High metal removal rate drilling
 

For some strange reason, I want to shoot a youtube video, showing how
I remove an ungodly amount of material with a carbide drill, on a CNC
mill.

It would be, sort of, something like a "hold my beer and watch this" stunt.

The point is to just make as many chips as fast as possible, so to
speak.

I would use something like 5/8" drill, drilling a 1/2" mild steel bar.

My question is,

1) Can I run this at 2,500 RPM
2) Do I have to use coolant or not with a carbide drill
3) What would happen if I do NOT use any kind of peck or interrupted
drilling, and just plunge into the material -- would the long chips
be a real hazard?

i

High metal removal rate drilling
 

Ignoramus1116 fired this volley in
:

I would use something like 5/8" drill, drilling a 1/2" mild steel bar.

Oh... I thought at first you meant "high metal removal rate". You mean
"low BAR removal rate". Ig, the drill's bigger than the bar.

But that's just little stuff! G

The heaviest "drill hogging" work I've seen done on steel wasn't with
carbide, but with HSS with through-the-spindle cooling.

Then there was some really heavy turning in Vallejo, with the lathe
taking out about a 3/8" deep chip at about 3/8" feed per revolution. Of
course, it wasn't really "big" work... just 12" or 16" prop shafts, but
I'll bet they get even heavier cuts on the _really_big_ shipyard lathes.

I saw one guy in Vietnam drill about .062" per revolution with a 3/4"
bit. He got away with it with no damage, but even with coolant, the
chips came out of the hole smokin' and blue. It was spectacular and
smelly, too, because he was using heavy sulfured oil for the
coolant/lubricant.

High tooth loads on carbide can be tricky, because it's so brittle. And
of course, it depends upon whether or not it's an indexable insert bit or
solid carbide (though I don't want to pay for new solid carbide in that
size).

I didn't check my tables, but I think 2500 RPM is a little slow for that
"small" a carbide bit at high feed rates. You'll have to talk to the
carbide guys... I use mostly HSS with a few indexable bits for boring and
finish work.

LLoyd

High metal removal rate drilling
 

On 2011-04-15, Lloyd E. Sponenburgh lloydspinsidemindspring.com wrote:
Ignoramus1116 fired this volley in
:

I would use something like 5/8" drill, drilling a 1/2" mild steel bar.

Oh... I thought at first you meant "high metal removal rate". You mean
"low BAR removal rate". Ig, the drill's bigger than the bar.

I meant, a 1/2" thick bar.

But that's just little stuff! G

The heaviest "drill hogging" work I've seen done on steel wasn't with
carbide, but with HSS with through-the-spindle cooling.

Dont have that.

Then there was some really heavy turning in Vallejo, with the lathe
taking out about a 3/8" deep chip at about 3/8" feed per revolution. Of
course, it wasn't really "big" work... just 12" or 16" prop shafts, but
I'll bet they get even heavier cuts on the _really_big_ shipyard lathes.

This is fun, I remember those 10 kW Russian lathes, with trepidation.



I saw one guy in Vietnam drill about .062" per revolution with a 3/4"
bit. He got away with it with no damage, but even with coolant, the
chips came out of the hole smokin' and blue. It was spectacular and
smelly, too, because he was using heavy sulfured oil for the
coolant/lubricant.

High tooth loads on carbide can be tricky, because it's so brittle. And
of course, it depends upon whether or not it's an indexable insert bit or
solid carbide (though I don't want to pay for new solid carbide in that
size).

I didn't check my tables, but I think 2500 RPM is a little slow for that
"small" a carbide bit at high feed rates. You'll have to talk to the
carbide guys... I use mostly HSS with a few indexable bits for boring and
finish work.

I just want to make a stunt video of a lot of chips being made.

For a short time, my mill can go up to 3000 RPM.

i

High metal removal rate drilling
 

"Ignoramus1116" wrote in message
...
On 2011-04-15, Lloyd E. Sponenburgh lloydspinsidemindspring.com wrote:
Ignoramus1116 fired this volley in
:

I would use something like 5/8" drill, drilling a 1/2" mild steel bar.

Oh... I thought at first you meant "high metal removal rate". You mean
"low BAR removal rate". Ig, the drill's bigger than the bar.

I meant, a 1/2" thick bar.

But that's just little stuff! G

The heaviest "drill hogging" work I've seen done on steel wasn't with
carbide, but with HSS with through-the-spindle cooling.

Dont have that.

Then there was some really heavy turning in Vallejo, with the lathe
taking out about a 3/8" deep chip at about 3/8" feed per revolution. Of
course, it wasn't really "big" work... just 12" or 16" prop shafts, but
I'll bet they get even heavier cuts on the _really_big_ shipyard lathes.

This is fun, I remember those 10 kW Russian lathes, with trepidation.



I saw one guy in Vietnam drill about .062" per revolution with a 3/4"
bit. He got away with it with no damage, but even with coolant, the
chips came out of the hole smokin' and blue. It was spectacular and
smelly, too, because he was using heavy sulfured oil for the
coolant/lubricant.

High tooth loads on carbide can be tricky, because it's so brittle. And
of course, it depends upon whether or not it's an indexable insert bit or
solid carbide (though I don't want to pay for new solid carbide in that
size).

I didn't check my tables, but I think 2500 RPM is a little slow for that
"small" a carbide bit at high feed rates. You'll have to talk to the
carbide guys... I use mostly HSS with a few indexable bits for boring and
finish work.

I just want to make a stunt video of a lot of chips being made.

For a short time, my mill can go up to 3000 RPM.


Be aware that on breakthrough with extremely heavy feed you can acidentally
pull the drill down out of the chuck...worse yet, if you pull the work up
out of your vise etc it will begin spinning and then finally it will
launch.....

--

High metal removal rate drilling
 

On Apr 15, 12:15*pm, Ignoramus1116
wrote:
For some strange reason, I want to shoot a youtube video, showing how
I remove an ungodly amount of material with a carbide drill, on a CNC
mill.

It would be, sort of, something like a "hold my beer and watch this" stunt.

High metal removal rate drilling
 

On Apr 15, 1:48*pm, Jim Wilkins wrote:
On Apr 15, 12:15*pm, Ignoramus1116
wrote:
For some strange reason, I want to shoot a youtube video, showing how
I remove an ungodly amount of material with a carbide drill, on a CNC
mill....

You could make a safer and well-controlled shower of blue smoking
chips with a horizontal milling cutter.

jsw

High metal removal rate drilling
 

On 2011-04-15, Jim Wilkins wrote:
On Apr 15, 12:15?pm, Ignoramus1116
wrote:
For some strange reason, I want to shoot a youtube video, showing how
I remove an ungodly amount of material with a carbide drill, on a CNC
mill.

It would be, sort of, something like a "hold my beer and watch this" stunt.

The point is to just make as many chips as fast as possible, so to
speak.

I would use something like 5/8" drill, drilling a 1/2" mild steel bar.

My question is,

1) Can I run this at 2,500 RPM
2) Do I have to use coolant or not with a carbide drill
3) What would happen if I do NOT use any kind of peck or interrupted
drilling, and just plunge into the material -- would the long chips
be a real hazard?

i

It might be safer for the camera to do this on a lathe, so the chips
and oil aren't flying all around.

My little 3/4 HP Clausing mill can whip big smoking blue drill chips
around that keep me from reaching the switch to shut it off. When they
become long enough to slap and hang on the column they start to wind
around the bit in a big wad, which traps the emerging chips and
obscures the effect.

jsw

I have an enclosure for the mill. I wanted to drill, say, 100 holes in
3 minutes or something of the sort.

i

High metal removal rate drilling
 

On 2011-04-15, PrecisionmachinisT wrote:

"Ignoramus1116" wrote in message
...
On 2011-04-15, Lloyd E. Sponenburgh lloydspinsidemindspring.com wrote:
Ignoramus1116 fired this volley in
:

I would use something like 5/8" drill, drilling a 1/2" mild steel bar.

Oh... I thought at first you meant "high metal removal rate". You mean
"low BAR removal rate". Ig, the drill's bigger than the bar.

I meant, a 1/2" thick bar.

But that's just little stuff! G

The heaviest "drill hogging" work I've seen done on steel wasn't with
carbide, but with HSS with through-the-spindle cooling.

Dont have that.

Then there was some really heavy turning in Vallejo, with the lathe
taking out about a 3/8" deep chip at about 3/8" feed per revolution. Of
course, it wasn't really "big" work... just 12" or 16" prop shafts, but
I'll bet they get even heavier cuts on the _really_big_ shipyard lathes.

This is fun, I remember those 10 kW Russian lathes, with trepidation.



I saw one guy in Vietnam drill about .062" per revolution with a 3/4"
bit. He got away with it with no damage, but even with coolant, the
chips came out of the hole smokin' and blue. It was spectacular and
smelly, too, because he was using heavy sulfured oil for the
coolant/lubricant.

High tooth loads on carbide can be tricky, because it's so brittle. And
of course, it depends upon whether or not it's an indexable insert bit or
solid carbide (though I don't want to pay for new solid carbide in that
size).

I didn't check my tables, but I think 2500 RPM is a little slow for that
"small" a carbide bit at high feed rates. You'll have to talk to the
carbide guys... I use mostly HSS with a few indexable bits for boring and
finish work.

I just want to make a stunt video of a lot of chips being made.

For a short time, my mill can go up to 3000 RPM.


Be aware that on breakthrough with extremely heavy feed you can acidentally
pull the drill down out of the chuck...worse yet, if you pull the work up
out of your vise etc it will begin spinning and then finally it will
launch.....

--



I would put the drill in a collet.

i

High metal removal rate drilling
 

"Ignoramus1116" wrote in message
...
On 2011-04-15, PrecisionmachinisT wrote:

"Ignoramus1116" wrote in message
...
On 2011-04-15, Lloyd E. Sponenburgh lloydspinsidemindspring.com wrote:
Ignoramus1116 fired this volley in
:

I would use something like 5/8" drill, drilling a 1/2" mild steel bar.

Oh... I thought at first you meant "high metal removal rate". You mean
"low BAR removal rate". Ig, the drill's bigger than the bar.

I meant, a 1/2" thick bar.

But that's just little stuff! G

The heaviest "drill hogging" work I've seen done on steel wasn't with
carbide, but with HSS with through-the-spindle cooling.

Dont have that.

Then there was some really heavy turning in Vallejo, with the lathe
taking out about a 3/8" deep chip at about 3/8" feed per revolution.
Of
course, it wasn't really "big" work... just 12" or 16" prop shafts, but
I'll bet they get even heavier cuts on the _really_big_ shipyard
lathes.

This is fun, I remember those 10 kW Russian lathes, with trepidation.



I saw one guy in Vietnam drill about .062" per revolution with a 3/4"
bit. He got away with it with no damage, but even with coolant, the
chips came out of the hole smokin' and blue. It was spectacular and
smelly, too, because he was using heavy sulfured oil for the
coolant/lubricant.

High tooth loads on carbide can be tricky, because it's so brittle.
And
of course, it depends upon whether or not it's an indexable insert bit
or
solid carbide (though I don't want to pay for new solid carbide in that
size).

I didn't check my tables, but I think 2500 RPM is a little slow for
that
"small" a carbide bit at high feed rates. You'll have to talk to the
carbide guys... I use mostly HSS with a few indexable bits for boring
and
finish work.

I just want to make a stunt video of a lot of chips being made.

For a short time, my mill can go up to 3000 RPM.


Be aware that on breakthrough with extremely heavy feed you can
acidentally
pull the drill down out of the chuck...worse yet, if you pull the work up
out of your vise etc it will begin spinning and then finally it will
launch.....

--



I would put the drill in a collet.


And then you are putting them both into a chuck.

A "collet chuck" to be more precise...and if you arent careful, it will slip
and ruin your drill as well as the collet...

High metal removal rate drilling
 

On Apr 15, 12:15*pm, Ignoramus1116
wrote:
For some strange reason, I want to shoot a youtube video, showing how
I remove an ungodly amount of material with a carbide drill, on a CNC
mill.

It would be, sort of, something like a "hold my beer and watch this" stunt.