BACKGROUND:
The Hole-O-Magic Guide is rapidly becoming one of the best methods to consistently
produce accurate one size, fur free holes in fiber reinforced plastic materials.
The maintenance suggestions is being presented to help you get the maximum
operations benefits of this type of tooling. The Hole-O-Magic Drill Guide
is a devise not a drill bit. A drill bit requires attention only when it
is dull or broken. The Hole-O-Magic Drill Guide is not the same. It has
parts that wear and need lubrication to achieve the maximum benefits from
this state of the art tooling aid.
PURPOSE: The
purpose of this report is to provide a suggested routine for keeping the
Hole-O-Magic Master Assemblies operating longer and also to provide a basis
for a check list for the individuals who use and/or supervise the use of
these tools. If the Hole-O-Magic Master Assembly Drill Guide is followed
they will make money for you every day!
SCOPE:
This maintenance
recommendation is limited to the Hole-0-Magic Master Assembly Drill Guide.
Cutter re-sharpening and operation techniques are specifically excluded
and are the subject or similar reports. The proper installation of the
Hole-O-Magic Master Assemblies has not been debugged and is "work in process"
while producing parts that are to specific manufacturing requirements.
This report is broken into two parts:
1.*Production
shop floor preventive maintenance.
2.*Supervisory
or setup maintenance.
ASSIGNMENT OF RESPONSIBILITY: Someone
in each organization MUST have responsibility for the proper maintenance
of the Hole-O-Magic Master Assemblies. Continual use of the Hole-O-Magic
over a period of time without the proper maintenance could result in getting
less productivity from your tools. Management commitment to the importance
of this program will significantly increase cost and productivity.
PRODUCTION FLOOR DAILY MAINTENANCE:
Each Hole-O-Magic Master Assembly should be inspected by the operator and
or the immediate shop floor supervisor at the beginning of each shift.
The following areas should be included in each inspection. This list is
not meant to be complete for each operation, but a good general list upon
which to build a complete program. In each instance where an unsatisfactory
condition is found the immediate solution is to remove the Hole-O-Magic
Master Assembly and replace it with a unit that has been recently inspected
and found to be in good working condition. We do NOT recommend that the
operator be given the job of replacing the Hole-O-Magic Master Assembly
parts. If the operator becomes involved in the replacement of parts in
can become an overly time expensive operation. Production operators are
to produce products.
Instructiions:
1. Hold
the Hole-O-Magic Drill Master Assembly and gently move the Hole-O-Magic
Hex Nut side ways, up and down and rotate it.
2. The hex nut should move freely between
the fingers. If not, use WD-40 or similar lubricant to loosen areas.
3. The hex Nut should not move easily from
side to side. If it does it may indicate that the Slip Fit Bushing body,
Hex Nut, or the cutter shaft are worn and need replacing. Remove and replace
Master Assembly.
4. You should be able to move the Hex Nut
up and down in the Master Assembly but you should have constant resistance
to movement. The Compression Control Spring inside the body of the Hole
-O-Magic Master Assembly is to hold the Hex Nut firmly at the extreme up
position. Looseness is caused by a Compression Control Spring that has
become overheated. Remove and replace the Master Assembly.
5. The Hex Nut is firmly held by shank of
the Hole-O-Magic cutter. If the cutter shank has worn down the square power
Notch in the Hex Nut will feel loose. Remove and replace the Master Assembly.
6. Hold the Hole-O-Magic Dust Cover an try
to move the entire Master Assembly. The hold down screw may have become
loose and needs tightening. Tighten the Lock Screw.Hole-O-Magic
Lock Screw: The
Hole-O-Magic Lock screw holds the Master Assembly so that holes are produced
in the same location. Inspect the Lock Screw to see that it is in
place and tightly holding the Master Assembly. tighten the Lock Screw if
necessary.
In some cases, installing the Lock Screw my
not be firmly seated and the Master Assembly can move in and out a short
distance, although this is not the ultimate execution, it will work well
provided that the Master Assembly fits into the hole very snug. As the
hole wears the amount of play will increase so that the hole location will
be effected. If you have this type of installation make sure that the holes
produced are within tolerance.
Hole-O-Magic Dust Cover: The
dust cover is is to protect the moving parts inside the Master Assembly
from abrasive fiberglass cutter dust. The Dust Cover also acts to center
the cutting shank and aids in the lubrication of the Hole-O-Magic Master
Assembly. DO NOT
Clean the Dust Cover by blowing air inside the tiny hole near the top.
This hole is for the application of a light lubricating oil (WD-40). If
air is blown into the hole fiberglass dust will enter causing damage.
- If the Dust Cover is melted, it is a good
indication that the Master Assembly was run without adequate lubrication
and the entire unit should be replaced. In some instances just the contact
area is destroyed where the Thrust Bearing and Depth Control Spacers press
on the top of the Dust Cover. Replace the entire Master Assembly.
Hole-O-Magic Carbide Cutter tip: Inspect
the cutter tip for chips or nicks. Especially, the point of the cutter.
Rough handling can cause the point of the carbide to break off, though
the cutter will continue to cut, eventually the cutter will not cut to
size and will completely destruct itself. Tools damaged should be replaced.
Remove and replace the Master Assembly.
- The cutting edge of the cutter is frequently
covered with a whitish dust. The cutting edge can be wiped with a damp
cloth to remove the dust. If the cutting edge does not have a clean look
and seems to cut harder that usual check to see if the cutting edge is
dull. Another clue to cutting edge condition can be found by running the
drill at a slightly slower speed than normal and checking the hole that
is produced for being fur free and on size. As the tool wears, the condition
of the hole wall will become rough and the end of efficient cutting is
near. If the cutter is replaced soon enough it is much easier to re-sharpen
to extend the life of the tool, otherwise replace the tool.
Hole-O-Magic Driver Coupler:
The purpose of the Driver coupler is to provide rotational torque and penetrating
thrust for the Hole-O-Magic Cutter. If the Driver coupler contacting surface
is rough or worn it can not provide the dependable torque and thrust necessary
for all day drilling. The Driver Coupler should be considered the expendable
part of the tooling. Frequent changes to new Driver Couplers should be
planned. Change of Driver Couplers are less time consuming and not as expensive
as the Hex Nut or Master Assembly, especially considering the time required
to replace these parts. Replace worn Driver Couplers.
Fixture: The
locking mechanisms of the fixture should be inspected to ensure that tools
are secure prior to machining, also the clamps and clamping mechanisms
may need lubricating at this time.
In Summary: Visually check each Hole-O-Magic Master Assembly to see that it is complete and not loose. If you have any doubt, remove it and replace with a Master Assembly in good working condition. Use a new Driver Coupler at the beginning of each shift.
In Summary: keep records to establish a performance history for replacement parts requirement and production standards.
Take apart and clean: On
a clean and proper work bench take the units apart by knocking out the
Hole-O-Magic Lock Pin with
a 5/64" drift pin. After taking apart, clean all parts in a solvent solution
that will cut the accumulated dust and oil. We recommend that the cutters
be separated from the other parts prior to putting the other Master Assembly
parts into the solvent. The cutters should be handled very carefully due
to the possibility of damaging the cutting edges. DG-106 Sub-micron tungsten
carbide cutting edge material is very hard and abrasive resistant, it is
also very brittle and will break with only a small amount of mishandling.
Great care should be taken to prevent the cutting edges from hitting each
other.
Inspect: After
cleaning, examine all parts for wear and replace if necessary. Special
attention should be given to the Compression Control Spring. This part
is designed to provide the force necessary to remove the cutter from the
hole after cutting and needs to be close to its original strength to function
properly. After squeezing the spring it should have a pressure of approximately
18 pounds. We recommend taking a new spring and comparing the amount of
force necessary to compress the spring to a solid. If the spring has been
subjected to elevated temperatures it will be very soft. A soft spring
MUST be replaced.
Thrust Bearing Depth Control Spacers: The
thrust Bearing Depth Control Spacers are very inexpensive items and their
replacement is usually good a idea. The wear pattern is a depressed ridge
around the outside edges. This indicates not enough lubrication was present
during use and the metal to metal contact is causing wear.
NOTE: Upon reassemble,
the Dust Cover should just cover the top the Slip Fit Bushing Body.
If not, add one or more Depth Control Spacers
so that cutting dust does not enter.
Slip Fit Bushing Body:The
slip fit bushing body is the most difficult item to check for wear because
the inside diameter can be dirty with dust and oil and not allow smooth
sliding of the parts. There are two inside gage pins available to help
in finding out if the bushing has worn and needs replacement.
- Use the HM-001 3/16" Slip Fit Bushing Body
Gage Pin for all of the cutter sizes one half inch or less. the
Gage Pin should be inserted from both ends of the Bushing Body. If the
Gage Pin can be pushed through the Slip Fit Bushing Body, the part needs
to be replaced, to continue use of the worn Bushing Body will result in
making the hole location and smoothness less than what you would expect
from a Hole-O-Magic Master Assembly in good condition.
- Use the HM-002 1/2" Slip Fit Bushing Body
Gage Pin for all Hole-O-Magic Cutter sizes over one half inch.
If the gage pin can be pushed through either end of the Slip Fit Bushing
Body, the part will need to be replaced.
Hole-O-Magic Cutter Shank: The
shank is made of M-2 High Speed Steel hardened to 60 Rockwell C.
Industrial quality twist drills are made of the same material and hardened
the same way. The shaft over a period of time will begin to wear faster
than the shank. To avoid damage to the shank and other components. Use
an adequate amount of lubrication to reduce the wear and avoid the surface
area to become hot and possibly melt. The melted material will ball up
an cause a rough condition on the shank. This rough condition is easily
felt with the finger nail and in severe cases you can see discoloration
and gouges in the surface with the naked eye. Light stoning with a grinding
stone can remove the small build ups, but if large areas or deep scratches
develop the cutter should be replaced.
Lubrication: The
small hole in the top of the Hole-O-Magic Dust Cover is for applying a
small quantity of light lubricating oil when needed. We have found WD-40
to be a good lubricant. After the parts have been freed up, the carrying
agent for the WD-40 evaporates and a small residue will provide a smooth
lubricating action without a large build up of oil. This reduces the danger
of contaminating the piece parts being machined. A high pressure grease
in small amounts is recommended.
In Summary: All
parts should slide easily if properly assembled, lubricated and cleaned.
if you find it necessary to force a part together, review the assembly
operation to that point for possible problems. Cutting edge protection
should provide for the cutters and assembled Hole-O-Magic Master Assemblies
during storage and movement around the plant. The DG-106 sub micron Tungsten
Carbide Cutting edge material is very hard, but also very brittle and easily
broken if gently bumped together. Hole-O-Magic Driver Couplers HM-004 should
be used to drive the Hole-O-Magic Assembly Hex Nut.
The Hole-O-Magic Driver Couple is designed to limit the depth that it will
engage the Hex Nut HM-003 and HM-114 this limits the force a pistol grip
type drill motor can exert on the shaft of a Hole-O-Magic Cutter, thus
preventing damage and breaking. After approximately 20 degrees of misalignment,
the Driver coupler will disengage from the Hex Nut without harm to the
assemblies. The Driver Coupler has been designed to be the disposable perishable
part of our Drill Guide System.
Lubrication: Hole-O-Magic
Master Assemblies are packed with a non migratory high pressure/Temperature
wax like lubricant. This lubricant will not run out on the work piece,
causing subsequent painting problems. Chip dust can become a thickening
agent in the lubricant. There is a small hole in the Dust Cover (HM-005)
for spraying a light solvent penetrating oil we recommend WD-40 because
it will not leave an oily residue) for freeing the thickened lubricant.
When a Master Assembly Unit is taken apart a small amount of good grade
high temperature wax lubricant should be put on the Compression Control
Regulator Spring coils. (HM-006). A few drips of a penetrating solvent
oil should be applied to all Master Assemblies weekly.
IMPORTANT NOTICE: Lubricate
immediately if a Master-Assembly feels warm during operation
Mounting: During
set up, the fit of the Hole-O-Magic Master Assembly should be checked.
A slip-fit is all that is required. A loose Master Assembly will
cause hole location variations, size control problems, and hole appearance
irregularities. If the Hole-O-Magic cutter is hit on the edge during removal
from the fixture, the tungsten carbide cutting edges will chip or break.
The Hole-O-Magic Master Assembly is removed by twisting and lifting on
the clamp ring or knurled head only. Do not force the Hole-O-Magic Master
Assembly. Careful cleaning of the Bushing Liner will aid in positioning.
Disassemble and Reassemble:
First Knock out the 5/16" Lock Pin (HM-008) holding the Hex Nut on the
Cutter Shank: Care must be taken during this operation because removal
of the lock pin releases the spring tension of the Compression Control
spring Regulator (HM-006)). It is recommended that hand and eye protection
be worn while handling the Hole-0-Magic Cutters. The Disassembly
should be made in a walled container (box or large can) so that spring
loaded parts do not hurl out and scatter around the work area. Next, clean
parts thoroughly with a penetrating oil solvent. We recommend WD-40.
All worn parts are unserviceable Slip Fit Bushing Bodies and Cutters should
be replaced .
Repair parts are available for all Hole-O-Magic
Assemblies. Care should be exercised in ordering shanks, two sizes are
available 3/16" and 1/4". When ordering Slip-Fit Bushing bodies be
sure to check the hole size and the body seat diameter that fits into the
fixture and secured by the Lock Screw. This dimension varies from 1/2"
to 1". Now securing the Hex Nut to the Cutter Shank with the Lock Pin requires
that all component parts be in correct sequence. Holding pressure is applied
to compress the spring so that the notched square end of the shank protrude
through the Thrust Bearing and Dust Cover. The notched side be faced up
and the Hex Nut held so that the two pin hole openings can be seen
when looking directly down at it. Slide the Hex Nut on to the Cutter Shank
and insert the Lock Pin. The use of Channel Lock Pliers is recommended
to squeeze the Lock Pin. Lubricate as described.
Custom Reconditioning and Sharpening Service
is available: Return your used, broken, dull
or cannibalized Hole-O-Magic's to us for reconditioning. We will clean,
re-sharpen and lubricate each tool and provide replacement parts for a
small service fee. Regrind prices are determined by the Cutter Size. The
"like New" appearance and performance are only a fraction of the original
cost.
International Carbide Corporation
Last Update February 8, 2007