What do you think about drilling and tapping in thin-walled parts?
As shown in the picture above, a fusion drill can handle this task.
The hot melt drilling process is a chipless technology for processing holes and bushings on a metal sheet or pipe, which completely replaces the process of welding (riveting) nuts on thin-walled workpieces.
With hot melt drilling technology, it is convenient to form bushings or light holes on thin-walled parts with a wall thickness of less than 12 mm. Inserts or light holes can be up to 4 times the wall thickness of the parent material, with hole diameters ranging from 1.8 mm to 32 mm.
The hot melt adhesive drill is made of wear-resistant and heat-resistant carbide. When the tool is in contact with the workpiece, the high speed (1000~4000) and the corresponding axial force (feed force) will cause strong friction between the drill and the metal, and the temperature will reach 600~800 degrees Celsius in an instant. The metal around the drill rapidly softens and thrust continues to be applied to rapidly extrude bosses and bushings about 3-5 times the thickness of the original insert on the top and bottom surfaces of the workpiece. The whole process takes only 2-6 seconds.
For machining that requires a smooth joint surface or chamfered hole, a platform drill can be used to remove the boss formed on the surface of the workpiece. The sleeve can be used as a bearing support, bifurcated neck weld, etc. The threads are extruded, and the processed threads can withstand higher tension and torque.
Short description of the processing process:
The hotmelt drill bit simply makes contact with the material, positions it, and then presses it against the material with high axial force and speed.
Applied pressure and speed generate the required frictional heat of around 600°C to plasticize and shape the material. The Fusion drill penetrates material in seconds.
The melting drill compresses the metal both horizontally and vertically, thereby moving the material down, creating a sleeve. As the hot melt drill penetrates the metal, the feed pressure is gradually reduced and the feed rate is gradually increased.
A bushing has formed during fusion drilling. Material fed in the opposite direction is extruded and forms a round table that can be used for compaction. This frame can be removed in the same operation using a flat tipped drill with a cutting edge on the drill bit.
The shaping tap can be used immediately to cut threads without chipping the resulting sleeve without storage. Threading by cold extrusion increases the hardness of the material.
The result: a connection capable of withstanding high loads and torques. No drilling, subsequent rivet or nut welding required.
Hot fusion drilling can be ductile with almost all thin-walled metals (except tin or zinc), such as: ordinary steel, stainless steel, mild steel, aluminum, copper, brass, bronze, titanium alloys and other permanent workpiece materials. and also can process electroplating blanks.