Drilling tool technology and innovation
In order to meet the growing demand for improved production efficiency, tool manufacturers are continuously innovating in the design and manufacturing of various drilling tools. Across industries such as automotive, medical instruments, aerospace, and general engineering, advanced drilling solutions like high-speed solid carbide drills, indexable insert drills, and replaceable carbide-tipped drills are being widely used. These tools enable the machining of small and deep holes, as well as combined operations like drilling, chamfering, and boring—all without the need for secondary processing.
Toolmakers leverage advancements in geometry, substrate materials, and surface coatings to develop new variants, expand product lines, and offer customized solutions. The evolution of CNC machine tools—especially machining centers, Swiss-type lathes, and long-bed lathes—has further enhanced the performance of long drills. Modern machines provide high rigidity and high-pressure coolant delivery, which are essential for efficient and precise drilling operations.
In metal cutting, reducing cycle time is a key objective, and hole machining is no exception. Certain industries, such as medical and aerospace, require high precision and consistency in hole accuracy, adding pressure on drilling processes. Machining advanced materials like titanium alloys, Inconel, and cobalt-chrome alloys presents additional challenges. Solid carbide drills remain a preferred choice due to their high rigidity and features like carbide coatings, optimized drill geometry, land width, and back taper. Multi-layer PVD coatings, combined with tough substrates, enhance chip control and tool life, making them ideal for high-feed applications.
Nachi America Inc. has developed several innovative drill bits, including MQL, AGPower, cobalt HSS, and TiAlN-coated drills. These have been successfully applied at Ford, GM, and Honda plants, doubling the number of crankshaft holes drilled and reducing per-piece machining costs by 50%. Multi-functional tools, such as Ingersoll Cutting Tools’ Qwik Twist interchangeable point drill, combine drilling, boring, and chamfering into one, significantly reducing machining time for complex parts like pull nails.
Sumitomo Electric has introduced systems like the SumiChamfer, which integrates chamfering into solid carbide drills or SMD replaceable tips. This system uses standard ER collet chucks and offers multiple chamfer ring options for different hole sizes. Similarly, Precision Twist Drill Co.’s Hydra Drill allows internal cooling and interchangeable tips, enabling high-volume machining across various materials, from cast iron to titanium.
MA Ford Mfg. Co. has developed multi-tasking carbide drills capable of drilling deep holes up to 20 times the diameter, suitable for automotive components. They also introduced a new series of standard drills that can handle a wide range of materials, from mild steel to exotic alloys, improving speed, efficiency, and tool life through tailored designs and coatings.
BIG Kaiser’s Sphinx drills, including Phoenix and Quadro 15 Plus, cater to small and medium-sized holes with high-speed capabilities. OSG’s Exocarb-Max Ultra Long Drill can drill up to 30 times the diameter, eliminating the need for stage drilling and saving significant time.
Mitsubishi Materials supplies ultra-fine MSE solid carbide drills for micro-holes and adds deep-hole capabilities for 1–3 mm diameters. Their MWS internal cooling drills feature wave-shaped edges for better chip evacuation. Kennametal’s HTS drilling system handles large-diameter deep holes up to 381 mm, ideal for heavy-duty applications.
Sandvik Coromant’s CoroDrill 805 enables deep-hole drilling on conventional machines, while Walter’s Xtra-tec B401x series offers high feed rates and precision. T3 Enterprises’ Omegadrill, designed with square slots, is used for extreme conditions, such as removing broken twist drills or machining hard materials like stellite and granite.
These innovations highlight the continuous efforts of toolmakers to address challenging machining needs, improve efficiency, and meet the evolving demands of modern manufacturing.
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