Congratulations! You are now the recipient of the DRILL executable of the machine shop software Feedrate Calculator series of programs. I think you will enjoy using these programs, which include executable modules for MILL, DRILL, REAM, TAP, TURN, COBORE, CSINK, CDRILL, and a generalized FRCALC. They use very little memory, and common PC software (word processors, CAD/CAM programs, DOS utilities) are versatile enough that the Feedrate Calculator programs can be executed without exiting the host software. You will not experience memory conflicts because these programs are not TSR (Terminate and Stay Resident) dependent. In fact, if using machine tool controls that support processing of DOS programs this software will be accessible on the shop floor as an integral part of the machine tool. The entire collection of Feedrate Calculator programs is available for just $79.95 US, and will entitle you to download additional Feedrate Calculator executable functions as they become available. * * * * * * * * * * * * * * REGISTRATION * * * * * * * * * * * * * * The accompanying DRILL.EXE program is not crippled in any way, the registration request is sincere, the copyright is real, and the disclaimer is real. Your financial support and technical input are appreciated. To register just the DRILL.EXE program send a check for $10 US payable to Axis Unlimited at the at the end of this file and write "DRILL.EXE" somewhere on the check. If you later decide to register the entire Feedrate Calculator series, the $10 will be applied to the balance due. * * * * * * * * * * * * * * DOCUMENTATION * * * * * * * * * * * * * * The DRILL.EXE commands are not case-dependent (you can use either upper or lower case), and diagnostic messages appear if valid syntax is violated. However, do not mix case - like this: mIxeD CAse. Each Feedrate Calculator program includes a help screen which appears by entering the command itself (DRILL) without command line parameters. On the help screen you will be encouraged to enter data in the following format: + - - - - - - - - - - - - - - - - - - - - - - - + | | | DRILL [AL] .5(DIA) [HSS], or | | DRILL [FE] .5(DIA) [COB], or | | DRILL [TI] .5(DIA) [CRB], or | | DRILL [NI] .5(DIA) [MCB], or | | DRILL [CU] .5(DIA) [HSS] | | | + - - - - - - - - - - - - - - - - - - - - - - - + What this means is that the all three of following examples are valid and are actually equivalent because the program default is to drill Al with a High Speed Steel (HSS) tool: DRILL .5 DRILL AL .5 DRILL AL .5 HSS To prevent you from being misled by the syntax on the help screen, you need to know that it is not necessary for you to enter the command line parameters that are enclosed in brackets [like this]. The bracket characters are NEVER required. They are shown on the help screen only to indicate the optional nature of the enclosed parameters. Naturally this saves you keystrokes when the default calculation for drilling Al with a HSS cutter is desired. Notice that after the numeric input, the "(DIA)" characters are not required either. Do not type in "(DIA)" with the DRILL command. "(DIA)" is only displayed on the help screen to indicate to you that the numeric value should represent the drill diameter. Thus you see that the DRILL calculation always requires at least two parameters (DRILL n), and no more than four parameters (DRILL xx n xxx). Simple enough? Further examples follow later on in this text. The Feedrate Calculator programs do not limit their output to just speeds and feeds. For example, the DRILL Feedrate Calculator provides additional information as to tool tip length and the predicted inaccuracy in oversize of the final hole diameter. The SFM and IPT used in each individual calculation is displayed also. One secret to the success of the Feedrate Calculator programs depends on their consideration of tool stiffness and standard shop practice in regard to tool geometry, tool composition, and machine stock characteristics. Intelligent shop practice is built into the program logic. The Feedrate Calculator software incorporates natural intelligence based on machine shop and offline part programming experience. There is no faster, easier way to determine this vital programming data. The tool stiffness formulas are proprietary, and correspond with actual machining behavior. Although you have only received the DRILL program, various other Feedrate Calculator programs that are available are described below also. * * * * * * * * * * * * * * * DRILL * * * * * * * * * * * * * * * EXAMPLES: If you input just 'DRILL ', you will see a screen of online documentation providing a list of options. If you input 'DRILL .5 ', you will get the following display: -------- + - - - - - - - - - - - - - - - - - - - - - - - + | | | DRILL AL .500(DIA) HSS | | Calculation assumes 250.00SFM, and .0070IPR. | | | | rpm= 1909.85 ipm= 13.37 | | | | tool tip= .150; oversize= .0048 | | | + - - - - - - - - - - - - - - - - - - - - - - - + The results above should be self-explanatory. To drill a .5" dia hole in aluminum with a High Speed Steel Cutter, a good starting point is 1900 RPM at 13 IPM. Notice that cutting Aluminum using a HSS cutter is the default. If you were to enter 'DRILL NI .5 CRB ' you would get a display recommending approximately 575 RPM and 4 IPM when using a Carbide cutter. The numbers can be rounded somewhat for convenience in data entry. You also notice the display: oversize= nnnnn. The oversize value is the mean inaccuracy in oversize expected for the life of a drill in "standard" shop practice. The object is to acknowledge factors affecting hole size such as wear and tool tip geometry. Reliable data was only available for drill diameters from .0625" to 1". Extrapolation was not performed beyond those values. The data used for the inaccuracy in oversize calculation was generated by the Metal Cutting Tool Institute in which the diameter of over 2800 holes drilled in steel and cast iron were measured. Factors affecting the inaccuracy in oversize include: the accuracy of the drill point, drill point symmetry, lip lengths, axial heights of lips, adequate relief angle behind the chisel edge, initial drill wandering or instability, drill diameter, drill length, work material, spindle runout, cutting fluid, and setup rigidity. Drilling generally results in holes that are oversize, but undersize holes can result in certain materials due to elastic action (like rubber) or thermal contraction. The table of values for inaccuracy in oversize appears in the Machinery's Handbook, 21st Edition, page 1669. Regarding maximum spindle speeds - being a general purpose program, the maximum spindle speed allowable in the DRILL program is 3000 RPM. This is to prevent ridiculously high spindle speeds from being output for machines that do not support them. High speed machining is simply not the main emphasis of this program. But yes, if it was a popular request it would not be difficult to include. If there's a market need, I'd be glad to fill it. * * * * * * * * * * * * * * ALLOY TYPES * * * * * * * * * * * * * The alloy parameters currently supported in this version of the DRILL program are: Al, Fe, Cu, Ni, and Ti. These categories may appear vague or too general, but in practice the program output is quite acceptable for general purpose work. If you are doing screw machine work then these values are not optimal. In my exposure to general machine shop work, and highly automated (not necessarily high volume) workload, most dead time is in job setups, tooling changeovers, scheduling, and other non-cutting tasks. In determining appropriate speeds and feeds, the philosophy employed in the Feedrate Calculator programs is not to reduce tool life to the point of working the tool so hard that tools wear out every 15 or 30 minutes. Believe it or not, many sources of feeds and speeds data base their recommendations on a tool life of 15 to 30 minutes. If your shop intends to replace tools every 15 minutes then you will need more agressive values than those incorporated in the Feedrate Calculator defaults. Proper tooling in conjunction with the present Feedrate Calculator values can generate chips faster than widespread shop practice will generally remove them. If the machining cycle has to be interrupted to handle chips, feedrates may not be the production bottleneck. But back to the subject of alloy types Al, Fe, Cu, Ni, and Ti. Well, just try them. The Al parameter will provide a calculation appropriate for A356, 7075, and other commercially common aluminum alloys. If you are cutting an alloy and that is not working quite right, tinker with it. Most likely you have a setup or tooling problem. The program can not account too much for that. These values will put you in the ball park. The abbreviations of Al, Fe, Cu, Ni, and Ti do not stand for the pure metals. They represent the common alloys in their class. A word of explanation is required regarding the intent of the values in the "Fe" classification. Although "Fe" is iron, in the Feedrate Calculator programs "Fe" does NOT mean gray iron or ductile iron! You might be surprised to know that there is more iron (Fe) in Steel than in gray iron, ductile iron, ni-hard, ni-resist, or malleable iron. Fe in the Feedrate calculator stands for STEEL. The Fe parameter is applicable to the range of steel alloys from the carbon steels, to alloy steels like 4140 or 8160, up to Rc35 or so. If the steel you are cutting really doesn't machine well enough using the Fe parameter, you should consider trying the Ni option, which is for the tougher nickel-based alloys like Waspaloy, Hastelloy, and Inconel. The Ni option might also work for Cobalt based alloys, but in that case I'd definitely start slower and use something other than a HSS drill. Likewise, I'd suggest at least a Cobalt cutter (not HSS) for Fe or Ni, but since those cutters may not always be on hand when you need them, the DRILL program does not force a cutter selection. Check with your tooling supplier when in doubt as to recommended tooling. As for coolant considerations for drilling, it may be somewhat of a necessary evil, but in aluminum I tend to prefer peck drilling without coolant instead of using coolant and drilling deeper. If you really want to drill iron alloys, I am willing to work with someone who has exposure to cutting iron. By the way, I've worked in foundries (iron, steel, brass, aluminum, and magnesium) in addition to machine shop experience, and so have had exposure to the behavior of a wide variety of commercial alloys. Oh, if you want to cut magnesium alloys, you can use the Al parameter. But, slowing down the feedrate for magnesium is NOT recommended. I also don't recommend any type of coolant while milling magnesium. I don't like coolant anyway. But magnesium castings *are* produced commercially using a clay and water binder in molding sand, so it is not absolutely crazy to use a water-based coolant (or just plain water) for something as benign as machining magnesium. If a magnesium part does catch fire DO NOT use water in an attempt to extinguish the fire. If I recall correctly, nascent oxygen combines with magnesium to form MgO, making available lots of disassociated hydrogen which burns nicely also, providing even more fuel for your fire. But that's another subject. * * * * * * * * * * * * * * * MILL * * * * * * * * * * * * * * * EXAMPLES: If you input just 'MILL ', you will see a list of options. Or, if you input 'MILL .5 ', the last line of information displayed provides RPM and Inches per Minute for machining purposes. The on-screen display will indicate the defaults used. Entering 'MILL FE 1 ', for example, employs two optional parameters - 1) the material type, and 2) the cutter diameter. The command parameter 'FE' performs the calculation for Steel alloys (not iron). In the resultant calculation note the difference between the defaults previously obtained. In the former case (in which no material was specified), the default number of flutes was two - for aluminum alloys. In the latter case, where 'FE' is designated as the material type, the default is four flutes - for steel alloys. Thus, in ordinary circumstances you will rarely need to specify more than two optional parameters. Acutally, for slotting purposes the values given in the MILL routine are somewhat agressive. You may want to get a feel for the program by running slotting toolpaths at 60% of the given IPM and 100% of the given RPM. Tool length and depth of cut also detract from optimum conditions, so be cautious until you are comfortable. Depth of cut guidelines are included on the MILL display. * * * * * * * * * * * * * * * CDRILL * * * * * * * * * * * * * * * CDRILL performs calculations for center drilling, employing the numbered "Combined Center Drill and Countersink". CDRILL not only provides the proper speeds and feeds, but it also specifies the proper drill depth and specific tool size number (#00 to #5). This is trickier than may first appear (must be why its never been done before.) Unless the dimensions of the particular center drill to be used is known, and its particular measurements are known, entering the appropriate center drill depth can be quite a challenge - particularly when considering the indiscriminate use of reground tooling. Regrinding typically shortens the distance from the tool tip to the included 60 deg countersink which can cause unpredictably oversize countersunk holes. CDRILL optimizes the stiffness of the center drill and reduces the accompanying tool wobble, while minimizing drill depth, cycle time, and the tendency to oversize the final countersink diameter due to reground geometry. CDRILL is as easy to use as the other Feedrate Calculator programs. Enter: "CDRILL n" ^^^^^^^^ This will result in a calculation for the default aluminum alloy type for a drill size "n". For a steel calculation enter: "CDRILL FE n" ^^^^^^^^^^^ If you had the CDRILL program, entering "CDRILL .120" would produce the following screen: + - - - - - - - - - - - - - - - - - - - - - - - + | | | Diameter argument .120(DIA) is used. | | Assumed command is: | | CDRILL AL .120(DIA) | | Parameters are: 250.00SFM, and .0021IPR. | | | rpm= 3000.000 ipm= 6.44 Use a #3 size center drill; DEPTH= .152 | | + - - - - - - - - - - - - - - - - - - - - - - - + * * * * * * * * * * * * * * * FRCALC * * * * * * * * * * * * * * * The FRCALC executable is unique in that it allows command line input of DIA, SFM, IPT, and #Teeth, for complete user preference. This is particularly useful for high-speed milling, special form tool usage, or unusual cutting circumstances. As indicated in the help screen for FRCALC, the couplet format is required for FRCALC. (Couplets are data entered by 2's, as in "n DIA" or "n TEETH".) In case you want to reissue the FRCALC command without retyping the whole thing - no problem. FRCALC allows you hit F3 to reissue the commands in the DOS command buffer, and to add on to the previous command the revised couplet condition. (Actually, usage of F3 to reissue the command is a DOS feature, for which no additional programming was required in these programs.) For example, if you originally entered: "FRCALC .5 DIA 4 FL 250 SFM .004 IPT", to reissue a revised command you may press F3 (at the DOS prompt) - to recall the DOS command buffer, and add any new couplet data at the end of the command. You could issue the revised command by saying: FRCALC .5 DIA 4 FL 250 SFM .004 IPT .125 DIA .002 IPT ^^^^ ^^^ ^^^^ ^^^ Notice how ".125 DIA .002 IPT" were appended to the original command. FRCALC will recalculate the command based on the last data entered in the DOS command. In many cases, the use of F3 will not be necessary because you may be issuing the FRCALC command from a program that provides an alternative method of recalling the last DOS command. In such a situation, it may even be easier to edit the last DOS command and reissue it. In general, the easiest technique to use will depend on the software from which you issue the DOS command. The main point here is that couplet data can be issued multiple times on the same command line, and FRCALC will only use the last specified couplet if it is given more than once. The help screen which is displayed by issuing FRCALC by itself explains the valid syntax. If you don't like issuing long DOS commands, the simplest form of FRCALC allows you to drop the "DIA" word, only if the first parameter after the command "FRCALC" represents the numeric diameter value. For example, the following commands are both valid: FRCALC .5 DIA 4 FL 250 SFM .004 IPT FRCALC .5 4 FL 250 SFM .004 IPT Notice that the "DIA" word is not required when the diameter is the first value after the "FRCALC" word. The additional spaces are not required either, but were included for illustration only. In FRCALC, at least one space is required between command line parameters. In FRCALC, the order in which the couplet data appears is not significant either. As an example in mixing the order of couplet data, the following commands are all equivalent: FRCALC .5 DIA 4 FL 250 SFM .004 IPT FRCALC .5 DIA 250 SFM 4 FL .004 IPT FRCALC .5 DIA 250 SFM .004 IPT 4 FL FRCALC 4 FL .5 DIA 250 SFM .004 IPT FRCALC .004 IPT 4 FL 250 SFM .5 DIA, etc. There are 256 possible FRCALC couplet combinations, and more considering that the DIA specification can be omitted when the diameter value is given immediately after the word "FRCALC". When in doubt, call up the help screen by entering "FRCALC" by itself, without additional command line parameters. Actually, the more powerful routines are not FRCALC, but the others, because the intelligent defaults based on common shop practice as to tool geometry (number of flutes), tool material (HSS, CObalt, CaRBide, MiCRograin carbide), maximum RPM, optimum SFM, and recommended IPT (based on tool stiffness), are already in the program. Consideration is also given to the fact that setups are not always ideal. It is not possible to cover every possible circumstance in such an easy to use program. But I think this as close as it gets. * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * The other Feedrate Calculator programs are excellent (if not fantastic) also. Rather than bore you with endless examples, free demo programs are available on the Manufacturing Technology BBS (210-821-6356). However those demos are not true shareware and they time out after 30 days, so you may want to download them at the beginning of the month. * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * COPYRIGHT Axis Unlimited 1993 The accompanying DRILL.EXE program is SHAREware, NOT FREEware. You may use it for up to 30 days for evaluation purposes. Using it with no intent to pay you is dishonest. The copyright notice is for real. Unauthorized use is illegal. * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * DISCLAIMER Use of this product constitutes consent to abide by the following terms and conditions. Under no circumstances shall Axis Unlimited be liable for any loss or damage, direct, indirect, consequential, or incidental, arising out of the use of or inability to use this software. This agreement is in lieu of all other agreements, express or implied, including any statement or implication of merchantability or fitness for a particular use or purpose. * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * PRODUCT SUPPORT As a registered user you are welcome to receive the latest updates via the Manufacturing Technology BBS support line: (210)821-6356. There is no additional charge if you download the upgrades yourself, except perhaps for phone company long distance charges. Please do not ask for distribution diskettes; and please limit product support requests to use of the BBS for that purpose. In other words, please do not request personalized telephone support. However, exceptions will be considered. Axis Unlimited 654 Shadywood Ln San Antonio TX 78216-6816 USA jerry.myer@f783.n387.z1.fidonet.org (210) 821-6356 (BBS/modem) (210) 821-6214. (voice) 1:387/783 FidoNet /eof...drill.txt