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Drilling for Quality - Amazon Web Servicessnocamp.s3. · PDF fileWhat kind of a defect is this? Eye Browed Hole Caused by drilling of a crooked hole then reentering the hole straight

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Text of Drilling for Quality - Amazon Web Servicessnocamp.s3. · PDF fileWhat kind of a defect is...

  • Drilling

    for

    Quality

    Copyright 2012 Boeing. All rights reserved.

  • Why do we need drilling for quality?

    Help the mechanic recognize the characteristics of what makes a quality hole

    Procedures required to drill quality holes

    Use the necessary tools to make a quality hole

    Countersink

    Shop safety

    Copyright 2012 Boeing. All rights reserved.

  • What is S tres s ?

    S tres s - During takeoff, in flight, and landing. Just sitting on the tarmac with the weight of the airplane causes stress.

    Weather, Temperature..

    What would happen if holes in the aircraft had some sort of defect?

    Do you think these stresses affect the holes / fastener installation?

    Copyright 2012 Boeing. All rights reserved.

  • S afety

    Leather Shoes (no open toes or high heels) No loose fitting clothing (ties, shirts or jackets) Pants to be below the kneecap. Loose jewelry will be taken off Long hair will be tied back No loose fitting gloves, Beware of loose fitting badge holders (make sure you have a breakaway holder)

    Copyright 2012 Boeing. All rights reserved.

  • www.elvex.com

    S afety

    Copyright 2012 Boeing. All rights reserved.

  • Drill Motors

    Typical Drill Motor

    Copyright 2012 Boeing. All rights reserved.

  • P is tol G rip Motors

    Copyright 2012 Boeing. All rights reserved.

  • 90 & 45 degree Drill Motors

    Copyright 2012 Boeing. All rights reserved.

  • Drill B it Nomenc lature

    S hank

    P oint A ngle

    L and

    S tep

    Margin

    Margin

    F lute

    F lute

    Copyright 2012 Boeing. All rights reserved.

  • Types

    Twis t Double Margin R eamer C ore G un B arrel C ompos ite

    Drill B its and R eamers

    Copyright 2012 Boeing. All rights reserved.

  • Drill B its and R eamers

    Shank Style

    Quic k C hange T hreaded Quic k C hange 90 and 45

    Degree Motors

    Tri-F lat

    Copyright 2012 Boeing. All rights reserved.

  • Quic k C hange T ype Drill B it S ize Identific ation

    R eamer

    S tandard Double Margin

    Copyright 2012 Boeing. All rights reserved.

  • E quivalenc y c ard (S tarrett C ard)

    F R ONT B A C K

    Copyright 2012 Boeing. All rights reserved.

  • Hole Qualities

    What qualities are we looking for in

    a properly drilled hole?

    Copyright 2012 Boeing. All rights reserved.

  • Diameter - (Within T oleranc e)

    Copyright 2012 Boeing. All rights reserved.

  • A ngularity - (S traight within 2 degrees )

    90 o

    +/- 2 o

    Copyright 2012 Boeing. All rights reserved.

  • Drill G uides

    Copyright 2012 Boeing. All rights reserved.

  • B us hing Identific ation

    Copyright 2012 Boeing. All rights reserved.

  • Drill S tops

    # 40 # 30 # 20 # 10 1/4 5/16

    Copyright 2012 Boeing. All rights reserved.

  • Give an example of a defect

    and what could cause that defect

    T here are many pos s ible defec ts to a drilled hole

    Copyright 2012 Boeing. All rights reserved.

  • T here are many pos s ible defec ts to a drilled hole

    Overs ize Unders ize E longated E ye B rowed G ouged / B arreled Tapered Drill S tarts Drill R uns Angled R ifled C hattered Over Deburred

    Double Hole Mis located Mismatch Misaligned Misoriented E xtra Hole S hort E dge Margin B reak Out C racked / F ractured B ellmouth B urned Deep C ounters ink

    Copyright 2012 Boeing. All rights reserved.

  • What kind of a defect is this?

    A ngled Hole

    C aus ed by improper us e of drill guide or more likely

    c aus ed by NOT us ing drill guide.

    T here are many pos s ible defec ts to a drilled hole

    Copyright 2012 Boeing. All rights reserved.

  • What kind of a defect is this?

    Rifled Hole

    C aus ed by the us e of a dull drill bit or too muc h lubric ation being us ed, exc es s c utter run out, damaged

    c utter margin or c hips welded to c utter

    T here are many pos s ible defec ts to a drilled hole

    Copyright 2012 Boeing. All rights reserved.

  • E dge Margin - (Drawing c all out or 2X diameter)

    Edge margin

    Copyright 2012 Boeing. All rights reserved.

  • S urfac e F inis h - s mooth finis h ins ide the hole

    Copyright 2012 Boeing. All rights reserved.

  • What kind of a defect is this?

    E ye B rowed Hole

    C aus ed by drilling of a c rooked hole then reentering the hole

    s traight or drilling a hole that has a pilot on the other s ide.

    T here are many pos s ible defec ts to a drilled hole

    Copyright 2012 Boeing. All rights reserved.

  • What kind of a defect is this? Drill R un

    Drill S tart

    Not us ing a s harp drill bit, not getting the drill bit

    into the pilot hole before pulling trigger or trying

    to drill too fas t and mis s ed the target! !

    T here are many pos s ible defec ts to a drilled hole

    Copyright 2012 Boeing. All rights reserved.

  • What kind of a defect is this?

    B arreled Hole

    C aus ed by the us e of too muc h lubric ant, lube holds

    debris in the flutes of drill bit and hones out the hole.

    T here are many pos s ible defec ts to a drilled hole

    Copyright 2012 Boeing. All rights reserved.

  • What kind of a defect is this?

    Double Hole

    C aus ed by walking of the drill bit, pos s ibly a dull drill

    bit. Drilling a c rooked pilot hole, then drilling bac k

    through the hole us ing a guide

    T here are many pos s ible defec ts to a drilled hole

    Copyright 2012 Boeing. All rights reserved.

  • What kind of a defect is this?

    E xtra Hole

    C aus ed by not looking at the drawing for proper

    layout, mis loc ated tool or c areles s drill bit plac ement.

    T here are many pos s ible defec ts to a drilled hole

  • What kind of a defect is this?

    Unders ized Hole

    C aus ed when the drill bit is dull or the inc orrec t drill

    bit is us ed.

    T here are many pos s ible defec ts to a drilled hole

    Copyright 2012 Boeing. All rights reserved.

  • R eliefs

    Deburr

    Chamfer

    Fillet Relief

    Fillet Relief Washer

    Copyright 2012 Boeing. All rights reserved.

  • F illet R elief, C hamfer, R adius

    R eliefs

    Copyright 2012 Boeing. All rights reserved.

  • F ilet R elief, C hamfer

    R eliefs

    F illet R elief, C hamfer, R adius

    Copyright 2012 Boeing. All rights reserved.

  • Deburring T ools

    Weldon

    Open Countersink

    Flat File

    Cogsdill Copyright 2012 Boeing. All rights reserved.

  • What kind of a defect is this?

    C aus ed by us ing inc orrec t deburring tool or a dull

    deburring tool.

    C hamfered Inc orrec tly

    T here are many pos s ible defec ts to a drilled hole

  • Not R ec ommended Deburring / R elief T ools

    R otary F iles

    Mac hinis t T riangle Drill bits R ed Devil S c raper

  • What kind of a defect is this?

    Deep C ounters ink

    Mus t s et c ounters ink on s c rap material before going to a/p s truc ture.

    Make s ure to loc k the s et ring. C hec k c ounters ink bearing, they do go bad.

    (A new Zephyr s mall body las ts 80,500 c ounters inks max.)

    T here are many pos s ible defec ts to a drilled hole

    Copyright 2012 Boeing. All rights reserved.

  • C ounters inks

    Shaft

    Locking Ring

    Cage / Body

    Countersink Cutter

    Rotating Foot Countersink Pilot

    Copyright 2012 Boeing. All rights reserved.

  • C ounters ink C utter

    Hex Drive or L oc k B olt 100 Deg. B olt

    100 degree R ivet C ounters ink

    100 Deg. WQ B olt

    82/30 Deg. R ivet

    Copyright 2012 Boeing. All rights reserved.

  • C ounters inks

    Pull back Cage / Body

    Copyright 2012 Boeing. All rights reserved.

  • C ounters inks

    Rotate Foot to

    change depth

    This way to make shallower

    Copyright 2012 Boeing. All rights reserved.

  • C ounters inks

    Rotate Foot to

    change depth

    This way to make it deeper

    The countersink is to be set on a scrap

    piece of material similar to the material

    that needs to countersink

    Copyright 2012 Boeing. All rights reserved.

  • Us e of C ounters ink

    S et c ounters ink on s ame type of material to be c ounters unk Matc h the c ounters ink pilot s ize to the hole s ize Hold the barrel of the c ounters ink while c ounters inking P rior to adjus ting c ounters ink deeper, always re-c ounters ink the

    hole to ens ure the c utting was c omplete

    Copyright 2012 Boeing. All rights reserved.

    Slide Number 1Why do we need drilling for quality?What is Stress?SafetySafetyDrill MotorsPistol Grip Motors90 & 45 degree Drill MotorsDrill Bit NomenclatureDrill Bits and ReamersDrill Bits and ReamersQuick Change Type Drill Bit Size IdentificationEquivalency card (Starrett Card) Hole QualitiesDiameter - (Within Tolerance) Angularity - (Straight within 2 degrees)Drill GuidesBushing IdentificationDrill StopsThere are many possible defects to a drilled hole There are many possible defects

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