Chipless hot melt drilling technology that can machine holes and bushings at a time (figure)
Figure 1 Chipless drilling technology uses friction to heat the workpiece material and simultaneously form holes and bushings in one pass.
Figure 2 Once the bushing is formed, the roll can be tapped on the bushing without the need to weld (rive) the nut on the thin-walled workpiece.
Drilling holes on thin-walled workpieces is not a big challenge, but such machining may require some kind of workpiece support to counteract the pressure generated when the drill bit begins to drill into the workpiece material. Depending on the processing requirements, the machined hole may also need to be deburred or chamfered.
In many cases, these holes are machined into bearings or fasteners when the parts are assembled. For conventional thin wall drilling, the depth of the hole is equal to the thickness of the workpiece. These holes may not be suitable for machining threads or providing adequate support for the bearing sleeve. For this purpose, it is often necessary to weld or rive a nut to the workpiece or to install a special bushing in the hole. The Flowdrill drill developed by Flowdrill uses a chipless drilling technology that allows both the hole and the support bushing to be machined in one pass, eliminating the need for additional welds or bushings.
The Flowdrill drilling concept uses a conical drill that contacts the workpiece material at high axial (downward) pressures and rotational speeds. The frictional heat generated by the drill bit softens and extensates the workpiece material, allowing the drill to be drilled. Into the workpiece and form a ring neck and bushing around the hole. The total thickness of the ring neck (above the surface of the workpiece) and the bushing (below the surface of the workpiece) can be up to 3 times the thickness of the workpiece. The increased thickness can provide support for the bearing or the thread can be machined using a Flowtap tap. Flowdrill's chipless drilling process is suitable for processing low carbon steel, stainless steel, titanium, aluminum, copper, brass and other ductile workpiece materials with wall thicknesses of 0.5 to 12.5 mm. Common processing objects include automotive exhaust, steering and frame components, pressure and water tanks, various conduits and piping systems, HVAC manifolds and metal furniture.
Flowdrill carbide drills range in diameter from 1.5 to 50 mm and repeatability up to 0.013 mm. They can be used on standard drilling machines or CNC machine tools with a machining power level of 1.5 to 3.5 kW and a spindle speed of 1000 to 3500 r/min. The cutting parameters selected vary depending on the machined hole diameter, workpiece material and thickness. In order to optimize the processing quality and precision of the holes, the lubricant must be applied manually or through an automatic spray system before each machining. Flowdrill drills typically have a processing cycle time of 2 to 6 seconds. The bit is clamped by a collet chuck, and the shank type is 2# and 3# Morse taper shank or 20mm straight cylindrical shank.
For machining that requires a smooth joining surface or a chamfered hole, a flat Flowdrill bit can be used to cut the ring neck formed on the surface of the workpiece. The grooved drill-tip Flowdrill drill is recommended for machining surface-coated workpiece materials because it helps to remove the coating at the beginning of the drilling process. The grooved Flowdrill drill bit also helps prevent deformation of thin-walled workpieces under the pressure of the drill bit. Deformation of the workpiece can also be avoided by pre-drilling a small starting hole.
Flowtap roll forming taps are available for a wide range of standard, metric and NPT thread profiles. Since this thread is formed not by cutting but by extrusion, it has a high tensile strength and torque value.
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