
   Congratulations! You are now the recipient of the DRILL executable of
 the machine shop software Feedrate Calculator series of programs. I 
 think you will enjoy using these programs, which include executable 
 modules for MILL, DRILL, REAM, TAP, TURN, COBORE, CSINK, CDRILL, and 
 a generalized FRCALC. They use very little memory, and common PC 
 software (word processors, CAD/CAM programs, DOS utilities) are versatile 
 enough that the Feedrate Calculator programs can be executed without 
 exiting the host software. You will not experience memory conflicts 
 because these programs are not TSR (Terminate and Stay Resident) 
 dependent. In fact, if using machine tool controls that support processing 
 of DOS programs this software will be accessible on the shop floor as an 
 integral part of the machine tool. The entire collection of Feedrate 
 Calculator programs is available for just $79.95 US, and will entitle you 
 to download additional Feedrate Calculator executable functions as they 
 become available. 
 
 * * * * * * * * * * * * * * REGISTRATION * * * * * * * * * * * * * *
       
   The accompanying DRILL.EXE program is not crippled in any way, 
 the registration request is sincere, the copyright is real, and the
 disclaimer is real. Your financial support and technical input are 
 appreciated. To register just the DRILL.EXE program send a check for 
 $10 US payable to Axis Unlimited at the at the end of this file and write
 "DRILL.EXE" somewhere on the check. If you later decide to register the
 entire Feedrate Calculator series, the $10 will be applied to the balance
 due.

 * * * * * * * * * * * * * * DOCUMENTATION * * * * * * * * * * * * * *

   The DRILL.EXE commands are not case-dependent (you can use either upper 
 or lower case), and diagnostic messages appear if valid syntax is violated. 
 However, do not mix case - like this: mIxeD CAse. 
  
   Each Feedrate Calculator program includes a help screen which appears 
 by entering the command itself (DRILL) without command line parameters.
 On the help screen you will be encouraged to enter data in the following
 format:

         + - - - - - - - - - - - - - - - - - - - - - - - +
         |                                               |
         |        DRILL [AL] .5(DIA) [HSS], or           |
         |        DRILL [FE] .5(DIA) [COB], or           |
         |        DRILL [TI] .5(DIA) [CRB], or           |
         |        DRILL [NI] .5(DIA) [MCB], or           |
         |        DRILL [CU] .5(DIA) [HSS]               |
         |                                               |
         + - - - - - - - - - - - - - - - - - - - - - - - +


   What this means is that the all three of following examples are valid 
 and are actually equivalent because the program default is to drill Al 
 with a High Speed Steel (HSS) tool:

                      DRILL .5
                      DRILL AL .5
                      DRILL AL .5 HSS

   To prevent you from being misled by the syntax on the help screen, 
 you need to know that it is not necessary for you to enter the command 
 line parameters that are enclosed in brackets [like this]. The bracket
 characters are NEVER required. They are shown on the help screen only to 
 indicate the optional nature of the enclosed parameters. Naturally this 
 saves you keystrokes when the default calculation for drilling Al with 
 a HSS cutter is desired. Notice that after the numeric input, the 
 "(DIA)" characters are not required either. Do not type in "(DIA)" with 
 the DRILL command. "(DIA)" is only displayed on the help screen to 
 indicate to you that the numeric value should represent the drill 
 diameter. Thus you see that the DRILL calculation always requires at 
 least two parameters (DRILL n), and no more than four parameters 
 (DRILL xx n xxx). Simple enough? Further examples follow later on in 
 this text.

   The Feedrate Calculator programs do not limit their output to just 
 speeds and feeds. For example, the DRILL Feedrate Calculator provides 
 additional information as to tool tip length and the predicted 
 inaccuracy in oversize of the final hole diameter. The SFM and IPT used 
 in each individual calculation is displayed also. 

   One secret to the success of the Feedrate Calculator programs depends 
 on their consideration of tool stiffness and standard shop practice in 
 regard to tool geometry, tool composition, and machine stock 
 characteristics. Intelligent shop practice is built into the program 
 logic. The Feedrate Calculator software incorporates natural intelligence 
 based on machine shop and offline part programming experience. There is 
 no faster, easier way to determine this vital programming data. The tool 
 stiffness formulas are proprietary, and correspond with actual machining 
 behavior. Although you have only received the DRILL program, various 
 other Feedrate Calculator programs that are available are described below 
 also.
 

 * * * * * * * * * * * * * * *  DRILL  * * * * * * * * * * * * * * *
 
   EXAMPLES: 

   If you input just 'DRILL <CR>', you will see a screen of online 
 documentation providing a list of options. 
 
   If you input  'DRILL .5 <CR>', you will get the following display:
                  --------

         + - - - - - - - - - - - - - - - - - - - - - - - +
         |                                               |
         | DRILL AL  .500(DIA) HSS                       |
         | Calculation assumes  250.00SFM, and .0070IPR. |
         |                                               |
         | rpm= 1909.85   ipm= 13.37                     |
         |                                               |
         | tool tip= .150;   oversize= .0048             |
         |                                               |
         + - - - - - - - - - - - - - - - - - - - - - - - +

   The results above should be self-explanatory. To drill a .5" dia 
 hole in aluminum with a High Speed Steel Cutter, a good starting point 
 is 1900 RPM at 13 IPM. Notice that cutting Aluminum using a HSS cutter 
 is the default.

   If you were to enter 'DRILL NI .5 CRB <CR>' you would get a display 
 recommending approximately 575 RPM and 4 IPM when using a Carbide cutter. 
 The numbers can be rounded somewhat for convenience in data entry.

   You also notice the display:
 
                       oversize= nnnnn.
 
   The oversize value is the mean inaccuracy in oversize expected for the 
 life of a drill in "standard" shop practice. The object is to 
 acknowledge factors affecting hole size such as wear and tool tip 
 geometry. Reliable data was only available for drill diameters 
 from .0625" to 1". Extrapolation was not performed beyond those values. 
 The data used for the inaccuracy in oversize calculation was generated 
 by the Metal Cutting Tool Institute in which the diameter of over 2800 
 holes drilled in steel and cast iron were measured. Factors affecting 
 the inaccuracy in oversize include: the accuracy of the drill point, 
 drill point symmetry, lip lengths, axial heights of lips, adequate 
 relief angle behind the chisel edge, initial drill wandering or 
 instability, drill diameter, drill length, work material, spindle 
 runout, cutting fluid, and setup rigidity. Drilling generally results in 
 holes that are oversize, but undersize holes can result in certain 
 materials due to elastic action (like rubber) or thermal contraction. 
 The table of values for inaccuracy in oversize appears in the 
 Machinery's Handbook, 21st Edition, page 1669.

   Regarding maximum spindle speeds - being a general purpose program, 
 the maximum spindle speed allowable in the DRILL program is 3000 RPM. 
 This is to prevent ridiculously high spindle speeds from being output for 
 machines that do not support them. High speed machining is simply not
 the main emphasis of this program. But yes, if it was a popular request 
 it would not be difficult to include. If there's a market need, I'd be 
 glad to fill it.

 
   * * * * * * * * * * * * * * ALLOY TYPES * * * * * * * * * * * * * 
                              
   The alloy parameters currently supported in this version of the 
 DRILL program are: Al, Fe, Cu, Ni, and Ti. These categories may 
 appear vague or too general, but in practice the program output is 
 quite acceptable for general purpose work. If you are doing screw 
 machine work then these values are not optimal. In my exposure to 
 general machine shop work, and highly automated (not necessarily 
 high volume) workload, most dead time is in job setups, tooling 
 changeovers, scheduling, and other non-cutting tasks. In determining
 appropriate speeds and feeds, the philosophy employed in the Feedrate 
 Calculator programs is not to reduce tool life to the point of working 
 the tool so hard that tools wear out every 15 or 30 minutes. Believe it 
 or not, many sources of feeds and speeds data base their recommendations 
 on a tool life of 15 to 30 minutes. If your shop intends to replace 
 tools every 15 minutes then you will need more agressive values than
 those incorporated in the Feedrate Calculator defaults. Proper tooling 
 in conjunction with the present Feedrate Calculator values can generate 
 chips faster than widespread shop practice will generally remove them. 
 If the machining cycle has to be interrupted to handle chips, feedrates 
 may not be the production bottleneck.
 
   But back to the subject of alloy types Al, Fe, Cu, Ni, and Ti. Well, 
 just try them. The Al parameter will provide a calculation appropriate 
 for A356, 7075, and other commercially common aluminum alloys. If you 
 are cutting an alloy and that is not working quite right, tinker with it. 
 Most likely you have a setup or tooling problem. The program can not 
 account too much for that. These values will put you in the ball park. 
 The abbreviations of Al, Fe, Cu, Ni, and Ti do not stand for the pure 
 metals. They represent the common alloys in their class. A word of 
 explanation is required regarding the intent of the values in the "Fe" 
 classification. Although "Fe" is iron, in the Feedrate Calculator 
 programs "Fe" does NOT mean gray iron or ductile iron! You might be 
 surprised to know that there is more iron (Fe) in Steel than in gray 
 iron, ductile iron, ni-hard, ni-resist, or malleable iron. Fe in the 
 Feedrate calculator stands for STEEL. The Fe parameter is applicable to 
 the range of steel alloys from the carbon steels, to alloy steels like 
 4140 or 8160, up to Rc35 or so. If the steel you are cutting really doesn't 
 machine well enough using the Fe parameter, you should consider trying 
 the Ni option, which is for the tougher nickel-based alloys like Waspaloy, 
 Hastelloy, and Inconel. The Ni option might also work for Cobalt based 
 alloys, but in that case I'd definitely start slower and use something 
 other than a HSS drill. Likewise, I'd suggest at least a Cobalt cutter 
 (not HSS) for Fe or Ni, but since those cutters may not always be 
 on hand when you need them, the DRILL program does not force a cutter 
 selection. Check with your tooling supplier when in doubt as to 
 recommended tooling.

   As for coolant considerations for drilling, it may be somewhat of a 
 necessary evil, but in aluminum I tend to prefer peck drilling without 
 coolant instead of using coolant and drilling deeper.

   If you really want to drill iron alloys, I am willing to work with 
 someone who has exposure to cutting iron. By the way, I've worked in 
 foundries (iron, steel, brass, aluminum, and magnesium) in addition to 
 machine shop experience, and so have had exposure to the behavior of a 
 wide variety of commercial alloys. 

   Oh, if you want to cut magnesium alloys, you can use the Al parameter. 
 But, slowing down the feedrate for magnesium is NOT recommended. I also 
 don't recommend any type of coolant while milling magnesium. I don't like 
 coolant anyway. But magnesium castings *are* produced commercially using a 
 clay and water binder in molding sand, so it is not absolutely crazy to 
 use a water-based coolant (or just plain water) for something as benign 
 as machining magnesium. If a magnesium part does catch fire DO NOT use 
 water in an attempt to extinguish the fire. If I recall correctly, nascent 
 oxygen combines with magnesium to form MgO, making available lots of 
 disassociated hydrogen which burns nicely also, providing even more fuel 
 for your fire. But that's another subject.


   * * * * * * * * * * * * * * *  MILL  * * * * * * * * * * * * * * *
 
   EXAMPLES: 
 
   If you input just 'MILL <CR>', you will see a list of options. 
 
   Or, if you input  'MILL .5 <CR>', the last line of information 
 displayed provides RPM and Inches per Minute for machining purposes. The 
 on-screen display will indicate the defaults used. 
 
   Entering 'MILL FE 1 <CR>', for example, employs two optional 
 parameters - 1) the material type, and 2) the cutter diameter. The 
 command parameter 'FE' performs the calculation for Steel alloys (not 
 iron). In the resultant calculation note the difference between the 
 defaults previously obtained. In the former case (in which no material 
 was specified), the default number of flutes was two - for aluminum 
 alloys. In the latter case, where 'FE' is designated as the material 
 type, the default is four flutes - for steel alloys. Thus, in ordinary 
 circumstances you will rarely need to specify more than two optional 
 parameters. Acutally, for slotting purposes the values given in the 
 MILL routine are somewhat agressive. You may want to get a feel for the
 program by running slotting toolpaths at 60% of the given IPM and 100% 
 of the given RPM. Tool length and depth of cut also detract from optimum 
 conditions, so be cautious until you are comfortable. Depth of cut 
 guidelines are included on the MILL display. 
 

  * * * * * * * * * * * * * * *  CDRILL  * * * * * * * * * * * * * * *
 
   CDRILL performs calculations for center drilling, employing the 
 numbered "Combined Center Drill and Countersink". CDRILL not only 
 provides the proper speeds and feeds, but it also specifies the proper 
 drill depth and specific tool size number (#00 to #5). This is trickier 
 than may first appear (must be why its never been done before.) Unless 
 the dimensions of the particular center drill to be used is known, and 
 its particular measurements are known, entering the appropriate center 
 drill depth can be quite a challenge - particularly when considering the 
 indiscriminate use of reground tooling. Regrinding typically shortens 
 the distance from the tool tip to the included 60 deg countersink which 
 can cause unpredictably oversize countersunk holes. 
 
   CDRILL optimizes the stiffness of the center drill and reduces 
 the accompanying tool wobble, while minimizing drill depth, cycle time, 
 and the tendency to oversize the final countersink diameter due to 
 reground geometry. 
 
   CDRILL is as easy to use as the other Feedrate Calculator programs. 
 Enter:
                            "CDRILL n"
                             ^^^^^^^^
 This will result in a calculation for the default aluminum alloy type 
 for a drill size "n". For a steel calculation enter:
 
                           "CDRILL FE n"
                            ^^^^^^^^^^^   
 
   If you had the CDRILL program, entering "CDRILL .120" would produce 
 the following screen:

         + - - - - - - - - - - - - - - - - - - - - - - - +
         |                                               |
         |  Diameter argument   .120(DIA) is used.       | 
         |  Assumed command is:                          |
         |  CDRILL AL   .120(DIA)                        |
         |  Parameters are:  250.00SFM, and .0021IPR.    |
         |                                               |
  rpm= 3000.000   ipm=  6.44   Use a #3 size center drill; DEPTH= .152
         |                                               |
         + - - - - - - - - - - - - - - - - - - - - - - - +


  * * * * * * * * * * * * * * *  FRCALC  * * * * * * * * * * * * * * *
 
   The FRCALC executable is unique in that it allows command line input 
 of DIA, SFM, IPT, and #Teeth, for complete user preference. This is 
 particularly useful for high-speed milling, special form tool usage, or 
 unusual cutting circumstances. As indicated in the help screen for 
 FRCALC, the couplet format is required for FRCALC. (Couplets are data 
 entered by 2's, as in "n DIA" or "n TEETH".) In case you want to reissue 
 the FRCALC command without retyping the whole thing - no problem. FRCALC 
 allows you hit F3 to reissue the commands in the DOS command buffer, and 
 to add on to the previous command the revised couplet condition. 
 (Actually, usage of F3 to reissue the command is a DOS feature, for 
 which no additional programming was required in these programs.) For 
 example, if you originally entered:
 
                  "FRCALC .5 DIA 4 FL 250 SFM .004 IPT",
 
 to reissue a revised command you may press F3 (at the DOS prompt) - to 
 recall the DOS command buffer, and add any new couplet data at the end 
 of the command. You could issue the revised command by saying:
 
          FRCALC .5 DIA 4 FL 250 SFM .004 IPT .125 DIA .002 IPT
                                              ^^^^ ^^^ ^^^^ ^^^   
 
   Notice how ".125 DIA .002 IPT" were appended to the original command. 
 FRCALC will recalculate the command based on the last data entered in 
 the DOS command. In many cases, the use of F3 will not be necessary 
 because you may be issuing the FRCALC command from a program that 
 provides an alternative method of recalling the last DOS command. In 
 such a situation, it may even be easier to edit the last DOS command and 
 reissue it. In general, the easiest technique to use will depend on the 
 software from which you issue the DOS command. The main point here is 
 that couplet data can be issued multiple times on the same command line, 
 and FRCALC will only use the last specified couplet if it is given more 
 than once. The help screen which is displayed by issuing FRCALC by 
 itself explains the valid syntax.
 
   If you don't like issuing long DOS commands, the simplest form of 
 FRCALC allows you to drop the "DIA" word, only if the first parameter 
 after the command "FRCALC" represents the numeric diameter value. For 
 example, the following commands are both valid:
 
                    FRCALC .5 DIA 4 FL 250 SFM .004 IPT
                    FRCALC .5     4 FL 250 SFM .004 IPT
 
   Notice that the "DIA" word is not required when the diameter is the 
 first value after the "FRCALC" word. The additional spaces are not 
 required either, but were included for illustration only. In FRCALC, at 
 least one space is required between command line parameters. In FRCALC, 
 the order in which the couplet data appears is not significant either. 
 As an example in mixing the order of couplet data, the following 
 commands are all equivalent:
 
              FRCALC  .5 DIA    4 FL     250 SFM   .004 IPT
              FRCALC  .5 DIA    250 SFM  4 FL      .004 IPT
              FRCALC  .5 DIA    250 SFM  .004 IPT   4 FL 
              FRCALC   4 FL     .5 DIA    250 SFM  .004 IPT
              FRCALC  .004 IPT  4 FL      250 SFM  .5 DIA, etc.
 
   There are 256 possible FRCALC couplet combinations, and more 
 considering that the DIA specification can be omitted when the diameter 
 value is given immediately after the word "FRCALC". 
 
   When in doubt, call up the help screen by entering "FRCALC" by itself, 
 without additional command line parameters. Actually, the more powerful 
 routines are not FRCALC, but the others, because the intelligent 
 defaults based on common shop practice as to tool geometry (number of 
 flutes), tool material (HSS, CObalt, CaRBide, MiCRograin carbide), 
 maximum RPM, optimum SFM, and recommended IPT (based on tool stiffness), 
 are already in the program. Consideration is also given to the fact that 
 setups are not always ideal. It is not possible to cover every possible 
 circumstance in such an easy to use program. But I think this as close as 
 it gets. 


     * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * 

   The other Feedrate Calculator programs are excellent (if not fantastic) 
 also. Rather than bore you with endless examples, free demo programs are 
 available on the Manufacturing Technology BBS (210-821-6356). However 
 those demos are not true shareware and they time out after 30 days, so 
 you may want to download them at the beginning of the month. 
 
     * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * 
                                      
                      COPYRIGHT Axis Unlimited 1993
 
   The accompanying DRILL.EXE program is SHAREware, NOT FREEware. You may 
 use it for up to 30 days for evaluation purposes. Using it with no intent 
 to pay you is dishonest. The copyright notice is for real. Unauthorized 
 use is illegal. 
 
    * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * 

 
                                DISCLAIMER
 
   Use of this product constitutes consent to abide by the following 
 terms and conditions.
 
   Under no circumstances shall Axis Unlimited be liable for any loss or 
 damage, direct, indirect, consequential, or incidental, arising out of 
 the use of or inability to use this software. This agreement is in lieu 
 of all other agreements, express or implied, including any statement or 
 implication of merchantability or fitness for a particular use or 
 purpose. 
 
    * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * 

  
                             PRODUCT SUPPORT
 
   As a registered user you are welcome to receive the latest updates via 
 the Manufacturing Technology BBS support line: (210)821-6356. There is 
 no additional charge if you download the upgrades yourself, except 
 perhaps for phone company long distance charges. Please do not ask for 
 distribution diskettes; and please limit product support requests to use 
 of the BBS for that purpose. In other words, please do not request 
 personalized telephone support. However, exceptions will be considered.
 
 
                              Axis Unlimited
                             654 Shadywood Ln
                        San Antonio TX 78216-6816 USA
                   jerry.myer@f783.n387.z1.fidonet.org
                        (210) 821-6356 (BBS/modem)
                         (210) 821-6214. (voice)
                            1:387/783 FidoNet
 /eof...drill.txt
