Kennametal has introduced the HiPACS drilling and countersinking system for aerospace fastener holes, designed to drill and chamfer holes in one operation, while delivering increased tool life in machining composite, titanium and aluminium aircraft skins.
Designed to be clamped in a standard hydraulic chuck, the HiPACS modular system consists of three components that are fast and easy to assemble – a reducer sleeve, a PCD countersinking insert, as well as the two series of solid carbide drills.
The reducer sleeve with a built-in high-precision pocket seat, in conjunction with a standard hydraulic chuck, provides ultra-secure clamping and a runout of no more than 3μm, significantly increasing tool life and hole quality. The PCD countersinking insert eliminates the need for expensive custom solution step drills, reducing manufacturing costs while meeting the industry’s accuracy requirements. Lastly, it consists of two series of solid carbide drills - both diamond-coated and PCD-tipped - covering all material combinations found in a typical aerospace assembly. In addition, the straight shanked tools allow for length adjustments in increments of 10mm.
The new HiPACS drilling and countersinking system can be utilised on all machines typically used for aerospace applications. In less stable conditions such as robot end effectors, the diamond coated carbide drills offer excellent tool life and hole quality. PCD-tipped drills, on the other hand, excel in stable conditions such as gantry machines.
“Most fastener hole tools used today are complex made to order tools with long lead times,” says Georg Roth, product manager, Kennametal. “HiPACS uses standard, off the shelf components for quick delivery and low cost per hole, by allowing the drill and chamfer insert to be indexed independently from one another. What’s more, it’s the only indexable drilling and countersinking system on the market that can hold the aerospace industry’s required fastener hole chamfer tolerances in just one operation.”
With an industry standard interface, HiPACS can be utilised on any CNC machine, and is suitable for a variety of drilling and countersinking applications.
Having joined the magazine in 2012, Claire developed her knowledge of the industry through the numerous company visits, exhibitions and conferences she attended both in the UK and abroad.
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