6D drilling Revolutionary innovation in drilling technology

6D drilling

The latest development in LTI Motion GmbH is a magnetic bearing drilling spindle with a HSK32 tool interface where the fluctuating shaft can be redirected and the frequency, amplitude and mode of vibration can be freely programed using the CNC control. This makes it possible to optimally adjust the chip size, chip shape, entry speed and entry angle of the cutting edge to the drilling process. Thanks to integrated sensor technology, important process data, for instance cutting power, can also be recorded and processed online to determine the drill wear. In addition, for example, the start of drilling or different material layers can be recognized, and the processing parameters can be flexibly adjusted during the process.

LeviSpin Magnetic bearing drilling spindle

  • Increase in productivity (e.g. through higher feed and cutting speeds)
  • Increase in quality by minimizing friction with very small chips
  • Process optimization (e.g. rear-side deburring in a single process step)
  • Intelligent process monitoring (e.g. tool wear detection)
  • Magnetic bearing drilling spindle with “floating” shaft (no abrasion)
  • Integrated sensor for intelligent monitoring of the process
  • Adjustment of the processing parameters such as chip size, chip shape, entry speed and entry angle chip size, chip shape, entry speed and entry angle

Principles of vibration assisted drilling Conventional and vibration assisted drilling in direct comparison

Chip formation

Chip formation

The basic difference between the two drilling processes can be seen in the geometry and size of the chip. With conventional drilling, a long spiral ship is created. With vibration drilling, the chip is constantly broken off by superimposing the rotary motion with an axial oscillating motion, resulting in the creation of lots of small chips.


Thermal load

Thermal load

One significant advantage of vibration drilling is the substantially lower thermal load on the drilling tool and on the raw material. An analysis of the drilling process using an infrared camera clearly illustrates the advantages of vibration drilling. With conventional drilling, the temperature rises as the drilling depth increases. With vibration drilling, the processing temperature is significantly lower and remains constant as the drilling depth increases, since the chips do not create friction.


Tool cutting-edge life

Tool cutting-edge life

An analysis of the tool cutting edges when drilling CFK / Ti6A14V clearly shows the benefits of vibration drilling regarding cutting-edge life because of the significantly lower thermal load

This effect is independent of the tool coating.

With friendly support and research by:

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All benefits for users at a glance

Increased productivity

  • Higher feed and cutting speeds
  • Use of PCD tools possible
    → higher cutting speed and cutting-edge life
  • Optimized tools (e.g. three-edged drills)
    → higher feed speeds
    → higher cutting-edge life

Cost saving

  • Increasing the cutting-edge life of the tools
  • Reduced infrastructure for coolants and chip removal
  • Higher spindle service life (due to the non-wearing bearing)

Process optimization

  • Composite processing: Sensory material recognition during composite processing with automatic adjustment of processing parameters
  • Automatic deburring of the bore exit
  • Tool-friendly chipping parameters

Process safety

  • Online process monitoring
  • Preventative error detection (e.g. tool wearing)
  • Reliable chip removal (important for automation)

Quality

  • Enhancement of the drilling quality, particularly with composite processing
  • Reduction of the burr at the bore exit
  • Reduced change of the structure at the drilling edge

Environmental protection

  • No noxious cooling emulsion
  • Energy efficiency (no friction loss in the spindle)
  • Shorter process times -> energy saving via shorter process times and better level of efficiency

Example of use Aviation industry

In the aviation industry, blends of different materials (e.g. titanium + CFK) are being used because of the demand for lightweight construction. Drilling these kinds of composite material is a particular challenge that cannot be solved satisfactorily in terms of productivity and quality using conventional drilling technologies. The long metal chips from conventional drilling (e.g. titanium or aluminum) rub against the bore hole wall and damage the softer CFK. As a result, the required bore hole tolerances cannot be produced reliably.

Here, the advantages of the newly developed innovative solution of LTI motion become very clear. The vibration assisted drilling process only produces short chips.

The air stream from the minimal lubrication blows the short chips out of the drill hole very quickly and they do not rub against the bore hole wall. No damage or expansion occurs in the bore!

Another unique selling point of this technology is that different material layers can be recognized by the high-resolution sensor and the processing parameters can be automatically adjusted to the respective material.

With friendly support and research by:

Logo IWT

Example of use Deep hole drilling

With conventional drilling, the process temperature rises as the drilling depth increases, as the chips are rubbing against the drilling wall for longer. Besides the thermal advantages of vibration assisted drilling, optimal chip removal is also very important, especially for deep hole drilling. Due to the low processing temperature, an environmentally-friendly minimum lubrication can be used instead of cooling emulsion.

Another feature of this technology is that the high-resolution sensor recognizes the necessary axial feed force and therefore, the tool wear can also be detected. This means that tool breakage can be prevented in advance. In turn, the magnetic bearing prevents the drill from shifting.

Video magnetic bearing spindle The innovative technology: 6D drilling

Discover the VAD spindle on our YouTube channel …

Video Vibration assisted drilling Revolutionary innovation in drilling technology

Discover the VAD spindle on our YouTube channel …

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