Single blade reamers - who knows about them?

[woodyrod]

Hello all,

We have a new drilling system, after waiting forever it seems on suppliers to get their lazy arses into gear, we finally have one. It is a Mapal unit, in 21,50mm diameter.

Now we require a single blade type reamer to go with the high speed / high penetration rates we need for production.

What have people experienced with these types of reamers? Any recommendations for brands and suppliers? We are in Australia, but buy tooling from all over the world.

We require an excellent finish, and H8 tolerance from 22,00mm hole.

 

[saberblue]

To get stared buy your reamers from Mapal who have apparently built your unit (tooling probably) -- once you have the kinks out of the process then you can look for another tooling source.

Being a fluids guy you are going to need a fluid (coolant) with very high levels of hydrodynamic lubrication to get the best results.

good luck and happy learning

A.R. "Andy" Nelson
Engineering Consultant
anelson@arnengineering.com

 

[unclesyd]

I just posted this on your deep hole thread. After going to all you troubles making your hole I would even think about blade reamers.

Here are two systems that we have use for precision hole in tool steels. The diamond hone from Engis is the best. One feature is you can't go oversize. The Helical is essentially the same thing.

http://www.engis.com/products/honing/

http://www.helicallap.com/

 

[woodyrod]

Ok, so how do we go from the 21,50mm hole to 22,00mm? A hone won't do this will it? Standard type machine reamers do not work in this material as it tears.

What is the issue with single blade reamers?

Also, we are working with annealed tool steel, not hardened. Process is mostly completed, then sent for heat treatment. We don't require the roundness that you are stating.

 

[woodyrod]

Oh, and the other issue is the next project we are working on is not a through hole, but not a blind one either - just a reduction. So any tooling with long leads will not work either, as it needs to machine mostly up to an internal shoulder.

 

[unclesyd]

I was assuming that your hole would be a little tighter based on your effort put forth in drilling. Both hole could be broached. I would also look at jig milling and/or better yet jig grinding.

I still would look to tighten your hole size tolerance.

Our procedure for working tool steels ,mainly D2. A2, T15, is machine to approximate size heat treat and finish by grinding or honing

 

[woodyrod]

Hello unclesyd,

What do you mean by "both holes could be broached?" You mean a broach reamer?

We won't be changing our process to include any milling or grinding of the holes - we don't have the gear, and I don't use contractors for such things, we are Australia where manufacturing is almost a dead art here.

All work will be done on our Mazak Machining center.

The tolerances are not that critical. If they fit as close as you may like, the item will never be of much use, as it will jam up easily with dirt etc. Call this field experience....

The part that fits inside the bore (the action bolt) is also made on the same machinery, same issues, except external of course. ALl parts are hand finished.

 

[unclesyd]

If your tolerance will allow it you might want to use a Dreamer to finish your holes.
In the Dreamer information they say they can go to 1.5" as their standard size is 5/8" max.
You could buy one at you local tool supplier and check the results.

http://www.dreamertoolinc.com/

Again I was thinking way ahead as I was thiinking of using a push type round broach for the through holes. The do make a broach for blind holes.

http://www.warrenbroach.com/punchBroach.html

 

[brengine]

Give these guys a call:

http://www.wincoindustries.com/

They can do anything. Awesome to work with. I think the name of the product you want to get from them is called an "Adjustable Padded Reamer". It has an insert and can be calibrated to the diameter you need.

Enjoy,
Ken

 

[woodyrod]

unclesyd said:If your tolerance will allow it you might want to use a Dreamer to finish your holes.
In the Dreamer information they say they can go to 1.5" as their standard size is 5/8" max.
You could buy one at you local tool supplier and check the results.

A dreamer being a drilling reamer? Maybe help me out by explaining what you mean in initial posts. I am not up with machining terminology. I doubt we could buy anything like that at our local supplier, as I have difficulty getting pretty much anything you can think of.

 

[unclesyd]

You might e-mail the Dreamer Co to find a distributor in Australia.

http://www.thomasnet.com/profile/412323/cutting-tools-inc-dreamer-tool-co.html

I did buy my dog's medicine in Australia. Even with the freight it was still 30%-50% cheaper than the local Vet.

Here is a better picture of round push broach.

You are probably not familiar with a product called Astroturf used in door mats but we used a round broach to broach over 33,000 5/16" holes in drums used to make the product. We used the quill of a Cinnamatic Milling maching to push the broach.

http://www.dumont.com/prod9c.html

You are probably not familiar with a product called Astroturf used in door mats but we used a round broach to broach over 33,000 3/8" holes in drums used to make the product. We used the quill of a Cinnamatic Milling maching to push the broach.

 

[woodyrod]

How would we go with 8 inch depth of cut on the bore with a broach? Would be highly unlikely I would thing that this would be possible with typical workshop equipment. I won't bother looking for a local supplier, have had very poor experiences with almost all suppliers I have dealt with in AU to date.

Am very familiar with Astroturf, I used to play on the international field hockey pitches in Western AUstralia while at school.

Still wondering about a reamer, using rotation provided by the main spindle of the CNC. We have a simple honing machine also, that has been used quite successfully in the past. All we need is to get the finish from the reamer better than we get now. Around 0.0002" or better should be ok.

 

[Tbirdhero]

Hello WoodyRod, we can meet your specifications, We are Winco Industries Inc, in Tipp City, Ohio; USA. Please call 937-667-4476 ask for Matt Gross

 

[woodyrod]

Matt, if you read the posts, you will find I am in Australia. We don't do phone calls to the USA.

How much and when can you do a reamer? I already sent an RFQ on your website. Any chance of replying?

 

[unclesyd]

It's been a while but I just run across this two bladed floating reamer.

How is the machining going?

http://www.bonehamusa.com/pdfs/Adj_floating_reamers.pdf

 

[woodyrod]

Hello unclesyd,

Well, what a timely question. I just yesterday received our new single blade reamer from Walter Germany. We are now able to produce the items we make to the standard we require.

The reamers you suggest are much too short, by around 80mm, or over 3 inches. We require 200mm cutting depth @ 22mm diameter. Close to 10D hole depth.

Anyway, the reamer works well. Took a few holes to get it sussed out, but had no bin jobs nonetheless. It works at quite a high speed, and due to the hole being a bit small, it the feed rate is slower than the book says. It works at 60m/min V, and 0,09mm F/rev. Facing, drilling, reaming and threading takes 7 minutes.

Am very happy with the outcome, although it did cost AU$2000, or around US$1800. A bargain really.

 

[unclesyd]

Thanks for the update.
Glad to see that the tool is doing the job. As you state the tool is a bargain if it does the job essentially out of the box. As I use to tell my boss the cost per hole gets less for each new hole.