Drilling two thru holes issues with perpendicularity, same spindle speed and feed all for all holes, but having issues with 1 or 2 holes being misaligned?
So we drill parts that have a 15 mm gap between the 2 surfaces however when drilling we have misalignment issues when going from one hole to the next hole
Just remember 2 of the 4 holes are always good. Feeds and speeds always the same. So I'm running into issues with perpendicularity, from one hole to another. There is a interior clamp and one on the top of the part. this is just a quick drawing that doesn't show the inside ID this part has or where the clamps would be on the top of part. also if its deflecting why only certain holes not all if everything is the same?
I'm picturing the fixture supports the pieces at two opposing locations, as shown in the sketch.
The upper piece rotates slightly when the drilling force is applied to the holes at 12:00 and 6:00.
Thus the perpendicularity of those holes in the upper piece would not be as good as the holes at 3 and 9.
Is that what you are finding?
Since the issue was described as a "robodrill" issue, rather than a drilling issue, the only choices are the Robodrill is mechanically incapable or the Robodrill software has a setting to drill them correctly.
Given that all of the important details that are left out, it's difficult to say what the problem is.
Are they 5 inch deep holes that are 0.0001 inch diameter?
Are they on opposite sides of a piece that is thick aluminum over a foam core?
Is the part configured exactly like you say?
Is the lack of perpendicularity 0.00000001 inch or is it .1 inch
Where is a picture of the item in the machine?
Where is a video of the drilling and all other operations?
Where is a diagram of the fixture?
Are these the first two holes, the last two holes; are these the only 4 holes?
Is there a tool change that uses a different drill for 2 of the holes?
Is there a chance that two holes are drilled complete then a profiling operation shoves the layers out of alignment and then the other two holes are drilled, but the one layer slides back?
What does the tool path look like?
You are asking for a diagnosis on a problem only you have access to information about and you cannot figure it out - yeah. You need aerospace expertise to at least be able to describe the problem in a way that any one else has the slightest chance to look over your shoulder and see what you are currently missing.
"Solid piece that holds together" - is this a tubular part (i.e. extends all around the part's circumferences? Or a two-place part like shown? If the latter, I could see that drilling the two off-axis holes might cause the fixture to deflect more, compared to the holes in-line with the solid pieces.
Similarly, is there an axis of alignment for whatever clamps and holds the two parts, and what measures are taken to keep the parts from rotating with the drilling torque applied.
A picture of the fixture with parts loaded might be helpful, or drawings, or video.
