In the series production of aluminum extrusion profiles, especially in the automotive industry, efficient and process-reliable machining is a top priority.
DRILLING CAPS DISRUPTED THE PRODUCTION PROCESS
A customer from the industry had been facing a persistent issue for years: During drilling into the material EN AW-6060, so-called "drilling caps" – disruptive material residues at the hole exit – formed regularly, making additional manual reworking necessary.
Despite extensive testing with various drills and manufacturers, the problem could not be satisfactorily resolved. The material posed a particular challenge due to its toughness and long chips – the goal of fully automated processing without manual intervention remained unmet for a long time.
TEST RUNS WITH THE EXBURRDRILL BROUGHT THE SOLUTION
By using the KEMPF ExBurrDrill with a diameter of Ø 9 mm, a sustainable solution was finally found.
Following a consultation and supervised test run with our application specialist Thomas Welte, a convincing result was achieved:
- Spindle speed (n): 9,000 rpm
- Feed per revolution (f): 0.3 mm/rev
- Feed rate (Vf): 2,700 mm/min
The ExBurrDrill handled the machining reliably and produced clean surfaces at all hole exits – completely free from drilling caps. As a result, the previously necessary manual inspection and rework process is now entirely eliminated.
The customer was extremely satisfied with this solution and plans to convert additional dimensions to the KEMPF ExBurrDrill in the future. This process optimization significantly contributes to increased efficiency and cost reduction in production.
CONCLUSION
With the KEMPF ExBurrDrill, even challenging materials such as EN AW-6060 can be machined efficiently and with high process reliability – without the need for subsequent rework. A major step forward in automation and quality improvement in manufacturing.
Are you also facing challenges in drilling operations?
Contact us – our experts will gladly support you in optimizing your production processes.