What is a deep hole drilling machine
What has been published about TBT
The following articles have been published in the specified journals:
Very clean in flight: The contract drilling division of the deep hole drilling machine specialist TBT supports customers with its know-how. The experts can do it. And often the customer can ...
Published in: Machine + Tools “, edition April 3rd, 2015
Published in: Produktion, Ausgabe No. 14, 04/2015
Published in: SCOPE online
Source: SCOPE Online: http://www.scope-online.de/produktionstechnik-werkzeugmaschinen/tiefbohren-im-lohnvertrag.htm
Published in: Zeitschrift Industrieanzeiger Edition, No. 1/2014
Published in: MM MaschinenMarkt 43/2013: Deep drilling machine improves surface for 9m long pipes
Published in: Journal NC Manufacturing, Issue 12/2013: Special challenges
Published in: MM MaschinenMarkt 43/2013: Deep drilling machine improves surface for 9m long pipes
Published in: Werkzeug & Formenbau, Edition 09/2012: A center for everything
Published in: Fräsen + Bohren, Edition 05/2012: Fully automatic tool changer for horizontal deep drilling machine
Published in: MM MaschinenMarkt 05/2012: Single-lip drills are used to produce deep holes from one side
Published in: Produktion Magazin, issue 6/9. February 2012: Services related to deep hole drilling
Published in: Produktion Magazin, issue 04/2011: One for all!
Published in: Production on July 4th, 2011
At full throttle into the depths
Single lip drilling tools: For the drilling of molded parts made of aluminum for the production of car tires, TCM relies on high-speed single-lip drilling tools from TBT Tiefbohrtechnik. With 500 bores per workpiece, the higher feed rate reduced the machining time by more than two hours.
The high-speed single-lip drills from TBT Tiefbohrtechnik have an optimized head grind for high performance and process reliability.
Printing forms for tires require ventilation holes to prevent the formation of air bubbles. Depending on the tire size, the number of ventilation holes is around 300 to 500. The material of the tire molds is aluminum. A shape consists of eight to nine segments that together form a closed circle. After the rubber compound has solidified, the segments move apart to remove the finished tire.
The mechanical processing of these parts is a complex matter. The mobility of the segments requires tight tolerances. In addition, the filigree tire profiles require a number of complicated operations. External specialists are often responsible for designing such complex processes.
This is also the case with a large tire manufacturer, who commissioned TCM Tool Management & Consulting GmbH with the development of a tool concept for the production of molded parts on a 5-axis machining center. Drilling the numerous ventilation holes is one of the more demanding operations. Reason: it's about depths of up to 80xD and relatively small bore diameters. The construction prescribes 1.5, 2.0 and 3.0 mm. With a view to process reliability, single-lip drilling tools are the first choice for such tasks.
TBT high-speed single-lip drillsThe high-speed single-lip drills from TBT have a special grind with a chip former on the main cutting edge. In order to be able to achieve feed rates of 400 to 800 mm / min, depending on the material, the entire tool is made of solid carbide. To reduce investment costs, the drill head of the HS single-lip drill is soldered onto a conventional steel shaft. This means that these drills can be produced much longer and more cheaply. With this variant of a high-speed single-lip drill, the feed rate could still be tripled compared to the conventional single-lip drill. The tool life of the drill head could be doubled despite the higher feed rate.
Standard single-lip drills
Initially, TCM resorted to standard single-lip drills, as they are also used in steel processing. For the 2 mm holes, those responsible decided to drill in two stages with drilling tools of different lengths. With the 1.5 mm holes, an even more complicated procedure seemed appropriate: Step 1: Drill 1.5 mm from the inside of the mold to a small depth of 20xD. Step 2: Drill from the opposite side with a 3 mm drill in line with the smaller hole.
The trick in such a case is to hit the other hole. But that's not a problem on a modern machining center. The profitability of such an approach is the more pressing question. The counter drill was therefore chosen to have a larger diameter in order to be able to drive with higher cutting values. Additional work steps such as turning the workpiece and milling a flat drilling surface on the convex outside had to be accepted. Despite the time saved by the larger counter drill, the bottom line was that a lot of machine hours were accumulated.
Too many in the eyes of those responsible at TCM - they consequently started looking for an alternative, even more economical solution. The Ratio specialists found what they were looking for at TBT Tiefbohrtechnik. In addition to deep drilling machines, the company also supplies the necessary drilling tools. One product line among several are the high-speed single-lip drills made of solid carbide. Equipped with internal cooling, among other things, these drilling tools meet all requirements for use on modern machining centers. TBT has optimized the head geometry for machining aluminum.
One of the special features is a specially designed chip former on the main cutting edge. This ensures a short chip break so that the chips are effortlessly flushed out of the bore by the coolant. A special coating prevents the formation of built-up edges and increases the service life. All features together bring about significant improvements in performance and process reliability compared to standard designs.
TBT has optimized the head geometry for machining aluminum. One of the special features is a specially designed chip former on the main cutting edge.
Reduction of non-productive times
“With our high-speed drilling tools, we are able to drill all ventilation holes in the molded tire parts in one go or from one side,” emphasizes Stefan Haas, sales engineer for the drilling tools division at TBT Tiefbohrtechnik. Tool changes within a hole or turning and reclamping of the workpiece for drilling from the opposite side are completely eliminated. The associated lower number of tools reduces a lot of non-productive times as well as other costs that are difficult to determine. The high feed rates of the high-speed tools speak a particularly clear language, as they lead to considerable reductions in machining times / drilling.
The savings exceed all expectations. "Of course, we expected shorter processing times from the start," says Jürgen Bek, Head of the Drilling Tools division, "but in the end we were surprised by the result achieved on this project." After a certain running-in period, the tire manufacturer is now drilling with up to 27 , 5 times the advance compared to before. On average, it saves up to 16 s per hole. With 500 holes per workpiece, the bottom line is a reduction in machining time of more than 2 hours. “The feed rate of 5000 mm / min, which we can achieve with our 3 mm drilling tool, is something that some machines cannot even achieve in rapid traverse”, explains the deep drilling specialist in conclusion.
.Published in: MM MaschinenMarkt 9/1. March 2010
Published in: Fräsen + Bohren, Edition: 1/2010, p. 57
Inclined deep hole drilling machine for drilling diameters up to 1,000 mmFor drilling diameters from 70 to 1,000 mm, TBT Tiefbohrtechnik GmbH + Co. has developed a completely new series of inclined bed designs.
Particularly with such large drilling diameters, special attention must be paid to the machine bed with regard to forces and vibrations. The choice fell on a composition made of steel and special concrete. The concrete does not serve as a simple filling compound, but is a self-supporting element with a special reinforcement.
In the computer simulation program of TBT, adapted to the special conditions of deep drilling, a machine bed was developed which has better damping properties and rigidity than pure cast beds, such as those used by TBT 20 years ago.
The inclined arrangement of the machine bed, which can also be found in modern lathes, offers the user numerous advantages such as easier set-up, improved chip evacuation and easier process control.
Thanks to the innovative design of the tailstock, special draw boring tools with free access can be changed. Auxiliary devices such as so-called lanterns for fixing the tool are a thing of the past. Compared to conventional constructions, new best values could be achieved in the course and in the surface quality with the inclined bed design.
Image: Inclined deep drilling machine
Published in WB Werkstatt + Betrieb 12/2009
Time saving of 50 percent
Milling and drilling work on one machine
Time is money. This applies in several respects to supplier companies: Accelerated manufacturing processes reduce manufacturing costs. Because they increase machine utilization, they also reduce capital expenditure. In addition, shortened production times make it possible to supply customers quickly and respond flexibly to their wishes.
The new BW 250-S from TBT Tiefbohrtechnik GmbH + Co, Dettingen, shows how efficiently a modern system can optimize the manufacturing process. Its innovative peculiarity: it merges the milling and deep drilling phases into one work step, reports TBT managing director Wolfgang Klein.
TBT has established its reputation as a specialist in boring mill solutions for four-sided machining of cubic workpieces. Up to now mainly present in the automotive industry, the company developed and built deep hole drilling machines in the diameter range between 0.7 and 1,000 mm. The model range extends to complete boring mills for series production with up to 20 NC axes.
The workpiece table with a maximum load of 15 tons also allows asymmetrical positioning of the workpiece with full utilization of the 15-ton load thanks to the special storage. In connection with this NC rotary table and the swiveling machining unit included in the standard, all machining operations can be carried out at two angles. The spindle drive has an automatic intermediate gear to increase the torque at lower speeds without having to forego high speeds for small drilling diameters.
Shear forces optimally absorbed
Active power measurement and coolant pressure monitoring are already included in the standard of the machines for process monitoring. With the changers for conventional tools and long single-lip drills, productivity has been significantly improved again. Another crucial point: the massive vertical stand optimally absorbs the transverse forces that occur during milling.
The successful example of the Zahoransky Group from Freiburg shows how efficiently the new BW 250-S can be used in practice. For many months it has been doing the job of relieving the existing machining centers of horizontal milling tasks. In addition to the originally planned deep drilling tasks, she also takes on heavier machining tasks for the TBT customer, explains Wolfgang Klein.
We are now working twice as fast as before
At the Zahoransky Group, which primarily manufactures injection molding tools, it drills cable ducts and mills pockets and threads in one operation, reports production manager Matthias Faber: "Since the milling and drilling work is carried out on one machine, we are now working twice as fast as before." In addition: In the past, between four and seven set-ups were required to machine a workpiece: “Since the BW 250-S can reach the workpiece from all sides, it is done with one clamping. And with the most important advantage: Two different work steps previously made it necessary to procure two different machines - but thanks to the deep drilling / milling combination, we can get by with one. "
Published in: mav competence in machining, edition 2009/10, page 87, 09/30/2009
Single-lip drills for feed matricesThe company TBT Tiefbohrtechnik has brought a new generation of high-speed single-lip drills onto the market, which is particularly suitable for types of steel that are used for feed matrices.
The demand for pellets as animal feed or as fuel is increasing worldwide. The pellets are manufactured in various types of pelleting systems. The raw material is pressed through dies, which have several hundred holes. The resulting strands are cut cyclically, depending on the desired pellet length, in order to obtain the desired pellet size. The round or flat die is made of different types of steel. Depending on the size of the die, the number and diameter of the holes, the drilling process in particular is very time-consuming and costly.
Drill faster for lower costs
The new high-speed single-lip drills from TBT bring the user significantly shorter machining times. Taking into account the non-productive processing times and the set-up times, the output can be doubled without major investments and the machine costs per workpiece can be halved.
Conventional single-lip drills are primarily used to produce the bores. Depending on the drilling diameter, drilling depth and material, feed rates of less than 200 mm / min can be achieved with these single-lip drills. Higher values are achieved with single-lip drills made of pure solid carbide. With the new generation of high-speed drills, peak values of up to 1000 mm / min can now be achieved. The higher acquisition costs and higher remanufacturing costs can be neutralized with a tool life that is up to 5 times longer, which, according to the manufacturer, means that the tool costs per drilled meter are comparable with values of previously commercially available ELBs. The drills are available in a diameter range of 3 - 8 mm.
Published in: Industrieanzeiger, edition: S3.2009, October 26, 2009
Single-lip drill - feed tripled, costs halved
The high-speed single-lip drills from TBT have a special grind with a chip former on the main cutting edge. In order to be able to achieve feed rates of 400 to 800 mm / min, depending on the material, the entire tool is made of solid carbide. To reduce investment costs, the drill head of the HS-ELB is soldered onto a conventional steel shaft. This means that these drills can be produced much longer and more cheaply. With this variant of a high-speed ELB, the feed rate could still be tripled compared to the conventional ELB. The tool life of the drill head could be doubled despite the higher feed rate.
Published in: Fräsen + Bohren, edition: 5/2009, p. 54
Productive deep drilling of small crankshafts
The deep drilling specialist TBT Tiefbohrtechnik is presenting the small version of the MultiCrank series for the first time at the EMO in Milan. The CX is especially designed for drilling crankshafts for 4- and 3-cylinder car engines.
This series was especially designed for the use of Spiral deep drills and high-speed end-lip drills developed. A special feature of the machine is a machine bed made of reinforced concrete with steel casing, which has better vibration properties than conventional cast or steel beds. This creates the prerequisites for long tool lives of the sensitive solid carbide tools. To reduce the positioning times, a linear drive with a travel speed of up to 100 m / min is used in the horizontal axis. For optimal radial positioning, each clamped crankshaft has its own direct drive to adjust the angular position.
A special feature is a laser measurement system integrated in the tool changer, with which the type and position of each tool is recorded and monitored without magnetic chips. With up to four crankshafts being processed at the same time, the machine achieves particularly high productivity.
Published in: Industrieanzeiger, edition: 2009/31, page 44, July 27, 2009
Deep drilling and milling center TBT BW250-S - One spindle cuts deep and wide
The machining center BW250-S from TBT is designed for both deep drilling and milling. This saves set-up processes and improves the precision of the components. The rigid structure enables high feed rates and long tool life.
"We use the same spindle for deep drilling and milling," says Wolfgang Klein. For milling, it moves forward on a linear axis. At the same time, the drill bushing carrier automatically moves diagonally upwards, "continues the managing director of the Dettingen-based TBT Tiefbohrtechnik GmbH Co. The advantages of the concept compared to separate spindles are maximum freedom from collisions and simpler programming Steady rests for the long deep drilling tools arranged on a separate guide rail.They stay on the machine, simply fold backwards when they are not needed.
In addition to a changer for 24 conventional tools, TBT also offers a magazine for ten deep drilling tools. "In this combination, the machine can be operated unmanned," says Klein. If the deep drilling tool is set up automatically from the changer, drilling depths of up to 1250 mm are possible in one go, and even up to 1500 mm with manual loading of the spindle. The diameter range is from 3 to 40 mm. Single-lip drills are used up to 35 mm, above that indexable insert drills. The work table is available in two sizes - 1200 mm x 1600 mm and 2000 mm x 2200 mm. The payload is 15 t, optionally 20 t.
In order for the deep drilling / milling unit to safely absorb the higher lateral forces that occur during milling and inclined drilling, the engineers designed the main stand to be extremely wide, thereby improving its rigidity. At the same time, access for setup processes remains free. An additional mechanical axis clamping of the swivel unit and the workpiece table increases the dynamic stability during machining. This eliminates micro-vibrations, which allows very good drilling performance and improves the tool life by up to 40 percent. "
As a special feature of the deep drilling and milling center, Klein mentions - in addition to the set-up and user-friendly design - the openness with regard to the control. It can come from Siemens or from Heidenhain. "It's nothing special for standard centers, but it is in our environment." TBT also recommends implementing a CAM system to automatically generate the NC programs. The majority of the BW250-S delivered are equipped with such systems. "It has long been standard for milling, but has not yet established itself in deep drilling."
The concept of the BW250-S arose from market research and customer surveys. "The results showed that the users wanted a machine with which they could also mill properly," describes Klein. When machining steel (1.2312), removal rates of up to 250 cm3 / min are possible. He mentions tool and mold making, special components for hydraulic systems and large connecting rods, for example for locomotives or ship engines, as target groups and potential applications.
The first BW250-S was completed at the end of 2007. Originally, this machine was supposed to stay in Dettingen and make chips there. "But one of our customers had an urgent need," says Wolfgang Klein. Twelve machines of this type have now been delivered and three more are under construction - a success that, according to Klein, no one at TBT expected. "Machines of this size do not sell in quantities like small universal machining centers. We initially assumed two lots of three that we wanted to sell in the first year."
The contract manufacturer Heck Tiefbohrtechnik from Usingen has been cutting with a BW250-S since August last year. The Hessians use deep boring mills from three manufacturers. Compared to his other machines, Daniel Wittmann - as foreman responsible for deep drilling - values his drilling and milling performance as well as the stability and accuracy at the Dettinger Center. "The drilling process is far below the permissible tolerances and the milling accuracy is absolutely sufficient for our applications. Compared to five-year-old deep boring mills, the BW250-S enables twice the feed rate and around 30% longer tool life.
Heck is currently considering investing in another BW250-S. Wittmann would have one more wish: "We could use a slightly larger work space." The Usinger will be happy that exactly this is being worked on in Dettingen. TBT managing director Klein: "We will close the gap between the BW250-S and our BW300." There shouldn't be any smaller models below the BW250-S. "Nowadays, the appropriate components are often drilled on conventional machining centers. That is why it is not worthwhile for us."
With its wide main column and mechanically clamped axes, the deep drilling and milling center BW250-S enables respectable cutting performance and twice as high feed rates as five-year-old machines. At the same time, the tool life is significantly longer. All of this reduces the unit costs of the components. In addition, the machine can optionally be equipped so that it can process large workpieces fully automatically in unmanned operation.
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