Drilling and “milling” in a single operation, how and why?

# Drilling and “milling” in a single operation, how and why?

What are the advantages?

The drilling and "milling" process in a single operation, often referred to as the "2-in-1 operation", has undeniable advantages in many industrial sectors. This method consists of combining two steps into a single machining pass, which allows both drilling a hole and making a "countersink" or chamfer around that hole. This technique is particularly advantageous in industries where speed and accuracy are essential, such as aerospace, automotive, and mechanical engineering.

One of the main advantages of the 2-in-1 operation is the considerable time savings it allows on production lines. By integrating drilling and milling into a single step, companies can significantly reduce the number of tool changes and downtime associated with changes in operations. This translates into increased productivity, especially in large-scale production environments where every minute counts. For example, in the automotive industry, this technique makes it possible to speed up the assembly of parts, while ensuring consistent quality of drilled holes and for screws and rivets.

In addition, the 2-in-1 process helps to maintain an optimal level of accuracy. When drilling and milling are done separately, there may be mismatches or inaccuracies between the two operations. This can lead to minor defects in the machined parts, which, cumulatively, can affect the quality of the final product. By combining the two operations, the tools specially designed for this type of task ensure perfect alignment and consistent quality of the milling around the drilled hole. This accuracy is especially crucial in industries such as aerospace, where improperly positioned screws or rivets can impact device safety and performance.

In addition to time saving and accuracy, the 2-in-1 operation also offers cost savings. By reducing the number of tools needed to perform drilling and milling operations separately, companies can reduce their expenses related to tool purchase and maintenance. Fewer tools also means less logistics management and machine maintenance, resulting in lower overall production costs.

Finally, this method also contributes to the reduction of human error. Fewer manual steps mean less chance of errors, which improves the reliability of machining operations. This not only results in better quality of the parts produced, but also in a reduction in scrap and the need to rework defective parts, which is another factor in savings.

Suitable tools for drilling and milling in one operation

The success of the 2-in-1 process, which combines drilling and milling in a single operation, is largely based on the use of tools that are specifically designed to meet these requirements. These tools not only allow both operations to be carried out simultaneously, but also ensure high accuracy and optimal efficiency. They must be able to handle a variety of materials while maintaining the quality and durability of the machined parts.

The combination tools for drilling and milling are mainly specific drills with a modified cutting geometry. These drill bits incorporate a standard drill head at the front, followed by a countersink part that performs chamfering or countersinking of the hole immediately after drilling. This design ensures a smooth transition between the two operations without removing the tool from the workpiece, reducing positioning errors that can occur when changing tools.

Another key factor for these tools is their composition and coating. Tools are typically made from tough materials such as tungsten carbide, a durable alloy that resists wear and tear and can withstand harsh cutting conditions, especially on abrasive materials. In addition, these tools are often coated with specific materials, such as titanium nitride (TiN) or polycrystalline diamond (PCD), which enhance tool life by reducing friction and improving wear resistance.

Depending on the application sector, the size and geometry of the drills can vary to suit specific needs. In the aerospace industry, for example, drilling and milling is often performed on light alloys or composites, requiring longer drills with tight tolerances. In contrast, in the automotive industry, where productivity is critical, tools must be designed for heavy-duty use on materials such as steel or aluminum, with cycle time optimization to ensure a smooth production flow.

Tool manufacturers also offer modular solutions, where the drill bit and milling head can be replaced independently. This allows businesses to adapt their tools to different applications without having to buy a complete new set each time. This modularity is particularly advantageous for companies that need to machine parts of various geometries and materials, while reducing their operating costs.

Industrial applications and sectors of use

The 2-in-1 operation, which combines drilling and milling, is widely used in various industrial sectors, including aerospace, automotive, and mechanical engineering, where precision and speed are essential. These industries require efficient machining processes to ensure high-quality products while reducing production costs. Single-pass drilling-milling meets precisely these requirements.

In the aerospace industry, this method is crucial for the production of complex structural parts, often made of lightweight materials such as aluminum or composites. These parts require precise drilling and countersinking to ensure assembly with screws or rivets. Drilling-milling in a single operation makes it possible to make bores to insert fasteners flush, thus guaranteeing the safety and aerodynamics of the components. For example, when manufacturing wings or fuselages, precise drilling and immediate deburring are essential to avoid structural weaknesses.

The automotive industry, on the other hand, is taking great advantage of this technique to optimize its production lines. With high-volume manufacturing goals, OEMs need to minimize cycle times and maximize productivity. The 2-in-1 drilling and milling process speeds up the assembly of components, especially in the production of engine blocks, chassis and body parts. This method allows fasteners to be quickly inserted into steel or aluminum parts, while maintaining consistent quality. It is particularly beneficial for electric and hybrid vehicles, where optimizing the weight and precision of parts is crucial to maximize fuel efficiency.

Apart from aeronautics and automotive, the general mechanical industry also adopts this method in various machining processes. Drilling and milling in a single operation is useful for applications such as the manufacture of tools, heavy equipment parts, or complex mechanical components. In this industry, this technique not only improves productivity, but also ensures the precision needed to manufacture parts with tight tolerances.

Thanks to this innovative method, companies in these sectors benefit from improved operational efficiency, reduced errors and scrap, as well as consistent production quality, making it a go-to choice for many industrial applications.

The 2-in-1 operation, which combines drilling and milling in a single pass, offers an innovative and efficient solution for multiple industries. With tools specifically designed for these tasks and a variety of applications in industries such as aerospace and automotive, this method saves time, improves accuracy, and reduces production costs. It is an essential technique for companies looking to optimize their processes while maintaining impeccable quality.