Roll forging process for twist drills

The formation of straight shank twist drill commonly used in the domestic rolling
process. The biggest advantage of this process is high production efficiency, which
can make full use of raw materials; the internal structure of the drill bit body
processed has fiber continuity, grain refinement, uniform distribution of carbides,
and high red hardness. However, the rolling process also has obvious defects, that
is, the bit blank is very easy to crack. Take our factory's production as an example.
Under normal circumstances, the straight shank twist drill's crush rate is 5% to
10%, sometimes as high as 20% to 40%, and the company only loses hundreds of
thousands of yuan each year due to bit cracking. Especially in the current situation
of expensive high-speed steel materials, to solve the problem of bit cracking and
reduce the rate of cracking will enable enterprises to obtain greater economic
benefits.

1. Rolling groove back grinding process

There are many factors that cause cracks in the drill bit, and different methods
can be used to reduce the cracking rate for different cracking reasons. However,
the existing methods are not satisfactory and cannot solve the problem of cracking
fundamentally. Through observation, it was found that more than 98% of the
cracks in the cracked drill bit appeared at the intersection of the land zone and
the blade groove. From this point of view, the generation of cracks is directly
related to the formation of the land. In the ordinary rolling process, the edge,
edge and edge of the drill bit are simultaneously rolled on the four-high mill, that
is, the rolling groove is synchronous with the rolling back. In response to this
feature, we propose a process plan for the formation of the cutting edge and land,
that is, rolling the edge of the drill bit on a four-high mill first, and then grinding
the back edge of the drill on a special grinding machine.

This is the rolling groove grinding back process that this text is going to
introduce, its main craft route is: Rolling ditch ¡ú wears the outer circle ¡ú cutting
tip chamfering ¡ú heat treatment ¡ú pass grinding outer circle ¡ú fine grinding outer
circle ¡ú rub back ¡ú sharpen the drill tip.

2 Rolling groove grinding back process principle

When using the rolling groove grinding back process rolling groove, the original
four-high rolling mill can still be used, but the truncated shape of the two blade
back sector plates is changed, that is, there is no land groove. At this time, the
role of the two blade back-sector plates is to fix the shape of the drill bit and
adjust the amount of blade back filling. The four-high mill pass for both rolling
processes is shown in the figure below. As can be seen from the figure, when the
groove and groove grinding back process is adopted, since the blade sector plate
does not have a land groove, the drill bit has a simple truncated shape, thus
avoiding cracks at the land area.
The reason for the cracking is as follows: When the rolling groove is rolled
back, the widths and depths of the land grooves on the blade-backed sectoral plate
are different due to the different sizes of the drill lands, which are generally
0.45-0.95 mm in width and depth. 0.55 to 1.15mm. During hot rolling, the drill bit
blank is heated under the rolling action of the sector plate to a molten state along
the hole shape of the rolling mill, extends, and flows into the metal in the land
groove to form a bit land. However, the narrow land grooves make it difficult for
the metal to flow smoothly, so that it is easy to generate land defects. In
particular, when the blank is cooled, the narrow and high cutting edge is at the
edge of the drill bit body, and the cooling rate is fastest and stress concentration
is easily generated. Due to the influence of materials, heating temperature, time
and speed, and the accuracy of the sector plate processing, cracks are easily
generated at the land. However, when the rolling groove is used to mill the back
process, the rolling mill is simple in shape, reasonable in structure, and in
conformity with the metal flow characteristics, thus avoiding the occurrence of
the above phenomena. At the same time, the formation of the lands also greatly
reduces the adjustment difficulty of the four-high rolling mill. Improves the
accuracy of core symmetry (one of the important inspection items for twist drills).
Specifications (mm) f3f4.2f5f6f6.8f8.5f9f10 Processing method Rolling ratio (%)
Rolling groove Rolling back 930122015271840 Rolling groove grinding back
02010203 Using the new technology Drill bit after the drill body after heat
treatment, fine grinding outer circle and other processes, then Grind the blade
back on a special grinder. This process can also improve the radial runout accuracy
of the working part of the drill (it is also one of the important inspection items for
the twist drill).

3 Rolling groove grinding back process application effect

Whether or not the new process is adopted should be determined by the actual
conditions in the production. For example, after the test rolling, the cracking rate
is less than 5%, and when the production volume is large, the straight groove shank
twist drill can still be processed by the rolling ditch rolling back process. However,
when the cracking rate is higher than 5%, the rolling groove grinding back process
should be used. The table below shows the comparison of the cracking rate when
some of the drills of our factory are processed with two different process
schemes. From the table, it can be seen that the rolling groove grinding back
process is very effective in reducing the bit cracking rate. After adopting this
technology, the pass rate of drill core core symmetry of our factory was increased
from 75% to 80%, and the radial circle runout qualification rate was increased
from 85% to 90%.
high-speed steel drill bit manufacturers continue to improve
the
bit processing according to the product category.
[ Published 2019/4/23 ¡¡

With the continuous refinement of modern technology, the drilling process of lathes has
continuously become more demanding, and the requirements for smaller and smaller
apertures have also become ever more refined. The smaller the diameter of the high-
speed steel drill, the higher the required spindle speed (r/min). However, the spindle
speed of most conventional machine tools is difficult to achieve such a high speed.
Even if it can be achieved, the spindle of the machine tool will continue to operate under
the limit state. Let it withstand excessive stress. Conventional CNC machining tools
using high-speed steel drills with a diameter of less than 0.5¡ä¡ä (12.7 mm) at 10,000
rpm or below, often result in unreasonable feed and high-speed drill bit damage. Mainly
small-diameter high-speed steel drills, in the same resilience of cutting, micro-high-
speed steel drill bits are brittle and easy to break, and there is poor chip evacuation. In
order to minimize the possibility of tool damage, we must make Chips are quickly
discharged from the cutting zone. Miniature high-speed steel drills require high spindle
speeds during machining, and the spindle speed required for fast chip removal is even
higher. Improve the machining efficiency of high-speed steel drills Three related factors
include the optimization of micro-tool design, the use of low-viscosity coolant and high-
speed cutting technology. The miniature high-speed steel drills obtained by simply
scaling down the geometric parameters of the larger diameter high-speed steel drill bits
are generally difficult to achieve efficient feeding and achieve satisfactory machining
accuracy. Because with the reduction of high-speed steel drill diameter and spindle
speed, their requirements are changing. The use of traditional methods is not suitable
for the current processing needs. This is mainly because the requirement for high-speed
steel drills to increase the rotational speed is not limited to the reduction in diameter.
Increased rotational speeds require better balance and greater chip space to ensure
smooth chip evacuation and prevent build-up. Miniaturized and efficient high-speed
machining requires special optimization. With the correct geometry plus high-speed
spindle machines and reasonable cooling methods, secondary machining to remove
burrs can be completely eliminated. The same principle is used for high-speed cutting
with a tool. Miniature high-speed steel drills require the use of lubricants with a lower
viscosity than water because of the need for the coolant to reach the cutting edge of a
high-speed rotating high-speed steel drill. Dairy-based coolants have a higher viscosity
than water-based coolants and are therefore not suitable for use as lubricants for high-
speed machining. Alcohol (ethanol) can be used as a coolant, and its low evaporation
point makes it a very effective cooling lubricant for high-speed machining. Since alcohol
is a natural compound, it is harmless to the environment, has no waste, and does not
require cleaning, so it will not incur related costs. In addition, the use of alcohol as a
cooling lubricant does not leave any grease on the workpiece, which can avoid the
secondary operation of re-oil removal of the workpiece, and the cost of these processes
are quite high. The smaller the diameter, the higher the spindle speed required to
effectively cut the workpiece. When milling, drilling, threading, and milling, high-
frequency spindles with speeds ranging from 6000 to 60000 r/min are ideal. High-speed
cutting technology uses a high speed, small step, large feed processing strategy.
Imagine moving your hand through a burning candle flame. If your hand moves slowly,
the flame will have enough time to burn your hand; if your hand passes quickly, the
flame will not burn your skin. The principle of high-speed cutting of high-speed steel
drills is similar to this. When high-speed steel drills move quickly, the cutting heat is too
late for incoming workpieces and causes various problems. Reasonable selection can
achieve the best use of results, high-speed steel drill bit manufacturers continue to
improve the bit processing according to the product category.