Kennametal, a leading tooling and advanced engineering specialist, has introduced the FBX drill for flat-bottom drilling of structural aerospace components.

The patented drill delivers superior stability and up to 200% higher metal removal rates when machining high temperature alloys, stainless steel, and other materials. It is the critical first step in a three-part tooling concept—including the HARVI Ultra 8X and the HARVI end mill series— specifically designed by Kennametal to decrease cycle time for these types of applications.

Quickly removing large amounts of material remains a challenge for these types of components. Traditionally, the first process step is to enter the material by using ramping techniques. This is a time-consuming process and low metal removal rates are the norm.

Georg Roth, Kennametal product manager, said: “The FBX drill dramatically speeds up the machining process by combining the advantages of a flat bottom drill and a Z-axis plunge mill.

“The flat bottom design eliminates radial forces while four effective cutting edges provide increased feed and speed rates, leading to up to 200% higher metal removal rates than traditional ramping techniques and freeing up capacity for aerospace manufacturers.”

Once the drill has shaped the basic structure of the component, roughing and finishing with indexable and solid end mills are the next process steps.

Unique design features
Four effective cutting edges provide stability in challenging applications like chain hole drilling, while large chip flutes ensure a ‘hassle-free’ chip evacuation. Supported by a series of exchangeable coolant nozzles to help eliminate heat build-up, the drill point is characterised by a centre insert with two effective cutting edges and chip splitters for maximum feed capabilities.

The drill bodies are available in diameters 60, 75, and 90mm, and come in a long (150mm) and short version (95mm). This modular drill connects to Kennametal’s bolt taper flange (BTF) mount adapters, available in various spindle connection styles.

The FBX is considered to be ideally suited for drilling into solid, chain hole drilling and plunging in a variety of materials such as high-temperature alloys, stainless steel, and steels and cast irons. It is equally as versatile and high-performing in similar applications for the general engineering and power generation markets.

With over 80 years as an industrial technology leader, Kennametal Inc delivers productivity to customers through materials science, tooling and wear-resistant solutions. Customers across aerospace, earthworks, energy, general engineering and transportation turn to Kennametal to help them manufacture with precision and efficiency.

Every day approximately 9,000 employees are helping customers in more than 60 countries stay competitive. Kennametal generated nearly $1.9 billion in revenues in fiscal 2020.