New drill hits a homer

END USER: Anderson Machining Service Inc., (920) 674-6003, www.amscnc.com.
CHALLENGE: Reduce cycle times when machining hydraulic components.
SOLUTION: A solid-carbide, through-coolant drill that orients the margins radially.
SOLUTION PROVIDER: Walter USA LLC, (800) 945-5554, www.walter-tools.com/us.

Anderson Machining Service Inc., Jefferson, Wis., specializes in machining close-tolerance, complex parts and, according to Operations Manager Erik Anderson, is always looking to improve its processes.

“We stress that no matter how many times you’ve machined a part, you never stop looking for a better way to do it,” he said. In keeping with this spirit, Anderson Machining opted to take a new approach to drilling manifolds.

“The purpose of a manifold is to direct oil components in a hydraulic system, so it stands to reason that this job entails drilling a lot of intersecting holes,” Anderson said.

The Walter DC170 through-coolant drill produces one of the many holes in a manifold at Anderson Machining Service. Image courtesy Walter USA.

The primary workpiece material is Dura-Bar 65-45-12, a continuous-cast ductile iron with a ferritic structure, and the number of cross-holes ranges from 25 to 30 in small manifolds to 300 in large ones. When drilling, the cutting speed had to be halved to 150 sfm (44.72 m/min.) each time the drill encountered an interruption, Anderson explained.

“The reason we needed to slow down with each interruption was to protect the drill from possible failure,” Anderson noted, adding that the drill was negatively impacted because not all intersecting holes are on center. “For instance, when a ¹/₂ ” hole intersects a 1 ” hole, it may be as much as 30 percent off centerline. In a case like this, the drill will start to dig on the corner of the intersecting 1 ” hole. This causes excessive tool wear and, in the worst-case scenario, catastrophic tool failure.”

Toolmaker Walter USA LLC, Waukesha, Wis., approached Anderson Machining, claiming to have a better way to drill the manifolds. “Anderson is a very progressive company, continually looking for ways to improve,” said Andy Wedesky, Walter field sales engineer. “We were confident they would consider a new approach.”