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While Rigid, Accurate CNC Machine Tools and Modern Drill Designs

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While Rigid, Accurate CNC Machine Tools and Modern Drill Designs MARCH 2005 / VOLUME 57 / NUMBER 3 special focus: holemaking ➤ BY BILL KENNEDY, CONTRIBUTING EDITOR STEADYSTEADY as it guides While rigid, accurate CNC machine tools and modern drill designs minimize the need for drill bushings, the well-proven concept remains a valuable tool for select applications. or decades, drill bush- Drill bushings ings were required for Side view F precision holemaking Jig operations. A shop would Locking screw build a fixture to lock in the Workpiece relative positions of the Top view Location pins drill and part, then use a jig Jigjig fitted with a hardened-steel bushing to guide the drill. Such setups ensured that Workpiece the drill entered the work- piece straight and produced Drill bushings an accurate hole. It also eliminated the need for B. Kennedy pilot holes; prevented drill In a classic drill bushing setup, a jig is located and wandering and chatter locked onto the workpiece to assure repeatable when drilling holes in an- positioning of the drill bushings and resultant holes. gled surfaces; provided sta- bility when drill overhang was exces- ago, automotive plants employed sive; and reduced tool breakage. transfer lines with dedicated machines Today, drill bushing use is in decline. arranged in multiple stations. “They The main reasons are the emergence of would use drill bushings at every sta- rigid, fast CNC machine tools and ad- tion where they used a drill,” he said. vanced drill designs. CNC machines Today, most automotive work is done can apply a spot drill and quickly fol- on CNC machines, where “there usu- low it with the drill that penetrates to ally isn’t space in the fixture to mount the specified depth. And sophisticated a bushing,” Stewart said. Acme geometries allow drills to enter a work- “Drill bushings were big for 50 or 60 A drill bushing positions and stabilizes piece without spotting. years,” said Al Rocheford, who manages the drill to assure precision and Scott Stewart, applications engineer daily operations at Axly Tool & Bush- repeatability. at International Drill Guide Inc., An- ing, a Briney Tooling Systems company derson, S.C., pointed out that 30 years located in Bad Axe, Mich. Axly still manufactures bushings and supports ex- isting installations, but the standard drill Bushing basics bushings that formerly made up the bulk of Axly’s output now constitute only he most widely used and least expensive drill bushing style is the press-fit about 8 percent of its business. T (ANSI Type P). These simple, short, hollow cylinders of hardened steel are Ray Yillik, founder of carbide bush- pressed into the drill jig. ing maker Yillik Precision Industries, A step beyond the Type P is the Type H, or head press-fit, which has a head Ontario, Calif., said: “In the smaller or shoulder on the bushing’s drill entry end. The head is designed to resist axial tool-and-die and production shops, they forces that can force a headless bushing out of the jig plate. The Type H’s head are still using drill bushings. The tech- limits how close together the bushings can be placed in the jig, and mounting nology is good. It works. But the reality holes must be counterbored if a flush fit with the jig plate is desired. For prac- is that it is a dying commodity, because tical purposes, Type P and H bushings are permanently installed in the jig and the machines are getting so good.” are best for production runs where wear-related replacement isn’t necessary, and where only one diameter of drill or reamer is applied. Types P and L—Headless press-fit or headless liner Type H—Headed press-fit illik Precision Y Drill bushings made of tungsten carbide Type HL—Headed liner can provide 10 to 50 times the wear life of plain steel bushings. Filling Needs While widespread use of commod- Type SF—Slip/fixed renewable ity-type drill bushings is on the decline, demand persists for bushings that fill specific needs. Marshall Johnston, plant manager for All American Prod- Type FM—Fixed renewable ucts Co., San Fernando, Calif., offered All American the example of a pin-locking bushing Type SF (slip/fixed renewable) and Type FM (fixed renewable) bushings fit into system that sees frequent application in headless liner (L) or headed liner bushings (HL) that are pressed into mounting the aerospace industry. The bushings holes in the jig. The bushings are held in the liners by lock screws or clamps, which are for use with a small (3⁄32" to 1⁄2"in permit the bushing to be changed quickly. Type SF and FM bushings work well on diameter) drill and an air-fed drill long production runs in which bushings need to be replaced as they wear, as well motor. Johnston said the system is as in situations where multiple tool diameters (e.g., drilling and reaming) are used. “real handy to get in small places.” Some bushings feature OD serrations or knurled patterns designed to grip jigs The drill motor is fairly small and made of softer materials. Type DG (diamond groove) bushings feature a knurled compact, akin to a hand drill. The pattern on the OD to enhance their grip in the jig. SG (serrata groove) bushings bushing system consists of a liner that have straight serrations that aid pressing into a jig made of a softer material. is mounted in the jig plate and a bush- Type SP (serrata press) bushings have serrations and also a finish-ground OD to ing that is secured in the liner with a facilitate press-in installation in soft materials. pin lock. “A little twist lock, with a 30˚ Bushing manufacturers also add functional features to their products such as turn, locks it in place. It makes it a lot chip control geometry on the edge facing the workpiece. Other bushings are de- easier for the operator, and it speeds up signed with ports to feed oil or coolant through the bushing body to clear chips the operation, too,” Johnston said. and cool the cutting zone. Johnston added that demand for ser- —B. Kennedy rated press bushings engineered for use in softer jig plate materials, such as alu- tomotive industry. Such products often The following companies minum (see sidebar, page 65), appears employ difficult-to-machine or abra- contributed to this report: to be increasing as “more people are sive materials, and tungsten carbide using aluminum for jig plates instead bushings provide advantages over steel Acme Industrial Co. of steel because they are a lot lighter to ones when side loads on the drill or (800) 323-5582 move around. Keeps people from hurt- abrasion from chips generate excessive www.acmeindustrial.com ing their backs.” bushing wear. Yillik said one application area for Yillik said a carbide bushing typi- All American Products Co. his company’s carbide bushings is pro- cally costs five times more than a com- (818) 361-0059 prietary product development in the au- parable steel bushing, but provides www.allamericanproducts.com from 10 to 50 times the wear life. In Axly Tool & Bushing Inc. When you get lemons ... long production runs, he said, it is easy to justify the extra cost. “If they are (800) 248-0622 www.brineytooling.com … make lemonade. Successful com- drilling 100,000 holes, they are better panies recognize and adapt to chal- off using the steel bushing, but if they International Drill Guide Inc. lenges that can come in strange forms. are drilling a million or 2 million holes, (864) 225-2214 For example, a manufacturer’s respected then they should look at carbide … www.gundrill.com trademark may become associated with they are crazy if they don’t.” a completely different image. Yillik Precision Industries Witness E.I. du Pont de Nemours & Long and Deep (800) 854-9847 Co.’s registered Teflon trademark. The Another continuing application for www.yillik.com well-known product name gained unin- drill bushings, Yillik said, is gun- tended subconscious baggage when the media named organized crime fig- Counterbore counterpoint ure John Gotti “The Teflon Don” after prosecutors couldn’t make their o support and guide the drill, the bushing ID or bearing surface at its work- charges stick. T piece end must be just slightly larger than the drill diameter, within a spec- Acme Industrial Co., Carpentersville, ified range. For example, for 1⁄4"- to 3⁄4"-dia. drills, a typical ID bearing surface Ill., has been serving customers for over tolerance is between 0.0005" and 0.0006" larger than the drill diameter. In other 90 years. For the last 55 of those years, words, for a 1⁄2"-dia. drill, the bearing surface ID tolerance is from 0.5005" to a certain animated desert bird has used 0.5006". But the bearing surface does not have to extend the entire length of the “Acme” products to counter the attacks bushing. For example, for a 1"-long, 1⁄4"-dia. 5 of one hapless cartoon coyote. drill bushing, the bearing surface might be ⁄8" Counterbore On its Web site, Acme steps up and long. The rest of the bushing can be counter- acknowledges the situation. The com- bored or relieved to a larger diameter, but pany immediately points out the con- this a somewhat controversial matter. No counterbore Full bearing trast between its products, quality and Acme Industrial Co. manufactures its stan- surface supports service and the often bizarre actions of dard bushings without counterbores, offer- the tool for the that odd couple of the Southwest: ing counterbored bushings as specials. Other entire length of “Acme Industrial Co. has a proven bushing makers reverse that policy, making bushing.
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