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- 27.06.2024
Improving drilling performance in the aerospace industry
Drilling composite and metal materials in the aerospace industry requires tools of high precision and reliability. The Z2 and Z3 drills developed by TIVOLY offer innovative solutions to meet these requirements. This article explores the features, benefits, and applications of Z2 and Z3 drills, demonstrating their usefulness for aviation professionals.
# Features of Z2 and Z3 drills
Versatile design
The Z2 and Z3 drill bits are specifically designed for manual drilling of various materials used in the aerospace industry, including CFRP (carbon fiber reinforced plastics) composites, aluminum, and titanium. This versatility is made possible by a range of varied diameters from 3 to 10 mm, making it possible to cover a multitude of applications in aircraft manufacturing processes.
Z2 and Z3 Geometry
The Z2 and Z3 drills feature specific geometries to meet the most demanding drilling needs:
- A Z2 Geometry designed for the production of pilot guide holes, this geometry is ideal for drilling stacks of composite and metal materials. It allows for the preparation of precise guide holes, reducing the risk of delamination and making it easier to drill complex materials. The standard aeronautical dimensions (2.5, 3.2 and 4.1 mm) are covered by this range, ensuring optimal compatibility with industrial needs.
- A Z3 Geometry which, thanks to its integrated driver, allows the holes to be enlarged precisely and without delamination. The Z3 drill is designed to finalize holes guaranteeing perfect quality at the opening, thus respecting H10 diametrical dimensions. This feature is crucial for maintaining the structural integrity of materials and ensuring high-quality assemblies.
Next-generation sharpening
These drills benefit from a new generation of sharpening, which significantly improves tool life by reducing wear. This optimized sharpening also helps to maintain sharp cutting edges for longer, ensuring consistent performance even after many uses.
# Compatibility with pneumatic tools
These drill bits are compatible with pneumatic hand drills commonly used in the aviation industry. They can be used at different speeds (1500, 3000, 4500 and 6000 rpm), offering great flexibility to adapt to the specific needs of each application. This compatibility maximizes the efficiency of drilling operations while minimizing the risk of material damage.
# Precise control of the cutting force
The Z3 (multi-material) drill geometry provides precise feed control, effectively preventing the undesirable "flick" effect of the hole uncut. This feature significantly reduces the risk of delamination and improves drilling comfort for operators. By enabling self-regulating thrust, Z3 drills minimize the likelihood of tool breakage or accidents, contributing to a safer, more ergonomic working environment.
# Special applications for aeronautics
The PCF Z2 and Z3 drills are specially designed to meet the stringent requirements of the aviation industry. They are particularly effective for drilling stacks of composite/metal materials, such as CFRP/titanium or CFRP/aluminum. Their ability to drill through these materials in a single pass reduces the number of tool changes required and thus optimizes production processes.
# What are their advantages?
Mastering delamination
The Z2 and Z3 drills are designed to prevent delamination of composites at the exit of the hole, a common problem when drilling laminated materials. The optimized geometry allows for efficient chip evacuation, reducing the risk of jamming and premature wear.
Reduction of Musculoskeletal Disorders (MSDs)
Thanks to their innovative design, the Z2 and Z3 drills minimize cutting forces and reduce vibration, helping to reduce musculoskeletal disorders in operators. This is especially important in a production environment where repetitive tasks are frequent.
Its practical applications
Z2 and Z3 multi-material drill bits are indispensable in the aerospace industry for precise and efficient operations. They are particularly advantageous for drilling composite/metal stacks, such as CFRP/titanium or CFRP/aluminum. Their ability to drill through these materials in a single pass improves the productivity and quality of the manufactured parts.
# Application case: drilling a CFRP/titanium stack
Drilling composite/metal stackups, such as CFRP (carbon fiber reinforced plastics) and titanium, poses unique challenges due to differences in material properties. CFRP is a lightweight and strong composite material, while titanium is an extremely durable metal that is difficult to machine. Drilling these two materials in a single pass requires tools specifically designed to avoid common problems such as delamination of composites and rapid wear of drill bits.
The goal is to create a final 6.35 mm hole in a CFRP/Titanium stack in three separate steps, using TIVOLY's Z2 and Z3 multi-material drills.
First, the guide hole must be prepared with a Z2 drill bit. To do this, a 3.2 mm Z2 drill is chosen, designed to efficiently drill through CFRP without causing delamination. The optimized geometry of the Z2 drill bit allows for the creation of a precise guide hole, which is crucial for subsequent drilling steps. When drilling titanium, it is essential to maintain a moderate speed in order to prevent overheating of the material and minimize wear and tear on the drill bit. The guide hole thus created serves as an initial pathway, ensuring better accuracy for subsequent operations.
Next, the guide hole should be enlarged using a Z3 drill bit. After drilling the 3.2 mm guide hole, a 4.1 mm Z3 drill is switched to. This drill, thanks to its built-in driver, allows the hole to be enlarged precisely without deviations, while maintaining a clean cut and without delamination of the CFRP. During this phase, it is important to control the drilling speed, gradually increasing the size of the hole to avoid overheating and minimize stress on the materials. The Z3 drill bit ensures a uniform and precise cut, preserving the integrity of the composite material and preventing cracking or delamination.
To finalize the hole and reach the final diameter of 6.35 mm, a Z3 drill is again used, but this time with a larger diameter adapted to the desired final size. The 4.1 mm Z3 drill bit is replaced with a 6.35 mm model. This final drilling step must also be done at the right speed to ensure a clean and precise cut, without compromising the materials. The optimized geometry of the Z3 drill helps maintain precise control of the feed, preventing the undesirable effect of "flicking" at the knockout and reducing the risk of delamination.
In summary, the process of drilling a CFRP/titanium stack with TIVOLY's Z2 and Z3 multi-material drills takes place in three essential steps: preparing the guide hole with a 3.2 mm Z2 drill, enlarging the hole with a 4.1 mm Z3 drill, and finalizing the hole with a 6.35mm Z3 drill. Each of these steps requires precise speed and feed control to ensure a clean, delamination-free cut, ensuring optimal results for demanding aerospace applications.
TIVOLY's Z2 and Z3 multi-material drills represent a significant advance in the field of multi-material manual drilling in the aerospace industry. Their unique design, versatility, and durability make them a go-to choice for professionals looking to improve the quality and efficiency of their drilling operations. Investing in Z2 and Z3 multi-material drills is a wise decision to optimize machining processes and achieve impeccable results.