Case Studies

AutoDrill Case Studies

How do the Professionals Drill Holes for Things Like Carburetor Jets?

Have you ever wondered how a professional drills holes?  We are not talking about your local professional wrench, but about the manufacturers.

Recently a carburetor manufacturer in Kentucky needed to drill some 1/32″ holes in brass.  They already had Dumore self-feeder drill in their shop but found that access to support and new machines was simply not up to their standards. So they contacted AutoDrill.

1100 series AutoDrill with DC Motor Set-Up

1100 Series AutoDrill for Carburetor Jet Process

After a brief discussion, it was obvious that AutoDrill’s products were of excellent quality and priced extremely competitively. So they purchased two machines immediately.

In May of 2012, the company took delivery of the drills and has been using them ever since.  Because they chose the 1100 Series AutoDrill the size of the units was kept to a minimum and their drilling fixture was extremely simple. they even chose to go with a 3500 RPM, 90VDC motor with a very simple 115VAC controller package.

The industry standard ER11 style collet chuck on the self feeding drill made it possible for them to purchase an entire set of properly sized collets for different jobs. Because these collets are available from thousands of vendors around the globe, they will never have to worry about finding proprietary items to stay in business.

AutoDrill can offer units with up to 1000 lbs. of thrust at 100 PSI and spinning multiple tools for drilling, tapping, reaming, etc.

Please CONTACT US to discuss your application and receive prompt product cost, literature and technical help.

An AutoDrill Customer Success Story

From a Crushing Challenge to Crushing the Competition

In Millington, NJ there is a company called Jersey Crusher. Jersey Crusher is an OEM who designs and builds Lumpbusters for customers around the world. Lump Busters are used in various industries on products such as chemicals, pharmaceutical products, fertilizers, spices, minerals, sugars, drugs, grains, food products, foundry by products, and other commodities that tend to lump or agglomerate in storage or from production processes. Recently, they have broken into the “green” movement by offering a machine that breaks up glass bottles and makes recycling storage and processing much more efficient. Because of this, their products are in high demand and the company’s employees stay extremely busy meeting their customers’ needs.

Lump Buster

One of Jersey Crusher's Lump Busters

A few months ago, there were thousands of parts waiting to be drilled and tapped in their shop. Drilling one hole at a time with 10 holes in each part means tens of thousands of holes were waiting to be drilled and tapped. As you can imagine, their drill press was set up with the highest quality tooling and was set to run as fast as possible. The high speed drilling and tapping operations meant the tooling was flying in and out of the holes as quickly as possible… Yet they couldn’t keep up. Taps were sometimes jammed into and yanked out of the parts. This often damaged the lead-in threads or even the tooling. At other times, drill tooling would be slammed into the workpiece accidentally causing premature wear or damage to the tool.

For Jersey Crusher, the race was on to complete all the parts and everyone there agreed that they would not finish in a winning position. They all knew that there had to be a better way… Their commitment to quality did not allow them to continue on in the same way for very much longer and certainly didn’t allow them to simply multiply the problems by adding more capacity with similar tooling solutions.

The answer was that they needed to produce more and better parts at a faster rate. They thought about hiring more people and buying more drill press machines but the thought of additional payroll, insurance costs, and training left them nervous and stuck in a tough situation. They searched around for a simple, cost-effective solution that would allow them to increase not only production numbers, but the quality of their product. …That is when they looked next door to their friends at AutoDrill.

AutoDrill thrives when a customer comes to them with a mass produced part that requires many holes to be drilled or tapped. Whether it is an automatic drill set-up or a highly efficient multiple spindle product, their solutions meet the needs of many customers in similar situations as Jersey Crusher.

The efficient and simple, yet effective design of AutoDrill’s products makes implementing their single or multiple spindle drills and tapping machines into production lines and manufacturing processes very easy. One of the benefits of a multiple spindle set-up for production drilling and tapping is the stability of the work piece. When using a drill press set-up, there is a much lower danger of a piece breaking free from its clamps and spinning. The part simply can not rotate around the axis of a single hole when more than one tool is engaged. In high volume production runs where automatic clamping and fixturing is present, the components can often be sized accordingly for a cost savings and even higher efficiency.

When a properly configured AutoDrill Control Feed Tapper is used, the work piece remains stable (will not lift up off the fixture) during the reverse rotation of the taps. This is because the machine is set to reverse the tooling at the proper speed for the tap to retract from the work with very little thrust being transferred to the part. AutoDrill has even heard of fixtures where a vertical tap station for rigid tap cycles does not use hold down clamping. While this is not suggested, it is the perfect example of how stable the process can be when set up properly.

Drilling Ten Holes at Once

Multiple Spindle Drilling and Tapping Head

Multiple spindle drill or tap heads can often be used on stacked parts for even greater efficiency and cost savings. This practice is often dangerous or impossible with a single spindle unit.

Back to Jersey Crusher…  The final solution allowed their products to be made in a much safer environment at a much lower cost. The AutoDrill products paid for themselves within a very short period of time. By implementing a multiple spindle head for drilling and tapping on a simple drill press, they were able to meet the needs of their production schedule. The custom pattern head was designed by AutoDrill so that if Jersey Crusher’s business grows even more, it can easily be migrated off the drill press to a self-feeder unit provided by AutoDrill.

Click right here for more information about Jersey Crusher’s products. Who knows, they may get busy enough to order more AutoDrill product because of your order!

Here at AutoDrill, we like to believe we are building great stories, not just great machines…

In the United States, AutoDrill has sold their product into 49 out of 50 states. They have provided products to customers in a multitude of countries on  every continent other than Antarctica. They offer sales and service directly out of their offices and shop located less than 50 miles from the heart of New York City and can refer you to distributors in many countries and regions around the world.

You can learn more about AutoDrill products by contacting them.

Toll Free: (800) 871-5022
International: 01.908.542.0244
Email: Sales@Drill-HQ.com

Please CONTACT US to discuss your application and receive prompt product cost, literature and technical help.

The Advantage of Multi-Spindle Heads Explained

Why a Gang Drill Set-Up Could Save You Lots of Money!

Many manufacturers are familiar with the term “fast cutting” when it comes to high-speed spindles on machine tools. It is so closely related to cutting tool technology that it is hard to separate. However, high-speed drilling or hole production is not achieved only through faster spindle rpm rates. One of the most effective ways to speed up a drilling or holemaking process is with a multiple spindle system. These systems can be used to create just a few holes or they can be much larger and produce several thousand holes at a time. Obviously, the second example is in high production situations.

Custom 32 Spindle Multi-Drill Head

A Perfect Example...

I want you to think for just a moment about a situation where you are drilling one hole at a time. Suddenly, you have the need for increased output. You have already worked with your tooling supplier to provide tooling that allows you to run a bit faster and with a slightly more aggressive feed rate, etc. No small tweaks are going to save you now. You need a totally new way of doing things in order to keep up. It might seem like a good idea to purchase more machines and hire more people to run them. Before you decide how many more machines you need, what the costs are going to be for payroll, insurance, additional space, etc. you wonder to yourself if there is a better answer. What if you decided to make the existing machines more efficient or even go to a dedicated machine that is specifically built for the process?

AutoDrill loves to solve high-production holemaking problems for their customers.

According to one expert in the field, “Manufacturers seek dedicated production solutions for two main reasons: first, because they have high production requirements on a newly designed part; or second, because they are currently using flexible machining centers to produce a part – or a family of parts – in large quantities, and they have reached a production plateau. Regardless of the reason, the goal is the same: to produce a large number of parts accurately, effectively and efficiently. In most cases, this involves creating multiple holes in a single pass.”

Imagine you need to perform a hole process on twelve holes. Now imagine that each hole requires three operations. First, you need to drill the hole to the proper size, then you need to chamfer the hole and finally, you need to tap a precision thread. With an AutoDrill set-up, you could drill and chamfer from one side of the part and then tap from the other. If the part does not allow this type of dual-sided operation, then you could set up two machines side-by-side and trigger both by a manual button push or PLC signal to perform the 36 operations in one step. You would simply use a rotary table or a shuttle mechanism to move the part from the first step to the second step while loading another part into the position for the first step.

Through an automated part fixture, the part would be drilled and chamfered at the first cluster, then moved to the second for tapping. This entire process would take only seconds. With a single spindle drill press, this same process would take much longer.

Because AutoDrill can mount a multiple spindle drill head or a multi-tap head onto a standard drill press, many customers choose to perform these processes manually but with the tremendous advantage of a multi-spindle solution for their process.

Some processes are much more simple requiring only two holes to be made whereas many drilling solutions are not always as simple as what we have described above.

AutoDrill has a customer who currently drills and taps three holes in a bolt circle pattern.  However, their bolt circle pattern often changes between 1.800”, 6.000” and 9.250” in diameter.  While AutoDrill could not offer an adjustable head for the process, they were able to make a nine spindle head that had the ability to meet all three patterns.  The customer simply removes tooling from the spindles that are not in use. This type of creative solution allowed the customer to use a single machine to perform more than one part process.

Two Spindle Drill Press

Drill Press Twice as Efficient

High speed production processes are often most effective when coupled with high-speed part handling. Indexing systems, robotic part handling systems, and even automatic part feeders facilitate simultaneous load and unload as a part of the machining cycle. These technologies are often paired with the AutoDrill machines for a highly reliable, highly efficient set-up.

Multi-spindle hole making opens a whole new arena of chip making and removal. AutoDrill often cautions its customers that chip removal and evacuation must be designed into the process. Many times, it can not simply be added later on after the drilling fixture is complete. It is very important for the end user or machine builder to study and evaluate customer applications. Often, this must be done not just from the standpoint of metal removal requirements, but also with consideration of all the operations that will be performed on the part before and after the drilling and/or tapping process. AutoDrill is often able to suggest changes in the process that contribute to the overall success of a project.

Although multiple-spindle drilling, tapping, reaming or other hole processes may sometimes be limited in terms of its rotational speed, it is extremely valuable because of its ability to produce many holes at once. Whether that is two holes or several thousand, the process can often be performed in less time than it would take to machine each hole individually on a CNC. The end result is not just an increase in production levels, but usually a lower cost for the equipment as well.

You can learn more about the AutoDrill product by contacting them.

Toll Free: (800) 871-5022
International: 01.908.542.0244
Email: Sales@Drill-HQ.com

Please CONTACT US to discuss your application and receive prompt product cost, literature and technical help.