF)
	3.1 Introduction
		3.1.1 Necessity of this Chapter
		3.1.2 Background Information
	3.2 Type of MWFs
		3.2.1 Straight Oils
		3.2.2 Water‑Based Fluids
		3.2.3 Solution Synthetic Fluids
		3.2.4 Solution Semi‑Synthetic MWFs
		3.2.5 Cryogenic MWFs
	3.3 Basics of MWF Selection
		3.3.1 Wish List
		3.3.2 Common Selection Methods
	3.4 MWF Application Methods
		3.4.1 Flood Application
		3.4.2 Through-Tool MWF Application
		3.4.3 Dry and Near-Dry (Minimum Quantity Lubricant) Applications
		3.4.4 Application of CMWFs
	3.5 High-Pressure MWF Supply: Essentials and Particularities of Tool Design
		3.5.1 Why is High MWF Pressure Needed?
		3.5.2 MWF Management in the Bottom Clearance Space (BCS)
	3.6 Dry Machining
	3.7 Near-Dry (MQL) Drilling Operations: Theory, Apparatus, and Particularities of Tool Design
		3.7.1 Underlaying Cause for the Development of NDM (MQL)
		3.7.2 Understanding the Subject
		3.7.3 Implementation Aspects
		3.7.4 Aerosol (Mist)
		3.7.5 Classification of NDM
		3.7.6 Cutting Tool
		3.7.7 Chip Management
		3.7.8 Machines
		3.7.9 Using Near-Net-Shape Blanks
	3.8 Cryogenic MWF
		3.8.1 Introduction
		3.8.2 CMWF as a Cooling Medium and Common Application Technique
		3.8.3 How CMWF Can Help to Improve the Metal Cutting Process
	3.9 MWF Essential Parameters To Be Maintained in HP Drilling Operations
		3.9.1 Concentration
		3.9.2 Water Quality
		3.9.3 MWF Filtration
		3.9.4 Tramp Oil
		3.9.5 Conclusion Remark
	References
Chapter 4 Tool Life, Wear, and Failure Analysis Procedures of Drilling Tools
	4.1 Tool Life
	4.2 Tool Wear
		4.2.1 Background Information
		4.2.2 Standard Wear Assessment
		4.2.3 Advanced Wear Assessment
		4.2.4 Mechanisms of Tool Wear
	4.3 Tool Life Testing
		4.3.1 Standard
		4.3.2 Advanced
	4.4 Drilling Tool Wear
		4.4.1 Common Wear Regions of Drilling Tools
		4.4.2 Assessment of Tool Wear of Drilling Tools
		4.4.3 Design of Experiment (DOE)
		4.4.4 Analysis of Drilling Tool Reliability
	4.5 Drilling Tool Failure Analysis
		4.5.1 Exordium
		4.5.2 Traditional Notions and Approaches
		4.5.3 Failure: A System-Related Definition
		4.5.4 Tool Failure Prime Sources
		4.5.5 Preparation Stage of Tool Failure Analysis (TFA): Collecting Information
		4.5.6 Assessment of the Collected Evidences: Obvious Root Causes
		4.5.7 Normal Tool Failure Analysis
		4.5.8 Special Tool Failure Analysis
	Note
	References
Appendix A: Geometrical Product Specification and Verification (GPS&V) Basics Related to Drilling Operations
Appendix B: Basics of Balancing
Appendix C: MWF Flow Fundamentals
Appendix D: Plastic Lowering of the Cutting Edge
Index