AerospaceIndustry - Frank Drucklufttechnik

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I-3 Cooper Power Tools Advanced Drilling Equipment Introduction Assuring You Of The Right Tool For The Right Application The Advanced Drilling Equipment line has been developed to address the singular nature of achieving optimum hole quality in the aerospace industry. In most traditional industries, precision holes can be successfully drilled with a drill press or CNC machine. But because a significant number of aircraft components are too large, too complex and too irregularly shaped to be taken to a machining center, portable precision drill motors must be taken to the plane itself. It is impractical to drill precision holes in a wing, fuselage or engine nacelle any other way. The wide range of hole sizes, the critically close tolerances required of those holes and the divergent materials used in the aerospace manufacturing industry demand that these portable precision drill Doler P3 Self Colleting Drill motors be available with a remarkably broad range of cutter speeds, feed rate combinations, and physical properties that can accommodate virtually any workspace or application. Responding successfully to these demands for quality and flexibility has made the Cooper Power Tools Advanced Drilling Equipment line the most impressive, and the most respected, in the business. Included are positive feed drills for deep hole drilling in in-line, piggyback, and right angle configurations, peck drills designed specifically to enhance hole quality when drilling through layers of dissimilar materials, and self colleting drills that are perfect for drilling smaller holes throughout the aircraft. We invite your attention to a detailed picture of the various Advanced Drilling Equipment tools and accessories in the pages that follow. Quackenbush HT4 Peck Feed Drill Selecting The Right Tool The old saying, “you’ve got to have the right tool to do the job right”, is so true in regards to advanced drilling equipment. For certain applications, as shown in the diagram below, a specific tool is required. However, other applications may be served by more than one tool. Detailed analysis by one of our experienced technical assistants will help you make the right tool selection for your particular applications. Some factors to consider are fixturing costs, access, hole quality, material(s) being drilled, production rate, budget, and familiarity with product. Peck Feed Drill • Stacks of different materials •Close tolerance, one-shot drilling Peck Feed or Positive Feed Drill Positive Feed Drill • Work hardening materials • Controlled fixed feed rates • Drilling stroke >4 inches Positive Feed or Self Clamping Drill Self Clamping Drill • Drilling and countersinking of wings and fuselage • Nutplate holes Self Clamping or Peck Feed Drill Peck Feed or Positive Feed or Self Clamping Drill Cooper Power Tools Advanced Drilling Equipment Introduction Quackenbush 10QNPD Nut Plate Drill Doler PB5 Peck Feed Drills ? Self Clamping Drills Positive Feed Drills Doler CD4 Composite Drill I-4
I-5 Cooper Power Tools Advanced Drilling Equipment Introduction Speed, Feed & Power Please use the chart below as a guide only. Many variables contribute to the optimum parameters for each application. These variables include: particular material characteristics, cutter design, cutter sharpness, airline pressure and flow capacity and cutter lubrication. All portable drilling tools have limited power and thrust. In most cases, holes over 1/2 inch diameter cannot be produced at machine tool rates. Feed rates and/or speeds are reduced. Consult Cooper Power Tools for advise on particular applications. For best results with your drilling system: 1. Maintain lubricated air to the tool with pressure of 90 psig while the tool is running. 2. Use high quality cutters. 3. Replace cutters when point dulls – hole diameter generally increases, cycle times lengthen (except positive feed) and hole finish worsens. 4. Whenever possible, provide lubricant mist to the drill point. 5. Insure there is an adequate flow path for drill chips (swarf). 6. Utilize fixtures that are secure and rigid. 7. Assure that accessory items are sized correctly and working properly. 8. Train operating personnel in the proper use of the tool. 1/8 3/16 1/4 Drill Diameter 5/16 3/8 7/16 1/2 Material Function .125 .188 .250 .313 .375 .437 .500 Aluminum (300 SFM) Speed (RPM) 9000 6000 4600 3600 3000 2600 2300 Feed Rate (IPR) .002 .003 .004 .004 .004 .004 .004 Power (HP) .2 .3 .6 1.0 1.5 1.8 2.0 Mild Steel (90 SFM) Speed (RPM) 2700 1800 1300 1100 900 750 650 Feed Rate (IPR) .005 .005 .005 .006 .006 .006 .006 Power (HP) .2 .3 .6 1.0 1.5 1.8 2.0 High Strength Steel Speed (RPM) 900 600 450 375 300 250 220 Stainless Steel Feed Rate (IPR) .001 .001 .001 .001 .001 .001 .001 (30 SFM) Power (HP) .2 .3 .6 1.0 1.5 1.8 2.0 Titanium/Inconel Speed (RPM) 600 400 300 250 200 175 150 (20 SFM) Feed Rate (IPR) .002 .003 .003 .003 .004 .004 .005 Power (HP) .2 .3 .6 1.0 1.5 1.8 2.0 Composites Graphite, kevlar, fiberglass, and other composite materials vary widely. Fiber, resin, processing method and type of cutting tool all affect the optimum drilling speed and feedrate. Little power or thrust is normally required, but controlled feedrates at the proper speed is mandatory. Carbide or diamond cutting tools are required. Contact your material supplier or experiment with an NC Drilling Machine. Stacks of Various Materials Use the lowest speed and feedrate of the materials in the stack. Peck feed drilling is best. A. Peck Drilling permits higher drilling speeds B. Carbide cutting tools (when applicable) permits higher drilling speeds C. Oil hole cutting tools permit higher drilling speeds. Speed (RPM) Describes the number of revolutions of the spindle per unit of time. Example: Revolutions per minute=RPM Surface Speed (SFM) Describes the velocity (speed) of the outside of the drill bit. Example: 30 surface feet per minute (30 SFM) Feed Rate (IPR) Describes the distance the spindle travels during each revolution. Example: 0.002 inches per revolution = .002 IPR 1 Revolution Time A Time 1 Revolution Velocity at point A Distance Speed = Revolution ÷ Time Surface = Distance ÷ Time Feed Rate = Distance ÷ Revolution Speed (rotational) Cooper Power Tools Advanced Drilling Equipment Introduction Diameter Straightness Perpendicularity Barrelling Ovality Bellmouthing Benefits of Proper Hole Preparation Improved Hole Quality Diameter tolerance Countersink depth tolerance Hole finish Hole straightness Lack of burrs No delamination in composites No fiber fraying in composites No metallurgical change from excess heat Lowered Cost Per Hole Decrease the drilling time Reduce the number of operations for a finished hole Combine drilling and countersinking into one operation Self clamping attachments minimize hole to hole time Reduced Inventory & Capital Investment Portable equipment eliminates expensive, large stationary machines Simultaneous drilling and countersinking reduces total equipment requirements Self clamping significantly reduces fixturing costs Modular designs reduce the number of complete backup units Reduced Safety Hazards Less operator contact Drill bit control through nosepieces and fixtured bushings All reactions of the drilling process are absorbed by the fixture and drilling equipment I-6
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Introduction Self Colleting Tools O
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Doler ® Self Colleting Machines* D
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Doler ® Self Colleting Machines Do
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Doler Self Colleting Machines Acces
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Doler ® Self Colleting Machines Do
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Specialty Tools Specialty Tools CD
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Cooper Power Tools P.O. Box 1410 Le
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6-2 Cutters A11N B51-Q C31-M D22-T
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6-6 Cutters Cutter Mounting Styles
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