KYOCERA SGS Precision Tools Group
KYOCERA SGS Precision Tools Group
Imagine you’re standing in front of your machine, blueprint in hand, knowing that every hole you drill needs to be spot-on. The clock is ticking, the material isn’t forgiving, and the pressure to deliver a perfect part is mounting. Drilling might seem straightforward—until you’re battling tight tolerances, stubborn materials, and the relentless demand for efficiency. The right drill doesn’t just cut a hole; it dictates cycle time, tool life, and part quality. Get it wrong, and you’re looking at scrap, costly rework, or worse—a halted production line.
With so many options on the market, how do you know if you’re using the best tool for the job? Let’s break it down and explore three primary categories of drills: indexable insert drills, replaceable tip drills, and solid carbide drills. Each has its place, and knowing which to choose can mean the difference between smooth sailing and a frustrating scrap pile.
Drilling large-diameter holes in a high-production environment requires a tool that can handle aggressive material removal while maintaining efficiency. That’s where indexable insert drills shine. These drills feature replaceable inserts, making them an economical choice for roughing out holes in materials like cast iron, steel, and stainless steel.
Indexable insert drills thrive in high-volume applications, particularly in industries like heavy equipment manufacturing, where productivity matters more than ultra-smooth finishes. They offer the flexibility of swapping inserts to optimize cutting performance in different materials—using positive rake inserts to reduce cutting forces in stainless and super alloys, or heavier-duty inserts to tackle interrupted cuts and high-feed applications.
However, indexable insert drills aren’t ideal for precision applications. If the goal is tight tolerances and smooth bore finishes, a different drill type may be a better fit. Additionally, these drills have limitations in depth capability, requiring alternative strategies for deep-hole drilling.
A job shop machining flanges and heavy equipment components needs to drill large-diameter holes in steel and cast iron. Since these holes don’t require a fine finish, an indexable insert drill allows for fast material removal, reducing cycle time before moving to a boring bar for final sizing.
For operations needing more precision while keeping costs under control, replaceable tip drills offer a balanced solution.
For machinists looking for a balance between precision and cost efficiency, replaceable tip drills provide an excellent middle ground. Unlike insert drills, these tools use carbide tips for accuracy while retaining a reusable steel body. Instead of replacing an entire drill, shops can swap out tips for different diameters or materials, reducing tool costs and inventory needs.
This flexibility makes replaceable tip drills ideal for shops switching between materials like aluminum, steel, and Inconel without requiring a full tool change. They provide better hole accuracy than insert drills while remaining more cost-effective than solid carbide. However, they do have their limitations—micro-diameter drilling and extreme speed applications typically require the rigidity of a solid carbide tool.
A machine shop producing hydraulic manifolds frequently switches between different hole sizes and materials. Instead of stocking multiple dedicated drills, they use replaceable tip drills, swapping out carbide tips to match each material while keeping the same tool body. This approach streamlines setup time and reduces tooling costs, making it ideal for shops handling varied production runs.
While replaceable tip drills offer a great balance of performance and cost, some applications demand absolute precision, high speeds, and extreme material toughness. That’s where solid carbide drills come in.
When tight tolerances, high speeds, and flawless surface finishes are required, solid carbide drills are the ultimate solution. Unlike their indexable counterparts, these drills are made from a single piece of carbide, delivering exceptional rigidity and cutting performance.
Solid carbide drills excel in challenging materials like titanium and Inconel, where advanced coatings like TiAlN enhance tool life and maintain superior surface finishes. Additionally, their extreme rigidity allows them to hold tight tolerances over extended production runs, something that may not be possible with replaceable tip drills, due to slight variances when replacing tips.
However, solid carbide drills come at a higher cost. Since they lack replaceable inserts, if the tool chips or breaks, replacement costs can be significant. They are also not ideal for large-diameter roughing, where indexable drills are more effective.
A medical machining company manufacturing titanium bone plates requires small-diameter, high-accuracy holes with strict tolerances. Any variation in hole size could impact the final fit of an implant, so they rely on solid carbide drills with high-performance coatings to maintain tight tolerances and extend tool life across long production runs.
Drilling generates significant heat, and without proper coolant strategies, excessive temperatures can lead to premature tool wear, built-up edge (BUE), and poor surface finishes. Through-coolant drills provide a direct path for coolant to flush chips away, reduce heat buildup, and maintain tool longevity. But even with the right coolant flow, effective chip evacuation is essential to prevent chip packing, improve hole quality, and extend tool life. Understanding the chip evacuation essentials can make the difference between smooth machining and costly tool failures.
For deep-hole drilling, through-coolant is one of the most effective ways to ensure chip evacuation and prevent tool failure. High-pressure coolant (1,000+ PSI) isn’t always necessary, but in tougher materials, it can be a game-changer.
When through-coolant isn’t available, peck cycles can be used as an alternative. By periodically retracting the drill, chips are cleared from the hole, reducing heat buildup. While this approach slightly increases cycle time, it extends tool life and improves hole quality, especially in deeper holes where chip evacuation is a challenge.
Selecting the right drill type is only part of the equation—geometry plays a crucial role in hole quality and tool performance.
Proper drill geometry can mean the difference between consistent, high-quality holes and premature tool wear or machining issues.
While cost is always a factor in tool selection, the real key is choosing a drill that matches your machining needs.
The best choice isn’t necessarily the cheapest—it’s the tool that maximizes performance while minimizing downtime and scrap.
Choosing the right drill isn’t always straightforward. Indexable insert drills are best for roughing large holes, replaceable tip drills offer flexibility and cost savings, and solid carbide drills provide unmatched precision for high-tolerance work.
Need help finding the right drill for your application?
Find the right drill for your job:
Q: How do I know if I’m using the wrong drill?
A: If you’re experiencing poor hole quality, excessive tool wear, or long cycle times, you may be using the wrong drill for your application. Here are some signs:
Choosing the right drill comes down to matching its strengths to your machining needs—indexable insert drills for roughing, replaceable tip drills for balanced performance, and solid carbide drills for precision.
Q: What’s the best way to reduce tool wear when drilling?
A: Proper speed and feed rates, through-coolant, and tool coatings can significantly extend tool life. Ensuring chip evacuation (either through high-pressure coolant or peck drilling) is also key to reducing wear and preventing tool breakage.
Q: Should I invest in high-pressure coolant systems?
A: High-pressure coolant is great for deep drilling and high-performance machining, but flood cooling or mist systems can be just as effective with proper alignment and direction.
Q: What’s the difference between single-margin and double-margin drills?
A: Single-margin drills have two points of contact and reduce friction, making them better for stainless steel and super alloys where heat buildup is a concern.
Double-margin drills have four contact points and provide better hole straightness and finish, but they generate more heat and wear faster.
Q: How do coatings impact drill performance?
A: Coatings like TiN, TiAlN, and KYOCERA’s MEGACOAT NANO help reduce wear, improve heat resistance, and extend tool life. The right coating depends on your material and cutting conditions.
Q: What should I do if my drilled holes are out of tolerance?
A: Try the following:
Machinists require reliable solutions to tackle intricate tasks efficiently. Indexable tooling provides exceptional flexibility, quality, durability, and delivers high-performance results. Customize your tooling for specific tasks by choosing the ideal combination of inserts and holders to optimize performance.
Explore our SGS branded high-performance and versatile solid round tooling options. Our quality tooling not only ensures precision but also minimizes downtime, allowing for increased material removal per hour. Explore a range of options including end mills, drills, routers, countersinks, and more to find the perfect tools for your specific needs.
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KYOCERA SGS Precision Tools, Inc.
(330) 686-5700
150 Marc Drive
Cuyahoga Falls, OH 44223
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