Removing broken drill

[plastibob]

What is the best way of removing a broken HS drill without using an EDM machine? Thanks

[stk2008]

is it possible to drill from the other side that way drill up to the drill bit then knock it out.

if no good will possibly have to spark erode it.

[plastibob]

Originally Posted by stk2008 is it possible to drill from the other side that way drill up to the drill bit then knock it out. if no good will possibly have to spark erode it.

No it's a blind hole.

[beege]

What size drill? What material is it stuck in? How deep do you suppose?

[plastibob]

It's a 5/32 drill in about 1 inch in aluminum 6061 broken off about 3/8" from the surface.

[rowbare]

Can you go in with a carbide end mill?

[garagefela]

Not really any help with the actual removal of the drill.

Depending on how the part is designed and if it is capable of it could you pocket out the material from around the drill so in effect you might end up with a 3/8" (or whatever) hole that could have a plug smacked and welded back in.
Then re drill the hole.

I suppose if you are going to stuff around that much just give the part to a company that spark erodes stuff out, they are out there. Or get friendly with someone that has one.

Sorry not much help with the actual drill part but just another option.

Cheers M

[Arquibaldo]

I remembered reading somewhere that certain chemicals will dissolve the steel while
preserving the aluminum... I googled and, sure enough, found:

http://www.atmlist.net/pipermail/atm...ch/007034.html and
http://www.atmlist.net/pipermail/atm...ch/007035.html and also
http://www.ytmag.com/articles/artint62.htm

I have no idea whether this will work, but you might try on a piece of scrap...

Nelson

[plastibob]

I'm going to try using carbide. I can't cut around it. Worst case I'll have to EDM it

[Mcgyver]

if its in AL, just dissolve it out with Alum

[kazikw]

Don't cur around it. Use scrap carbide end mill. Sharp like shamfer tool 45 deg. Go slowly like with feed 3. in center of drill with rpm 300. For sure 1 carbide tool will be not enough but they are already scrap.

[plastibob]

Thanks for the tips, I ended up milling around it and plugged it. Barely had the room - thin walls but I salvaged it and it worked out fine.