Mold cooling systems contain straight water channels, long cooling passages, angled holes, intersecting channels, cross holes, inlet and outlet ports, plug-hole preparation, threaded-port preparation, deep blind holes, and small distribution passages.
These features are commonly machined in mold bases, mold plates, core inserts, cavity inserts, support blocks, tooling plates, and other temperature-control components. Materials may include pre-hardened mold steel, tool steel, stainless mold steel, hardened insert materials, aluminum tooling plate, and copper alloys.
High depth-to-diameter ratios, long chip-travel distances, passage intersections, limited access, and strict channel-position requirements increase the risk of chip packing, drill deviation, cutting-edge wear, internal burrs, inaccurate passage connections, and drill breakage.
Landun CNC Tool supports drill selection and custom carbide drill development based on the mold drawing, workpiece material, hardness, channel diameter and length, drilling direction, passage intersection, coolant pressure, machine rigidity, and current machining problem.
Long cooling channels and deep water passages may experience chip congestion, rising cutting load, poor hole-wall quality, drill deviation, or sudden drill breakage.
As drilling depth increases, chips must travel a longer distance through the flute. Insufficient coolant pressure, unsuitable flute geometry, excessive feed, high runout, or chips collecting near a blind-hole bottom can interrupt normal chip evacuation.
Through-tool coolant, suitable flute geometry, stable coolant pressure, controlled drilling parameters, and rigid toolholding help move chips away from the drill point. Drill length and coolant configuration should be selected according to channel diameter, drilling depth, material, and machine conditions.
Cooling passages must maintain sufficient straightness and positional accuracy to connect with designed cross holes, inlet ports, outlet ports, or other channels inside the mold component.
High depth-to-diameter ratios, inaccurate initial positioning, excessive spindle runout, unstable workholding, machine-axis error, uneven material, and chip congestion can gradually push the drill away from the intended path.
Accurate hole positioning, low-runout toolholding, rigid fixturing, stable machine alignment, suitable drill geometry, and controlled deep-hole procedures help reduce deviation. The drilling sequence should also be planned according to the channel layout and intersection tolerance.
Long deep-hole drills may enter unstably, follow an inaccurate pilot hole, or begin drilling at an incorrect angle, resulting in excessive vibration, poor straightness, or cutting-edge damage.
An oversized, undersized, shallow, misaligned, or poorly finished pilot hole may not guide the deep-hole drill correctly. Excessive runout, incorrect drill engagement, and unsuitable entry parameters can further increase instability.
A short, rigid pilot drill should create an accurate entry hole with suitable diameter, depth, position, and bottom condition. Longer drilling depths require controlled engagement, stable coolant supply, low runout, and careful entry and withdrawal procedures.
Cross-drilled cooling holes and intersecting water passages may develop internal burrs, loose chips, incomplete passage connections, or unstable breakthrough surfaces.
When the drill enters an existing passage, cutting support decreases suddenly and the cutting forces become unbalanced. Excessive feed, unsuitable point geometry, incorrect drilling sequence, or insufficient coolant flow can increase internal burr formation.
Controlled breakthrough parameters, suitable drill-point geometry, stable entry direction, and through-tool coolant help reduce burr size and move chips away from the intersection. Custom drills may be developed according to the passage angle, wall thickness, and intersection diameter.
Long-hole drilling in pre-hardened mold steel, tool steel, stainless mold steel, and hardened inserts may cause rapid flank wear, coating failure, cutting-edge chipping, rising spindle load, or inconsistent channel diameter.
High material hardness, alloy content, long cutting contact, heat accumulation, unstable chip evacuation, and insufficient coolant delivery can accelerate cutting-edge wear.
Suitable carbide grades, wear-resistant coatings, controlled edge preparation, stable point geometry, and through-tool coolant help improve heat control and tool-life consistency. Drill geometry and coating should be selected according to the material hardness, channel depth, coolant condition, and required productivity.
Common drilling applications include long straight water channels, parallel cooling holes, inlet and outlet passages, plug-hole preparation, and repeated deep holes in mold bases, support plates, and tooling plates.
Typical features include cross holes, intersecting water passages, distribution channels, angled connections, plug holes, and channels connecting several mold sections.
Common applications include deep blind water holes, small-diameter cooling passages, angled insert channels, localized cooling features, and channels located close to molding surfaces.
Typical applications include cooling-system inlet holes, outlet holes, threaded-port preparation, sealing-related holes, plug holes, stepped connections, and drilling-plus-chamfering features.
For pilot holes, inlet and outlet holes, plug-hole preparation, threaded-hole preparation, short cooling passages, and general drilling in mold bases, plates, and inserts.
For small cooling passages, vent holes, narrow distribution channels, compact insert features, and other small-diameter precision holes.
For long cooling channels, deep water passages, angled cooling holes, and high depth-to-diameter drilling in thick mold bases, mold plates, and inserts.
For special channel diameters, angled entry, cross-hole intersections, flat-bottom passages, stepped ports, combined drilling and chamfering, and drawing-based non-standard cooling structures.
| INFORMATION | WHY IT MATTERS |
|---|---|
| Mold or component drawing | Confirms channel positions, drilling directions, intersections, ports, wall thickness, tolerances, and special requirements. |
| Workpiece material and hardness | Helps determine carbide grade, drill geometry, edge preparation, coating, coolant demand, and cutting parameters. |
| Channel diameter and drilling depth | Defines drill size, working length, depth-to-diameter ratio, flute capacity, and suitable drill series. |
| Pilot-hole diameter and depth | Helps determine whether the deep-hole drill can enter stably and follow the intended drilling direction. |
| Drilling angle and entry surface | Helps evaluate entry stability, drill walking, spotting requirements, tool access, and custom-geometry needs. |
| Passage intersections and remaining wall thickness | Helps assess channel alignment, breakthrough conditions, internal burr risk, and structural safety. |
| Coolant method, pressure, and filtration | Helps evaluate heat removal, chip evacuation, coolant-hole configuration, and deep-hole drilling stability. |
| Machine, holder, fixture, and runout conditions | Helps assess machine rigidity, spindle accuracy, tool overhang, workholding stability, and achievable straightness. |
| Current machining problem | Clarifies chip packing, drill deviation, breakage, burrs, channel misalignment, tool wear, or cycle-time targets. |
Review the component drawing, workpiece material, hole structure, machine conditions, and current drilling problem.
Select a suitable standard drill series or develop a custom drill based on hole depth, tolerance, entry conditions, and machining requirements.
Produce the drill with controlled geometry, edge preparation, coating selection, and multi-stage inspection to support consistent quality.
Support sample testing, specification confirmation, and stable repeat production after the drill solution is approved.
Walter 5-axis grinding supports stable drill-point geometry, flute consistency, diameter accuracy, and shank concentricity.
Controlled edge preparation helps improve cutting-edge consistency, coating adhesion, wear resistance, and tool-life stability.
Coating selection is matched to the workpiece material and drilling conditions to improve wear resistance, heat control, and cutting stability.
HELICHECK PLUS and 150× / 300× visual inspection help verify dimensions, cutting edges, coating appearance, and overall tool condition.
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