On December 5, 2007, Hitachi Tools launched the "Epoch Micro Step Borer," a specialized drill bit designed for micro-hole machining (Fig. 1). This innovative tool is capable of creating holes with an aspect ratio of up to 100:1 (length-to-diameter ratio), making it ideal for precision applications such as fuel nozzles in automotive engines, air vents in molds, and intricate components in electronics.
One of the key design features of the Epoch Micro Step Borer is its short flute length—approximately five times the tool diameter. This design is optimized for step-by-step drilling, allowing for greater control and accuracy during the machining process. Additionally, the tool incorporates a reinforced non-cutting section (neck) to enhance overall rigidity, which is crucial when working with long, slender tools.
However, reducing the flute length can lead to chip accumulation, as chips may flow toward the neck and become welded to it, causing potential damage or tool failure. To address this issue, the product includes a structural feature known as a "chip stopper" located between the flute and the neck (Fig. 2). The chip stopper has a diameter nearly equal to the tool's outer diameter, ensuring that chips are effectively contained and do not interfere with the neck area. This design allows the cutting edge to taper gradually from the tip to the neck, while maintaining full thickness just before the neck, improving both performance and durability.
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