Carbide reamers are specifically engineered to increase the diameter of an existing hole while maintaining a high level of precision, consistency, and predictability throughout the process.
The general conditions for using reamers and the results they produce might vary greatly depending on the state of the material, the configuration of the tool, and the equipment. The correct execution of reaming, on the other hand, calls for thorough planning and close attention to detail. Important considerations include the speeds and feeds of the drill as well as the quantity of stock that should be left over after drilling and choosing the appropriate reamer for the task. In most cases, reamers are only designed to cut away between 2% and 3% of the target size.
Carbide Reamer: What Is It?
A reamer is a tool that is used to enlarge or finish holes that have been pre-drilled, bored, or cored in order to provide a high-quality finish and an accurate size. A reamer is a multi-tooth cutter that is used to cut through comparatively little material at once. There are several categories of reamers, each of which is distinguished from the others by the operation, the function, and the form.
What Exactly Is Reaming?
In the cutting process known as reaming, a specialized tool known as a reamer is used to widen an existing hole to a certain diameter while simultaneously creating a smooth finish on the walls of the hole. This is accomplished by the use of the reamer. A milling machine, a lathe, or drill presses are the common types of machines used for reaming. As a finishing operation, reaming is therefore performed. Before the hole can be reamed, it must first be roughed out using a different method, such as drilling. There are other ways to make holes with accurate sizes and a high quality finish on the walls, but reaming is frequently the best choice because of how quickly it can be done and how little it costs.
If you need to maintain hole diameter tolerances that are more stringent than +/- 0.002 inches, using a reamer is definitely the best option for you. For instance, you might figure out the desired hole size by using our Press Fit Calculator, and then you could use a reamer to get that hole size while staying within the tolerances. The material of the workpiece has an effect on the surface finish that is produced by reaming. The range for steels is 30 to 60 rms, but the range for cast iron is 50 to 80 rms. Aluminum may be given a finish that is as fine as 8 rms by using a PCD reamer.
Carbide Reamer Geometry
Reamers with numerous cutting edges typically have anywhere from four to six of these cutting blades. On the other hand, larger-diameter instruments can contain eight or even 12 blades. When there are more cutting edges, the rate of penetration will be higher, and the completed holes will have a tendency to be rounder. Additionally, more edges result in lower chip sizes. You do not want there to be a difficulty with chip evacuation because there are too many flutes. The vast majority of reamers are organized into size ranges, each of which has a certain number of teeth that corresponds to that size range.
The geometry of the reamer changes depending on whether the flutes are spiraled to the left or the right, or if they are straight. When it comes to clearing chips, spiral flutes are superior to straight flutes; nevertheless, straight flutes may also be used because the number of chips produced during the reaming process is little.
The reamer should have a left-hand spiral or a straight flute if it is to be used for through-holes. When using the left-hand spiral, the flute’s helix turns to the left, or in a counterclockwise direction. During the process of cutting, the reamer will force the chips to advance through the hole.
Reamers with straight flutes or right-hand spirals are the ones that are recommended for use while drilling blind holes. When using the right-hand spiral, the helix of the flute will move in the right direction, which is clockwise. In order for the reamer to be able to reach the bottom of the hole, it pushes the chip back up through the cut and out the top of the hole.
When reaming blind holes, one must use extreme caution. It is imperative that careful thought be given to chip evacuation in order to avoid the chips marring the hole. It is best to never chop a chip more than once. This is the situation that occurs when a chip that has been cut becomes squeezed between the reamer and the hole, and the reamer pushes the chip between the finished hole and the reamer. This leads to a hole that is of low quality or possibly one that is out of tolerance altogether.
The most common type of reamer is the straight-flute variety. When using the straight flute, chips are not compelled to go in either direction. The arrangement of the coolant that pushes the chips has an effect on it. The chips are propelled forward by the radial coolant that runs via through-holes. When it comes to blind holes, having central coolant can assist in pushing the chips up and out of the hole.
In spite of the fact that spiral kinds have the potential to improve chip evacuation; the straight-flute reamer is the most cost-effective option. Spirals are more difficult to manufacture than other types of blades because the machine tools need an additional axis in order to grind the blade. As a result, we’ve come up with geometries for the straight flute that either assist shatter the chips or drive them ahead.
When working with some substances, you should avoid using a left-hand spiral. Cast iron and some aluminum alloys are examples of these types of materials. Because a spiral flute does not shear the material as well as a straight flute does, it is possible that the spiral will smear the silicon that is present in the aluminum, for instance, when working with high-silicon aluminum..
Types of Carbide Reamers
- Chucking Reamer with Taper Fluted
Chucking Reamer with Taper or Parallel Shank (Fluted) is another name for the tool that is often referred to as a machine reamer. The cutting blades of these sorts of reamers are short and parallel, and they have a beveled lead. The bodies of these reamers have large recesses between the shanks. Reamers often have cutting blades that are incorporated into a parallel or taper shank that is used for grasping the tool. The shanks can either be straight or taper, but the flutes themselves are invariably straight.
The reamer can be utilized in a drill press, turret lathe, or screw-cutting machine, depending on the application. It is operated at a modest pace, and the entire cutting process is completed while the flutes are in motion. The flutes travel at varying speeds and directions around the body of the reamer, which is round. Because of this, there is less of an inclination to babble. For work that requires greater precision, the use of a fluted reamer is recommended. Chucking reamers with a straight shank can have a diameter ranging from 0.5 to 32 millimeters, while those with a taper shank can have a diameter ranging from 5 to 32 millimeters.
- Chucking Reamer
The cutting action is carried out entirely by the beveled edges at the very tip, which differentiates it from the fluted kind. The angle formed by the chamfered cutting edges is 45 degrees. The body, which is fluted, may be inserted into the reamed hole. In order to prevent the body from bending when it is inserted into the hole, it has a little taper and gets narrower towards the shank. A higher amount of metal may be removed with this style of reamer as opposed to using a fluted type.
- Machine Bridge Reamer
Reaming in shipbuilding, structural construction, and plate work can be accomplished with the use of a portable electric or pneumatic tool with a machine bridge reamer, as shown in figures (A) and (B). These are the sorts of reamers that have cutting blades that are parallel to one another. They also include a lengthy lead that is an integrated part of a tapered shank for gripping and driving the reamer. The flutes might be spiral or they could be straight. The reamer has a diameter that can range anywhere from 6.4 to 37 millimeters.
- Machine Jig Reamer
A machine jig reamer has cutting edges that are short and parallel, and they have a bevel lead. Additionally, there is a guide between the shank and the cutting blades, and it is integrated with a tapered shank that is used for gripping and driving. The flutes are shaped like helicoids. The reamer can be properly located thanks to the plain portion of the body, which slides into a bushing on the jig. The reamer can have a diameter anywhere from 7 to 50 millimeters.
- Parallel Hand Reamer with Parallel Shank
This reamer has parallel cutting blades that have a taper and a bevel lead integrated with a shank that is the nominal diameter of the cutting edges, and the end of the reamer has a square. The flutes might be spiral or they could be straight. The hand reamer has a square tang, and it is designed to be operated with the hand in order to correctly size the holes. The reamers’ primary objective is to remove the least amount of metal possible between 0.05 and 0.125 millimeters. Because it needs to be easy to start, it has a modest taper towards the end over a distance that is equivalent to its diameter.
- Socket Reamer for Morse Taper
This reamer might have a straight shank or a taper shank, and it could be operated by hand or by a machine. The reamers feature cutting edges that are tapered to fit a Morse taper, and they have shanks that are either parallel or tapered. The flutes might be spiral or they could be straight. It is possible to purchase the reamers in a package of three, which includes a roughing, a pre-finishing, and a finishing tool. There is a choice in terms of the diameter of the reamers for the finishing.
- Shell Reamer
The shell reamer with an axial hole may be used on an arbor. It also features cutting edges that are almost parallel to one another and a sharpened bevel lead. These kinds of reamers are utilized for the finishing process of huge holes in order to preserve the tool. One arbor may accommodate a variety of different shell sizes when switched out. This results in a reduction in the cost of the solid shank for each individual instance. The shell reamer can either be of the rose chucking type or the fluted kind, depending on whether it is being used for finishing or truing the hole. The flutes might be spiral or they could be straight. The reamer can have a diameter ranging from 24 to 100 millimeters.
- Taper Pin Reamer
The taper reamer may either be driven by hand or by a machine. This features taper cutting edges for holes that fit pins with a taper of I in 50, and it has a parallel or taper shank for gripping and driving the reamer. The taper cutting edges are used to create holes that are compatible with pins. The flutes might be spiral or they could be straight.
Specifications
The performance of a reamer is determined by various variables, including speed, feeds, and workpiece material:
- Specifications For Flute
Reamer flutes are situated at the front of the device. Small chips are removed by passing along the reamer’s flutes. Flutes are classified into two types: straight and helical. Helix is further classified into four types: right hand, left hand, slow, and quick.
Straight fluted reamers are utilized for a range of materials and applications in general. The length will be determined by the application. The entering end will be tapered somewhat. This causes the flute to self-center as it enters the hole, while the larger section of the flute will have a constant diameter to allow for the growth. Because right hand spiral reamers have a tendency to suck chips and coolant out of the hole, a right hand kind of helix should never be used on a tapered reamer; otherwise, the reamer may wedge, resulting in catastrophic tool failure.
Left-hand spiral reamers have a propensity to push chips and coolant in front of the cut, allowing coolant to enter the hole and the reamer to exit. On tapered reamers, a left hand spiral can be employed to aid prevent grasping and binding. They should not be used in blind hole applications because the chips will pack at the bottom of the hole and prevent the reamer from cutting all the way to the bottom. There are four crucial criteria to consider when choosing a flute: flute diameter and length, pilot diameter and length, number of flutes, and flute depth.
- Specifications For Shanks
A shank is the reamer’s shaft or stem. It’s just next to the flute. When choosing a shank, four major factors must be considered: diameter, type, hardness, and one or two piece construction.
- Machine Vs. Hand
A hand reamer is designed for manual reaming and usually has a handle. To compensate for the difficulties of beginning a hole by hand power along, it is built with a longer taper or lead in at the front than a machine reamer. It also allows the reamer to begin straight, lowering the chance of breakage.
Machine reamers have a tiny lead in, and spiral flutes offer the benefit of automatically cleaning swarf. The reamer and the work piece are pre-aligned, eliminating the chance of the reamer deviating from its intended path. The machine’s steady force guarantees that the cutting begins quickly.
- Specialty Reamers
There are several specialty carbide reamer possibilities. Chucking reamers, which generally have a straight shank and are used for general purpose reaming, automobile reamers, which are used for heavy-duty structural work, and repair reamers, which are widely used in utility and maintenance applications, are the most popular types of reamers.
- Materials
High speed steel is the most widely utilized material since it is reasonably affordable and works effectively on a wide range of materials. However, many other materials, such as carbide and high cobalt alloy steel, are utilized to create reamers. Carbide is more costly than high speed steel, but when reaming steel, it outlasts it by a factor of ten. The most costly alternative for reaming titanium and stainless steel is high cobalt alloy steel. The cutting fluid that must be used to extend the life of the reamer is determined by the material of the workpiece. Aluminum, brass, stainless steel, and mild steel may all be treated with soluble oil. When reaming cast iron, cold air can be utilized, and synthetic oil can be used with aluminum and plastics.
Applications of Carbide Reamer
- A carbide reamer is a rotary cutting tool that is commonly used in metalworking
- A carbide reamer is a tool used for enlarging or completing pre-drilled holes that have been bored or cored to provide a nice finish and accurate size.
- The carbide reamer is designed for use in a drill press or turret lathe.
- A carbide reamer can also be found in a screw-cutting machine.
- Typically, carbide reamers remove 0.012″ to 0.014″ of material on diameter. The amount of material removed rises with increasing diameter and decreases with decreasing diameter
The reamer’s material is determined by the workpiece material, however reamers may cut practically any metal. To attain exceedingly fine tolerances, the hole must be drilled, rough bored, and then ream. However, with aluminum, a reamer can occasionally remove material straight from a casting. A reamer is intended for precise hole tolerances rather than material removal. However, with aluminum, there are many cases where we can instantly run the reamer into the prefabricated hole and remove the material.
One issue with reamers is preventing cutting edge chipping. The cutting edges are razor-sharp. Dropping them can damage the edge by leaving a burr or creating a negative cutting edge. This would have an impact on the way any tool cuts, but particularly reamers.
Cutting edges on reamers are inherently more delicate than those on other cutting instruments, but they are also more important. All cutting edges are fragile, but protecting all reamer edges is important because if you damage even one, it will compromise your size and surface polish. If your cutting edge is chipped, one of those teeth is creating a void within that portion while it is in that cut.
Optimal Operating Conditions
- Given a good hole and a suitable reamer, the following are some of the remaining operational criteria that must be satisfied for best performance:
- Hold the workpiece securely so it does not flex, move, or vibrate/chatter.
- To hold the reamer, use a high-quality chuck.
- Use the reamer’s approved cutting fluids
- Do not allow the flutes of the reamer to become clogged with chips
- Align the reamer’s centerline with the hole’s centerline as precisely as feasible
- If the angle is greater than 5 degrees, reaming is not suggested
- Makes use of the smallest tool overhang (stickout) feasible
Conclusion
So, we hope that we have dispelled all of your concerns regarding Carbide Reamers. HUANA carbide reamers are intended for a wide range of reaming applications and materials, including titanium, super alloys, hardened steels, stainless steels, steels, cast iron, graphite, brass & copper, composites, plastics, and wood.
That’s all for now, and thanks for reading. If you like our story, please tell your friends about it. If you have any inquiries or want to order carbide reamers, please contact HUANA..
