Micro drilling in VA
This customer saves 70% in machining time

The Zurich-based IBAG Group is a renowned manufacturer of high-frequency motor spindles in the world of tool and mould making as well as engraving, dressing and grinding. The highest quality standards and precision requirements play a central role here, especially in demanding micro-machining operations. IBAG finds the solution to these challenges in the ExclusiveLine micro-precision drill for stainless steel from Gühring, an expert in micro-precision drilling. This innovative tooling solution not only enables efficient job completion, but also results in an impressive reduction in machining times of up to 70 %.

At its site in Lindlar, IBAG Germany has not only specialised in the high-precision parts for its spindles: At its technology and demonstration centre, it is also able to immediately implement, analyse and optimise customer requirements. “We have the highest quality requirements for our components, including when it comes to positional tolerances,” explains Niki Hörner, CNC specialist at IBAG. “Some components require small holes, which are used for air transmission, for example. These holes must be manufactured with precise positioning – there is hardly any room for tolerances.” For this, the spindle manufacturer requires tools that are up to its own high standards. And with the help of Gühring, IBAG quickly found what it needed.

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Micro-drilling in stainless steel
A case for the ExclusiveLine micro-precision drill for stainless steel

“In order to manufacture its high-performance spindles, the company IBAG needs reliable micro-tools that work very precisely even in the smallest range – and even in demanding materials,” says sales representative Marcel Horn. “I quickly realised: This is a case for the ExclusiveLine micro-precision drill for stainless steel.”

Tool highlight for micro-drilling
ExclusiveLine micro-precision drill for stainless steel

The spindle manufacturer from the Rhineland region is also confronted with these high requirements when manufacturing air rings made of high-alloyed steel. An air ring has the important task of generating overpressure of 1 bar for sealing air in the front section of the spindle. This overpressure prevents external influences – such as grinding sludge, chips or other impurities – from entering the spindle and damaging it. For this protection mechanism to work, several holes with a diameter of 1.5 mm are needed. And they have to be in exactly the right position.

But this seems easier said than done at first: With the conventional HSS drill that IBAG used to use, the hole exits were anything but positionally accurate despite pre-centring. “The holes were partly tapered, and we also had to accept some tool breakage at the hole exit due to the incline,” explains Niki Hörner. For sales representative Marcel Horn, it was clear: The ExclusiveLine micro-precision drill for stainless steel would be better at this.

The tool is used in the 10xD design with a diameter of 1.5 mm (item no. 6490). And it achieved immediate success: “With the carbide micro-precision drill, we were able to make precise and straight holes in the air rings,” praises Hörner. In addition to the properties specially designed for machining high-alloyed steels, the internal cooling of the selected tool design also promotes optimum chip removal. But the ExclusiveLine micro-precision drill not only impresses in terms of its process reliability and precision: IBAG now also saves valuable time previously needed for pre-centring.
ExclusiveLine micro-precision drills in the online shop

For shorter machining times
70 % faster drilling

However, IBAG achieves unbeatable time savings in another component made of high-alloyed case hardened steel. A total of 5 holes with a drilling depth of just under 15 mm need to be drilled for each component. IBAG used to use an HSS drill for this, too, which required around 90 seconds for completion with an infeed of 1.5 mm per stroke per component. Impressed by the performance and precision of the ExclusiveLine micro-precision drill for stainless steel, IBAG also decided to test the high-tech tool for this application. And it achieved impressive time savings right from the outset: “With the solid carbide micro-precision drill, we were able to reduce the machining time per component by 60 seconds,” says Hörner happily. This is due to the high cutting data that can be achieved with the solid carbide micro-precision drill: With a feed rate of 0.5 mm/rev during piloting and a subsequent feed rate of 0.7 mm/rev, IBAG machines all 150 components – saving a total of 70% pure machining time. In addition to reduced tool wear, the company also saves on the additional centring tools, as the micro-precision drill facilitates direct machining on the shell without centring. IBAG can also significantly improve position accuracy and process reliability through the tool change cycle. “Thanks to IBAG’s high requirements, we were able to fully exploit the potential of the micro-precision drill. The cooperation is also beneficial for Gühring, because both sides can learn from each other,” summarises Marcel Horn.

Suitable tools with optimum cutting data
The Gühring online shop

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