Aircraft tools countersinks

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Seller's other items. The integral-pilot style Figure 2 predominates, because it has a controlled fillet radius at the intersection of the angle and the pilot, which is generally favored by the aircraft industry for countersinking.

This design eliminates the sharp corner, which is a stress point on the tool. The radius is ground at the same time the pilot is ground to ensure tangency.

In most cases, if such a radius were ground into a removable-pilot tool, the user could employ only one size of pilot for that tool. And if the pilot did not line up correctly because of runout in the hole or pilot shank, the user might score the hole or end up with a partial radius in the workpiece. The carbide version of the integral-pilot tool is manufactured in two ways: carbide tipped, in which the cutting edges are carbide and the pilot is HSS; or solid carbide, in which the entire front end of the tool is carbide.

The carbide-tipped tool is less expensive but has a shorter tool life than the solid tool, due to the wear on the HSS pilot. The more abrasive the workpiece material is, the shorter the tool life. The solid-carbide tool is superior if one considers cost per hole rather than cost per tool. The increased use of composite materials in the aircraft industry has changed the type and configuration of countersinks used today. For composites, PCD is the optimal tool material.

Carbide will work, but with greatly reduced tool life compared to its performance in titanium. Nevertheless, it is sometimes necessary to use carbide rather than PCD when a certain geometry required on the cutting tool cannot be achieved with PCD blanks - for example, a drillpoint or a radically hooked face for a more burr-free countersink in Kevlar. See Table 1 for recommended cutting tool materials for various workpiece materials.

PCD cannot be used in ferrous materials. Because it is carbon-based, under heat it will become one with the workpiece. Thus it is limited to nonferrous and composite applications. Ferrous machining requires carbide or HSS tools. Coolant should not be applied when countersinking composites using PCD tools. Coolant has a tendency to react with the composite and cause delamination. When using carbide on composites, a cold-air spray may help.

One of the problems shops face when working with PCD is the limited ability to grind certain tool geometries. But Craig Tools Inc. Unlike other PCD countersinks, the replaceable-blade tool has a controlled fillet radius. Normally, this filleted radius is difficult to achieve on a PCD countersink, especially in a 2-flute configuration, without causing lip-height variation. Craig accomplished this by grinding the blades separately on a specially jigged machine and then mechanically holding the blades in the body.

The Versi-Sink accepts replaceable blades that have the controlled radius or replaceable straight blades for use when the radius is not required. The tool can be used in a 1- or 2-flute configuration. The pilot also is replaceable, so that as it wears out or the hole size to be machined changes, a new pilot can be installed and the same set of blades used.

The radius will remain tangent to the pilot diameter as the insert locates on a ground flat on the pilot shank and can be set by the mechanic without the use of an optical comparator. This provides more versatility than the traditional removable-pilot countersink.

A brazed-tip, 2-flute, nonradiused PCD countersink can be used when the fillet radius is not required Figure 4. The 2-flute design is generally preferable to 1- or 3-flute designs.

Balance and cutting action is superior as long as the tool has good lip height. If one flute protrudes too much, then chatter and egg-shaped holes will result. In the past, this problem was more prevalent, so users opted for 1-flute PCD countersinks to avoid this problem and to minimize the diamond cost.

Register Forgot password? What's New? Forum Manufacturing Today General Problem with aircraft countersinks. Likes: 1 Post 1.

Results 1 to 7 of 7. Thread: Problem with aircraft countersinks. Thread Tools Show Printable Version. Appearance and debth is important. The caged type countersink would be perfect to regulate debth. The countersinking almost finished when it grabbed and snapped. I have never seen directions for using these. I am very open to suggestions. It might be that your cutter was intended and ground for cutting aluminum but you are cutting stainless.

They aren't cheap. I would give them a call and explain your application and problem. I dealt with Pan American Tool decades ago and found them to be very helpful How deep is the countersink?