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The difference between traditional drilling and spiral milling

As a new hole machining method, the spiral hole milling technology has the advantages of smooth cutting process, small cutting force and one machining can meet the precision requirements.This technology has become one of the hot and difficult points in the research of material processing at home and abroad.So, what is the difference between traditional drilling and spiral milling?

Traditional drilling process

Traditional drilling has the following characteristics:

First, in the process of traditional drilling, the center of the main shaft linear velocity is zero, namely don't participate in cutting bit center, the central regions of the workpiece material to depend entirely on the drill down thrust to squeeze to remove it, thus bit of Z axis force is very big, when processing difficult-to-machine materials such as titanium alloy, the rapid wear failure is inevitable.

Second, the traditional drilling process is a continuous cutting process, the blade is always in contact with the workpiece, cutting contact surface temperature is very high, and the heat conductivity of titanium alloy is poor, the continuous cutting process makes the temperature accumulation, which also accelerated the tool wear and failure, resulting in the quality of the processing surface decline.

Third, the traditional way of cutting in drilling is also a cause of tool failure.In the process of drilling, the chip is discharged from the slot of the bit, the chip discharge speed is slow, and the cutting heat is mainly taken away by the chip, when the cutting heat cannot be evacuated in time, a lot of cutting heat is left on the workpiece and tool, which will accelerate the tool wear failure.

In addition, when the chip has direct contact with the surface of the processed hole, the processed surface will be scratched, obviously this way of chip discharge and affect the surface quality of the hole.Generally speaking, the quality of traditional drilling can not meet the precision requirements of the aircraft manufacturing industry, and must rely on other processes to ensure the surface quality of holes, thus reducing the work efficiency, but also increase the processing cost.From a technical and economic point of view, the traditional drilling process is no longer suitable for aircraft manufacturing.

Screw hole milling process

Compared with the traditional drilling, the spiral milling hole adopts a completely different processing method.The spiral hole milling process is composed of the "rotation" of the spindle and the "revolution" of the spindle around the center of the hole.

First of all, the trajectory of the tool center is a spiral line rather than a straight line, that is, the tool center and the center of the machining hole no longer coincide, is an eccentric machining process.The diameter of the tool is different from the diameter of the hole, which breaks through the limitation of machining the same diameter hole with a tool in the traditional drilling technology, and realizes the machining of a series of diameter holes with a single diameter tool.This not only improves the processing efficiency, but also greatly reduces the number and types of knives stored and reduces the processing cost.

Secondly, the spiral hole milling process is intermittent milling process, conducive to the heat dissipation of the tool, so as to reduce the risk of tool wear and failure caused by temperature accumulation.More importantly, compared with the traditional drilling, the spiral milling process in the use of coolant has been greatly improved, the whole milling process can be used trace lubrication or even air cooling to achieve cooling, is a green process.

Thirdly, the way of eccentric machining makes the chip have enough space to discharge from the hole groove, so the chip discharge mode is no longer the main factor affecting the hole quality.It can be seen that this technology has a broad development space and a good market prospect, but as a new processing method, its processing mechanism needs to be further studied and discussed.

Advantages of screw milling holes

(1) improve the quality of machining holes and tool life.

Compared with the traditional drilling technique, the quality and strength of the hole are greatly improved.Screw milling hole belongs to intermittent cutting, the lower milling force makes the hole without burr;The tool diameter is smaller than the hole, the chip can be discharged smoothly, so that the roughness of the hole surface can be greatly reduced;In the processing of composite materials, the traditional punching due to the passivation of the tool tip caused by delamination, stripping, hole surface quality is eliminated.

Traditional drilling tool center cutting ability is low, and easy to accumulate heat and wear quickly, tool life is generally low;Screw milling hole because of the lower milling force to significantly increase the life of the tool.

(2) shorten the development cycle and save the processing cost.

The use of helical hole milling in aircraft and other heavy machinery will greatly shorten the development cycle and reduce costs.

With the helical hole milling technique, holes with different diameters and complex shapes can be machined with the same tool.Because of the advantages of the machining method, the traditional counter - cone and reaming work can be saved.This means that in the future, the number of tool types will continue to reduce.From the point of view of the whole development cycle, the use of screw technology can reduce many processes (such as different holes after decomposition and disassembly for burr removal, reaming, cooling fluid removal, and assembly), greatly shorten the processing cycle.

(3) high degree of automation.

Achieving a higher degree of automation is also a way to reduce processing costs.Because of the low milling force of screw hole milling, this technology can be applied to industrial robot devices.Because the industrial robot device is relatively weak, and the traditional borehole axial force is too large, so the traditional borehole cannot be applied to this kind of device. 

(4) promote the use of new materials.

It is an obvious trend to use new materials in aircraft parts. New materials such as titanium alloy and composite materials have been widely used.However, the development and use of new materials require suitable processing technology support, in the hole processing, research shows that, compared with the traditional drilling technology, the spiral milling technology has a significant advantage.

Helical hole milling process only 1 tool can be processed out of different diameters, high quality holes, not only reduce the time to change the tool, and save the process of finishing, greatly improve the work efficiency.In view of the advantages of screw hole milling technology, many enterprises, especially in aviation and mold industry, have started to apply it to production practice.With the popularization and application of this technology, the traditional drilling tool will be gradually eliminated, and the new hole milling device will appear more and more in the machining workshop.

Source: machine tool press

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