Drills: Science and Technology of Advanced Operations (Manufacturing Design and Technology)

In a presentation that balances theory and practice, Drills: Science and Technology of Advanced Operations details the basic concepts, terminology, and essentials of drilling. The book addresses important issues in drilling operations, and provides help with the design of such operations. It debunks many old notions and beliefs while introducing scientifically and technically sound concepts with detailed explanations. The book presents a nine-step drilling tool failure analysis methodology that includes part autopsy and tool reconstruction procedure. A special feature of the book is the presentation of special mechanisms of carbide (e.g. cobalt leaching) and polycrystalline (PCD) tool wear and failure presented and correlated with the tool design, manufacturing, and implementation practice. The author also introduces the system approach to the design of the drilling system formulating the coherency law. Using this law as the guideline, he shows how to formulate the requirement to the components of such a system, pointing out that the drilling tool is the key component to be improved. Teaching how to achieve this improvement, the book provides the comprehensive scientific and engineering foundations for drilling tool design, manufacturing, and applications of high-performance tools. It includes detailed explanations of the design features, tool manufacturing and implementation practices, metrology of drilling and drilling tools, and the tool failure analysis. It gives you the information needed for proper manufacturing and selection of a tool material for any given application. Content: Drilling System -- Tool Failure as a System Problem: Investigation, Assessment, and Recommendations -- Tool Materials -- Twist and Straight-Flute Drills: Geometry and Design Components -- PCD and Deep-Hole Drills -- Metalworking Fluid in Drilling -- Metrology of Drilling Operations and Drills -- Appendix A: Axial Force, Torque, and Power in Drilling Operations -- Appendix B: Tool Material Fundamentals -- Appendix C: Basics of the Tool Geometry. Abstract: The weakest link in the design of high-efficiency drilling operations is the readiness of cutting tool users/machining operation designer/planners and cutting tool manufacturers plus the lack of relevant research works on the modern hole making operations. This book addresses the most important issues in drilling operations, and is designed to familiarize application specialists with properly defined basic concepts, terminology, and essentials of drilling "... Very valuable knowledge ... new procedures to find the root causes of tool failure with accuracy ... based on the innovative concepts ... the right methodologies and practices to help ... selection of the drilling system components to manufacture high-quality products, improve the efficiency of the drilling process and development of the next generation of high-performance (HP) drills."-J. C. Outeiro, Arts et Metiers ParisTech"... explains drilling (science and technology of advanced operations) with high quality and innovation. ... a useful reference for academics, researchers, mechanical, manufacturing, industrial engineers, and professionals familiar with machining technology."-J. Paulo Davim, University of Aveiro Front Cover 1 Contents 6 Preface 16 Acknowledgments 26 Author 28 Chapter 1: Drilling System 30 Chapter 2: Tool Failure as a System Problem: Investigation, Assessment, and Recommendations 84 Chapter 3: Tool Materials 172 Chapter 4: Twist and Straight-Flute Drills: Geometry and Design Components 288 Chapter 5: PCD and Deep-Hole Drills 426 Chapter 6: Metalworking Fluid in Drilling 552 Chapter 7: Metrology of Drilling Operations and Drills 640 Appendix A: Axial Force, Torque, and Power in Drilling Operations 764 Appendix B: Tool Material Fundamentals 776 Appendix C: Basics of the Tool Geometry 818 Back Cover 876 The weakest link in the design of high-efficiency drilling operations is the readiness of cutting tool users/machining operation designer/planners and cutting tool manufacturers plus the lack of relevant research works on the modern hole making operations. This book addresses the most important issues in drilling operations, and is designed to familiarize application specialists with properly defined basic concepts, terminology, and essentials of drilling. Materials common for making drilling tools are considered from the point of the cutting tool design and implementation to deliver an unp