EMUGE-FRANKEN USA, a manufacturer of high-performance taps, thread mills, end mills, drills, and other rotary tools, introduced the PunchDrill, a totally new drill design offering high feed drilling which doubles the feed rate compared to standard drills without increasing the axial force or spindle speed. PunchDrill reduces machining forces and optimizes chip-breaking, producing cycle time savings of 50% or more when machining cast aluminum alloys with at least 7% Si content and magnesium alloys. EMUGE PunchDrill results in shorter machining times, fewer tool changes, and high metal removal rates, in addition to higher productivity and reduced power consumption.

“At a time when aluminum usage is steadily growing, we are pleased to offer our customers the fastest drill available on the market, another innovative EMUGE cutting tool solution that significantly saves time and enhances productivity,” says Bob Hellinger, President of EMUGE-FRANKEN USA.

PunchDrill features patent-pending geometry with an innovative chip breaker which produces short chips to control machining forces. The new drill also has newly developed surface treatments and a hard diamond-like coating specially designed for this application to provide reliable chip removal and increased process reliability. When high-speed PunchDrill is used at the recommended feed and speed, axial force is reduced by half. The increase of the feed at the same rotational speed results in a significant decrease of machining time with less machine wear, while retaining tool life. This in turn reduces machine power consumption, saving costs and supporting sustainability.

The exceptional self-centering capability of the drill tip on PunchDrill enables the best possible positioning accuracy on holes. EMUGE PunchDrill is available in drilling depth ranges up to approximately 8 x D, the nominal diameter range from 0.129" to 0.472" (3.3mm to 12mm). Machining is done with a normal drilling cycle on CNC machines with cutting speeds and coolant pressures similar to conventional drilling. Even on unstable parts and clamping, PunchDrill can perform with greater process reliability. PunchDrill can also perform as a step tool.