Chapter 3. Gundrilling Tooling

First we introduce you to the basic single flute gundrill, disecting the tool and explaining the configuration and function of each of its component parts. We explain how a gundrill cuts, then explore the various grinds (tip geometries) and where to apply each one. Then we discuss regrinding, and show you how to tell a good grind from a bad one.
Next comes the section on 'contours', the feature which provides stability to the drill tip and controls surface finish and then we review alternate gundrill configurations including the two-flute drill, the half-round drill and several additional configurations, each with its own characteristics and uses.
To round out the chapter we describe and define the function of all the related tooling you'll find necessary to do a proper gundrilling job.

Chapter 4. Accuracy/Workholding

As with most manufacturing processes, if the workpiece is not presented correctly, bad things happen. This important chapter discusses the various approaches to workholding for gundrilling, and explains their resultant effects on accuracy. We also compare the three basic gundrilling approaches– Rotating Part, Rotating Tool, and Counter-Rotation as regards inherent accuracy and practicality.

Chapter 5. The Basic Process

There are numerous types of gundrilling machines available, from 'plain vanilla' to fancy, multi-function units; but all of them have certain components and functions in common. This chapter explores the basics, and demonstrates the primary functions of the process.

Chapter 6. The CNC Process

More and more companies are adapting the gundrilling process to their CNC equipment as well as more conventional machines such as engine lathes and screw machines. Gundrilling on these types of equipment is entirely practical, but there are important differences which have to be considered. Here we define and explain the differences, explore coolant system options, and provide the procedures and techniques necessary for successful drilling. Then we tell you what not to do in "A Few Definite No-No's".

Chapter 7. Oil & Coolant Selection

In gundrilling, having the right coolant in your machine is as important as the gundrill itself. There are several, if not many, acceptable oils and coolants in the marketplace. This chapter is devoted to assuring that you know what characteristics you're looking for when you go 'shopping'.

Chapter 8. Gundrilling Parameters

'Parameters' spells it all out for you, giving you feed and speed formulas, starting feed rates and surface feet per minute for an array of materials ranging from ferrous and non-ferrous metals (broken down by hardness levels) to wood and plastics to graphite and sintered parts. The chapter also includes required coolant pressures and flow rates, and maximum unsupported length considerations. And... when you don't know the material spec but do know the chemistry, we have tables for that too!
Next come sections with invaluable information on tool life and expected surface finish, plus some visual tricks that will help you optimize your parameters.

Chapter 9. Troubleshooting & Tool Wear

Got a problem? The Troubleshooting Chart will usually give you the solution. Wondering why your gundrill is wearing (or breaking) in a particular way? The Tool Wear Guide will answer your question.
And we don't stop there. The charts and guides are a great assist, but more important is how you troubleshoot: we go on to give you a problem solving philosophy that will help you get to the right answer in minimum time. This chapter is an education in itself, and for an extra bonus we include a section on the effects of alloying elements.

• PART III. THE BONUS CHAPTERS •

Chapter 10. Process Optimization

Your company doesn't necessarily have the same objectives as the outfit down the street or across the country. Call it "Tweaking", "Fine Tuning" or whatever– whether you're looking for maximum productivity, maximum tool life or maximum quality, this chapter shows you step by step how to do it.

Chapter 11. Tips & Tricks

Once you get into gundrilling, sooner or later you're going to run into a situation where strange things start happening. This chapter covers typical problems which are easy to solve once you know the right 'Tips & Tricks'

Chapter 12. Case Histories

These case histories are actual instances of problems (some common, some not so common) which were encountered in the field, and what was done to eliminate them. Nothing beats 'real life'!