Im using a custom ground step drill pictured below to drill and countersink a blind hole in aluminum
Its been giving me trouble from the get go
Im feeding to +.100 of final depth,
retract to clearance, rapid back to +.120 final depth,
then feed to final depth and dwell a half second
hitting it with M.O.M. oil every 2 seconds
this is coded long-hand
the first "peck" is S7000 F15.
the finish "peck" is S3000 F7.5
the upper diameter of the c-sink is .300
I was breaking these drills left and right till I got to these feeds and speeds
now the problem is the taps are breaking
these taps were doing over 2000 holes each and never broke, now two have snapped in as many days
the tap breaks off in one hole on the frame, but the remaining un-tapped holes all look fine,
the tap is an oversized HSS 8-32 spiral flute for helicoil inserts
I had no idea these blind holes would be so problematic
I use a similar step drill on another frame with thru holes and it just keeps going and going...
I decrease the speed on the last feed move because the countersink doesn't like high rpm
I think the fact that the countersink and the drill tip are both cutting the last .100 simultaneously at low rpm is causing the trouble
Anybody got some insight on this combined operation for thru holes?
a better tool maybe?
a coding tweak?
thanks in advance
Kenny