The challenge was to achieve both hard and soft cost savings, as well as time spent on drilling flanges from one side, chamfering the backside and creating a controlled chamfer on the top surface which was a secondary process.
We designed an indexable drill with our rear cutting carbide deburring insert along with a fixed pocket chamfer insert to create the precision top chamfer that was required. The spade drill insert also had a special feature that allowed it to chamfer the top side of the bottom hole that was pre-drilled.
The Burr-Free Drill drilled the hole, deburred and chamfered the back all in one step, thus eliminating the secondary step of chamfering the bottom surface on the top hole. This saved time as well as money, plus the tool life of the Burr-Free Drill achieved a more consistent result and had a longer tool life than the previous method. Four operations were completed in one pass.