Need to drill 22000 holes .010" dia thru .030" thick aluminium wall

[?Mark]

We're using an air motor now, but need to make it quicker. Farming out is on the table. Small lot o few dozen parts to begin with.

Looking for suggestions.

 

TIA

[Guest MTB Technical Services]

If this kind of work is a regularity, RoboDrill with a 24,000 RPM spindle.

[?Mark]

We are doing it on a RoboDrill with the rotary (the material is a tube) using 100k air motor. Still too slow.

Looking into Electron Beam...They can do 2000 holes per second...I wonder how much will that be $$$

[jeff]

.I wonder how much will that be $$$

 

What's that old saying? If you have to ask, you can't afford it.

[Guest MTB Technical Services]

We are doing it on a RoboDrill with the rotary (the material is a tube) using 100k air motor. Still too slow.

Looking into Electron Beam...They can do 2000 holes per second...I wonder how much will that be $$$

 

Oh Wow!

You're into a takt time area that going to require the most expensive technology available.

 

Keep us updated on what you find.

[Newbeeee™]

Wow x10!!!

100k motor not quick enough and the robo's dragging its heels!

Out of curiosity Mark is it a case of the part isn't making money (as in taking too long) or bottleneck of throughput (as in too long)?

 

Also if you find a link for a vid of the electron drilling please share - that'll be mighty impressive.

[GoetzInd]

NSK makes a 150K spindle w/ bt 30 shank. That would help a little over your 100k spindle.

 

Mike

[?Mark]

I guess this technology is nothing new. Modern Machine Shop article from 2002 describes it.

They've done 6.000.000 holes in a single SS part before...wow!

We have some parts with over 80000 holes that size on a tapered thin walled tube as well. Some development, some small run production. So yeah, everything drags on...even on a robodrill.

My associate is getting a quote...will be interesting.

[Guest]

One thing I've found with doing the small stuff over the years, as quick as the Robodrill is, it still takes nearly 10mm to get up to full rapid so you'll need to figure out where are you spending most of your time. in the cut or positioning. In the cut, you'll gain 30% performance with a faster spindle. If it's positioning, you're going to need to go to a linear motor machine where you can get I be 80,000 mm/min and up range. Physics Is your real enemy in this situation.

[Joe788]

Can you imagine being a machinist in the 1950's, and the boss walks in and hands you a print for a tube with 22,000 holes in it?

 

 

 

 

[?Mark]

ROFLMAO!!!!

 

Good one Joe!

[Guest]

[Mic6]

AHAHA! The first GIF. I like how the guy turns when he breaks thru the window.

[?Mark]

Not unexpected...the tooling charges are substantial. For few hundred pcs/year lots not very cost efficient. If we hit thousands it's definitely worth pursuing. Still looking...

[Guest]

Can you imagine being a machinist in the 1950's, and the boss walks in and hands you a print for a tube with 22,000 holes in it?

 

 

 

 

 

That was called a career

[zero_divide]

With a 100 k air spindle you can feed at around 60 ipm.

A 30 thou deep hole will be drilled in no time.

 

You will loose more time on positioning.

Physics of the machine is the limiting factor here.

[CRW]

Small hole EDM?

[35K chipper]

Mark,

These people make Femtosecond lasers for hole drilling.

There is an article about drilling holes in injector nozzles in

the current issue of Laser Focus World.

Here is a link to the company that sells the equipment. http://www.raydiance.com

hope this helps.

.

.

35k

[?Mark]

Mark,

These people make Femtosecond lasers for hole drilling.

There is an article about drilling holes in injector nozzles in

the current issue of Laser Focus World.

Here is a link to the company that sells the equipment. http://www.raydiance.com

hope this helps.

.

.

35k

 

Thanks chipper. Cycle time is 1-2 seconds per hole though. A little slow for our application.

Interesting stuff though!

 

Thanks! <cheers>

[jeff]

What about 2,000 holes per second?

 

http://www.practicalmachinist.com/vb/cutting-tools/high-speed-holemaking-272445/

 

Is that fast enough? lol

[Newbeeee™]

^^^

quote:

Want to join the elite club of EBD shops? You’ll need some serious cash. “You’re looking at $1.5 to $2 million for a decent-sized driller, which means a vacuum chamber with a couple cubic meters of capacity and 20kW to 30kW of power,” Rugh said. However, these machines are so fast and productive that a shop considering a new EBD might be able to do in a week or so what previously took them a year, leaving the machine idle unless the shop can generate new business. “In that regard, it can be hard to justify the investment,” he said.

 

WOW!

[GoetzInd]

I wonder about hole quality and location with a system like that.

 

Mike

[Guest]

I wonder about hole quality and location with a system like that.

 

Mike

True dat.