HiPACS Drilling and Countersinking System

July 09, 2021
HiPACS for Aerospace Fastener Hole Drilling and Countersinking

Kennametal has introduced the HiPACS drilling and countersinking system for aerospace fastener holes. Designed to drill and chamfer holes in one operation, the high-precision tool meets the aerospace industry's stringent accuracy requirements, while delivering increased tool life in machining composite, titanium and aluminum aircraft skins.

"Most fastener hole tools used today are complex made-to-order tools with long lead-times," says Georg Roth, Product Manager, Kennametal. "HiPACS uses standard, off-the-shelf components for quick delivery and low cost per hole, by allowing the drill and chamfer insert to be indexed independently from one another. What´s more, it´s the only indexable drilling and countersinking system on the market that can hold the aerospace industry´s required fastener hole chamfer tolerances in just one operation."

Kennametal's HiPACS is a cost effective and easy to assemble system comprised of three components: a reducer sleeve, countersinking insert and solid caribe drill. The system works with any standard hydraulic chuck.
  
Three simple components eliminate the need for custom tooling
Designed to be clamped in a standard hydraulic chuck, the HiPACS modular system consists of three components that are fast and easy to assemble: 

  • A reducer sleeve with a built-in high-precision pocket seat. In conjunction with a standard hydraulic chuck, this component provides ultra-secure clamping and a runout of no more than 3µm, significantly increasing tool life and hole quality. 
  • A PCD countersinking insert. This eliminates the need for expensive custom solution step drills, reducing manufacturing costs while meeting the industry´s accuracy requirements.
  • The two series of solid carbide drills —both diamond-coated and PCD-tipped—covering all material combinations found in a typical aerospace assembly. In addition, the straight shanked tools allow for length adjustments in increments of 10mm.

The new HiPACS drilling and countersinking system can be utilized on all machines typically used for aerospace applications. In less stable conditions such as robot end effectors, the diamond coated carbide drills offer excellent tool life and hole quality. PCD-tipped drills, on the other hand, excel in stable conditions such as gantry machines. 

With an industry standard interface, HiPACS can be utilized on any CNC machine, and is suitable for a variety of drilling and countersinking applications.

Related Glossary Terms

  • chuck

    chuck

    Workholding device that affixes to a mill, lathe or drill-press spindle. It holds a tool or workpiece by one end, allowing it to be rotated. May also be fitted to the machine table to hold a workpiece. Two or more adjustable jaws actually hold the tool or part. May be actuated manually, pneumatically, hydraulically or electrically. See collet.

  • computer numerical control ( CNC)

    computer numerical control ( CNC)

    Microprocessor-based controller dedicated to a machine tool that permits the creation or modification of parts. Programmed numerical control activates the machine’s servos and spindle drives and controls the various machining operations. See DNC, direct numerical control; NC, numerical control.

  • countersinking

    countersinking

    Cutting a beveled edge at the entrance of a hole so a screw head sits flush with the workpiece surface.

  • polycrystalline diamond ( PCD)

    polycrystalline diamond ( PCD)

    Cutting tool material consisting of natural or synthetic diamond crystals bonded together under high pressure at elevated temperatures. PCD is available as a tip brazed to a carbide insert carrier. Used for machining nonferrous alloys and nonmetallic materials at high cutting speeds.

Additional Products from Kennametal Inc.

Designed for extended tool life and smooth drilling at high metal removal rates, Drill Fix PRO has outboard inserts that feature a wiper geometry for smoother surface finishes and larger coolant channels for high-volume flow. Other platform advancements include the versatility of the four-time…

The product expansion includes best-in-class features and advanced technology for metal cutting applications. The launch includes eight products that expand on and support existing platforms in delivering superior performance across multiple applications as well as address common machining…

The Blast Ninja reduces air exit velocity while maintaining particle velocity, resulting in a significant reduction in noise production at the source while maintaining blasting production. This proven technology remains Kennametal-manufactured and is now available directly through authorized…

Using the 140-degree solid carbide point design from Kennametal’s GOdrill, the KenTIP FS GTP insert allows for multiple machining applications across a range of materials including steel, stainless steel and cast iron. KenTIP FS GTP also features excellent centering capabilities, even at moderate…

KYHK15B provides excellent edge stability, high chipping resistance, and a PVD gold coating makes wear progression identification very easy. From smooth and varying depths of cut to heavy depths of cut, KYHK15B can be an economic alternative to PcBN inserts.

All Beyond Evolution insert styles feature the Triple-V Seating: Tight grip on the back (1) and top & bottom (2) provides maximum stability, especially when operating multidirectional turning and profiling.

KCK20B and KCKP10 are suitable for wet or dry cuts. These include rotor hubs used in windmills, pump housings, steering knuckles and gear housings for heavy equipment, and automotive components like crankshafts and cylinder heads. While KCK20B delivers higher productivity in roughing and semi-…

Machining three diameters in one operation, the stator bore tool ensures the alignment and concentricity of the machined surfaces whilst reducing the cycle time significantly. The lightweight 3D printed combination tool enables a faster tool change and spin-up even on less powerful machines. The…

The tangential design of the FIX8 insert features a rigid clamping system that pulls the insert securely into the pocket seat, offering superior stability that enables the insert to withstand large cutting forces and vibrations for optimal performance. The insert is also supported by a replaceable…

Drawing on its deep materials science expertise, Kennametal developed KAR85-AM-K to provide corrosion and wear resistant properties analogous to its conventional counterpart grade, CN13S. Combined with Kennametal’s binder jet additive manufacturing capabilities, KAR85-AM-K results in fully…