Consider the place of proper precision drilling tools on every drilling project in the quest for that desired outcome precisely. Precision drilling tools are meant to make holes very accurately in very varied materials, and they find their use in critical applications, for example, aerospace, automotive, electronics, and manufacturing. These tools have a direct bearing on the efficiency, accuracy, and quality of work overall. This guide comprehensively describes how to choose high-speed drill bits, custom tooling solutions, and even custom drill bits for your project so that you can have the best results possible.
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Precision drilling tools are used for drilling holes in hard or specific materials with tight tolerances. Any task that demands the utmost levels of accuracy and reliability is done with precision drilling tools. Unlike the standard drill bits, the precision drilling tools have been engineered for optimal performance under very tightly controlled conditions specified by other tooling parameters, minimizing wear, maximizing repeatability, and increasing productivity.
The choice of precision drilling tools has to start with what material is being worked upon. Different materials, be it metal, wood, plastic, or composites, require varied drilling techniques and tools.
High-Speed Drill Bits: These types of bits work best in penetrating very hard materials like metals and alloys. Constructed of hardened steel or cobalt, high-speed drill bits suffer mischief only at intense temperatures, leaving razor edges perfectly suited to high-performance applications. Drilling speed is improved even under reduced cutting speeds, with extremely high durability as well for use in much harder or tougher materials.
Carbide-Tipped Drill Bits: These are a good choice for drilling through very hard materials like hardened steel or titanium. Carbide-tipped bits are tough and maintain sharp edges longer than standard high-speed steel bits.
Whatever material you are working with, it automatically directs you to select the most suitable drill that will render the desired precision with minimal wear out of the drill and therefore, help you to achieve excellent quality work.
The precision and tolerance of your project are also an important point in this. In this case, precision drilling tools are those specifically developed to very small tolerances—within a few microns. Should your project require such accuracy, you would require the specific accuracy engineered for it.
Custom Drill Bits: If your needs involve pretty specific results or if you are dealing with very peculiar materials, custom drill bits might be the best solution for you. These are drill bits tailored to your specific applications, including the hole size, shape, and depth you want to achieve. These are commonly used in workshops with fields that require a drill that's not yet available in stores and doesn't meet the precision requirements.
Because custom tooling solutions depend greatly upon the specifications of project-including such design requirements as hole depth, cutting speeds, and material type-there is virtually no end to the variations that can be imagined. Indeed, whether for prototype work or high-volume manufacture, custom drill bits will provide flexibility for precise specifications.
The selection of material and coating of precise drilling tools affects the tool's performance. Different coatings and materials are designed to minimize friction, generate less heat, and enhance tool life.
Coatings like TiN (Titanium Nitride): Particularly for high-speed drill bits, where coatings such as TiN enhance the hardness of the tool and make it wear- and heat-resistant, this is necessary for improved performance in long drilling cycles or in drilling tough materials. Besides, coatings also reduce friction and consequently, smoother and more efficient drilling is made possible.
This means generally that, with respect to precision drilling, it becomes very important to match the material and coating to the demands pertinent to the project. Tools that have the coating needed to make for good finishes would extend tool life along with accuracy.
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Much of this decision comes down to the material. For instance, a bi-metal hole saw is one of the more common tools for woodworkers, hobbyists, or a homeowner tasked with repairs around the house. As a rule, these are limited to soft materials like plywood and plaster, although as you will see, a good one is quite effective in cutting many steels and aluminum.
Hole size is another important consideration. The bi-metal hole saws just mentioned can produce holes many inches in diameter or ones as small as your thumb. At the other end of the holemaking spectrum are so-called circuit board drills, micro-sized tools common in the electronics industry and for plastic machining. Between these two lies a host of holemaking tools, most of which are suitable for CNC machining, sheet metal fabrication, ironworking and heavy construction, and more.
Perhaps the most widely used of these is the twist drill, named for its corkscrew-like twisted flutes. Many styles are available, including the most common of them, the jobber drill, followed by screw machine, taper length, aircraft drills, and many others. Diameters range from 1/32" or so up to 2" and larger—beyond this, more cost-effective options like hole saws, spade drills, and Forstner bits—a special type of woodworking tool—might be used.
Most are made of high-speed steel (HSS), although cobalt steel or even carbide-tipped drills are preferred on very tough or hardened metals. Whatever the style, twist drills are relatively inexpensive, making them a favorite of machine shops and hobbyists alike, even though a more productive and cost-effective alternative exists.
That alternative is solid carbide. For holes 3/4" in diameter and smaller, it is the clear choice for CNC machining and turning operations, especially where production quantities warrant the admittedly higher price tag. As with HSS drill bits, a range of geometries, coatings, and lengths are available, some designed for specific materials. For instance, Kennametal offers its HPR series drills for cast iron, the HPX series for steel, and the HPS for aluminum, each optimized for maximum productivity in these metals. Other manufacturers offer similar drills.
Another benefit to solid carbide drills is coolant through the tool. As its name describes, this feature allows cutting fluid to flow through the inside of the drill directly to the drill point. Not only does this cool and lubricate the work area, but it also serves to flush chips out of the hole, further increasing holemaking efficiency. Most modern CNC lathes and machining centers have this ability, and some even force the coolant through at very high pressures for greater efficiency and increased tool life. Learn more about cutting fluid for drilling operations.
Tungsten carbide is an expensive metal, so most cutting tool manufacturers provide alternatives for larger holes. Here's where indexable insert drills come in. Made of a heat-treated steel shank and equipped with two or more screw-on carbide inserts at the business end of the tool, these cost-effective tools pick up where solid carbide leaves off. Here again, different grades of carbide are available to meet various machining demands, as are specialized insert geometries and coatings. Coolant through the tool is guaranteed (and is a must) with indexable insert drills.
Spade drills are another option. Rather than a series of screw-on inserts, these have a single replaceable bit made of carbide or HSS. The technology dates back well before the development of CNC machinery but remains a viable option for very large holemaking needs where indexable drills are unavailable. Coolant through the tool is available in some cases, and due to the simple design, the tools are relatively inexpensive. The caveat is power—as with all supersized holes, a geared-head machine with sufficient axial thrust is often needed to drive these tools.
There's a more modern alternative to indexable drills, one that's less expensive than solid carbide and offers nearly equivalent performance. It's called the modular drill. In Kennametal's case, it provides a "full solid" carbide front in the form of a twist-on, single-piece insert. This makes tool replacement very fast, and due to its special design, extremely strong and accurate. Here again, other manufacturers offer similar tools, although we feel ours—the KenTIP™ FS—is superior. Try it and see for yourself.
That brings us back to hole saws. For drilling sheet metal and for very large holes in soft materials—say several inches or more in diameter—they are certainly an option in manual drilling operations. Hole saws are not recommended, however, for CNC machining. The reason is the slug. If you’ve never seen one, hole saws resemble an inverted, straight-sided wine glass. The stem or shank is clamped into a drill chuck while the opposite end (the part with the sharp sawtooth face) is forced into the material while rotating. When the drill breaks through, a slug of metal or plastic remains inside, which the operator must remove before drilling the next hole. If not, the hole saw will quickly fill with spent material, jamming it.
Everything thus far is only the tip of the holemaking iceberg. We didn't mention trepanning tools, the more elegant alternative to hole saws, or annular cutters (both of which suffer the slug problem just discussed). Nor did we discuss the many other drill bit types, among them step, brad point, augur, and hammer. Most have no place in a CNC machine shop unless it's to make repairs to the building or anchor equipment to the floor, but all are worthy companions of homeowners and hobbyists alike.
As for advice, it's quite simple: read the directions. Use the manufacturer's feed and speed recommendations. Grip the tool in a well-maintained, high-quality drill chuck or collet system. Do not use side-lock or Weldon-style toolholders if you wish the drills to last and the holes to run true. When dull, solid carbide drills should be returned to the manufacturer for resharpening, and spent carbide inserts and other cutting tools recycled. And cutting oil is advisable with all drilling operations, but in the case of CNC equipment, it’s essential to use clean, filtered cutting fluid mixed to the proper concentration level for the machining conditions. If you have any questions, reach out to your cutting tool manufacturer for advice. We’re here to help.
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