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Description
Diameter24 mm
Drilling depth120 mm (5×D)
Inserts2 × WCMT 040208
Overall length195 mm
Ø24 indexable drill – 5×D insert drill
Varel 5×D: drilling depth 120 mm, shank 25 mm, WCMT 040208 inserts
| Technical data | |
|---|---|
| Drilling diameter | 24 mm |
| Drilling depth l1 | 120 mm (5×D) |
| Length to flange l2 | 140 mm |
| Shank length l3 | 56 mm |
| Overall length L | 195 mm |
| Shank diameter d1 | 25 mm, Weldon flat |
| Flange diameter d2 | 34 mm |
| Inserts | 2 × WCMT 040208 |
| Insert screw | M2.5x6.5, Torx T8 |
| Coolant supply | internal, 2 channels |
Ø24 indexable drill Varel drills tap holes for M27 threads: diameter 24 mm, depth up to 120 mm, or five diameters. This is the tap drill size for M27 threads in the drill size table in PN-86/M-59601. Instead of a steel cutting edge, it has two replaceable WCMT 040208 cemented carbide inserts. A dull edge is replaced by indexing the insert, while the body remains in service. The drill operates on machining centers and CNC lathes.
Coolant flows through two channels inside the drill directly beneath the inserts. It flushes chips out of the hole and cools the cutting edges. The 25 mm shank has a Weldon flat for the holder screw, preventing the drill from rotating in the holder. This type of indexable drill is also called an insert drill or U-drill.
Drilling depth of 120 mm and hole bottom shape
How deep the drill can drill and what remains at the bottom
The flutes end 120 mm from the drill face. Up to this depth, chips have a path out of the hole. The drilling depth is therefore 5×D, or 5 × 24 mm = 120 mm. At this depth, only through-tool coolant can flush chips from the bottom. For holes up to 72 mm deep, use the shorter Ø24 3D indexable drill.
The hole bottom does not have the cone left by a 118° twist drill. It is nearly flat, with slight undulations left by the two inserts. Only a low cone remains at the center.
When drilling to 5×D, the hole diameter depends on machine rigidity and holder runout. Holes requiring a specified fit are reamed or bored after drilling.
How the two WCMT 040208 inserts work
Center insert, peripheral insert and self-centering
Both inserts sit on the drill face: the center insert near the axis and the peripheral insert at the edge of the body. The flutes guide chips from the inserts toward the shank.
The same WCMT 040208 insert is used in both pockets. The center insert cuts from the hole axis, while the peripheral insert cuts the 24 mm diameter. Their cutting edges overlap, so no uncut ring remains at the bottom.
Cutting speed increases from zero at the axis to its maximum at the periphery. Near the axis, the insert pushes material aside more than it cuts it. As a result, the center insert is more prone to chipping, while the peripheral insert wears due to heat. Check both inserts whenever indexing the cutting edges.
The two inserts guide the drill along its axis, so spot drilling is not required. Drilling starts directly in solid material. A pilot hole in the workpiece must not exceed 6 mm, or 1/4 of the drill diameter. A larger hole pulls the drill off-axis.
The insert designation is interpreted according to ISO 1832. W denotes a 80° trigon with three cutting edges. C indicates a 7° clearance angle, M the tolerance class, and T a screw hole and chip breaker. 04 indicates the insert size (inscribed circle 6.35 mm), 02 the thickness of 2.38 mm, and 08 the corner radius of 0.8 mm. Our store offers the Horn WCMT 040208 insert for indexable drills.
After loosening the screw, rotate the insert in its pocket by 120° to bring the next cutting edge into use. Each WCMT 040208 insert has three edges, so a set of two inserts provides three indexing positions.
Changing the insert cutting edge
1Loosening the screw
Key: Torx T8
2Indexing the insert
Rotation: 120°
3Cleaning the insert seat
Chips: to be removed
4Tightening the screw
Screw: M2.5x6.5
Included: body, Torx T8 key and two M2.5x6.5 screws.
Drilling on a machining center and CNC lathe
Coolant, axis alignment and difficult material entry
Machining center – through-spindle coolant from 6 bar
Coolant is supplied through the spindle and drill at a pressure of at least 6 bar. At a depth of 120 mm, this is essential because chips must travel the full length of the flutes. Mount the drill in a rigid holder with minimal runout relative to the spindle.
▲
External coolant: 36 mm in a single pass, deeper holes with retraction
With externally supplied coolant, the drill can drill up to 1.5 × 24 mm = 36 mm in a single pass. For deeper holes, retract the drill every few millimeters to flush out chips.
CNC lathe – coaxial alignment within 0.03 mm
On a lathe, the drill remains stationary in the turret while the workpiece rotates. The drill axis must align with the spindle axis within 0.03 mm.
Setup on a lathe
1Test bar
Bar: Drill Ø and length
2Runout measurement
Indicator: on the chuck, 360° rotation
3Axis adjustment
Deviation: below 0.03 mm
4Insert positioning
Peripheral insert: parallel to the X axis
Peripheral insert on the outer side of the turret; check axis alignment again after a lathe collision.
▲
A disc is ejected at breakthrough
When drilling through, a disc of material is ejected from the bottom of the workpiece at high speed. Keep the lathe guard closed throughout drilling.
Difficult entry – inclined, concave and uneven surfaces
It is best to drill into a surface perpendicular to the drill axis. On other surfaces, the inserts are loaded unevenly and the drill moves off-axis. In this case, reduce the feed to 1/3 of the recommended value.
Convex surface
The drill center contacts the material first. Normal feed.
Inclination over 2°
One insert enters earlier and wears faster. Feed 1/3.
Concave surface
The drill moves off-center. Feed 1/3.
On uneven surfaces, reduce the feed at entry and breakthrough to protect the insert from chipping. Drill intersecting holes at approximately 1/3 of the recommended feed.
Drilling symptoms and adjustments
| Symptom | Cause | What to adjust |
|---|---|---|
| Chipped center insert edge | Cutting speed drops to zero at the axis and the insert pushes material aside | Lower feed at entry and breakthrough, tougher insert grade |
| Rapid peripheral insert wear | Cutting speed and temperature are highest at the periphery | Cutting speed at the lower end of the range, through-tool coolant |
| Drill moves off-axis | Inclined or concave surface, pilot hole larger than 6 mm | Feed at 1/3 of the recommended value on entry, pilot hole up to 6 mm |
| Chips accumulate in the flutes | External coolant at depths greater than 36 mm or pressure below 6 bar | Through-tool coolant from 6 bar; use peck drilling with external coolant |
| Hole larger than intended | Holder runout, axis misalignment over 0.03 mm on a lathe | Rigid holder, adjust turret axis alignment using an indicator |
Cutting data for steel, stainless steel and cast iron
Cutting speed, spindle speed and feed – starting values
The table lists the lower cutting speed limit from the Varel catalog. Feed per revolution for the WCMT 040208 insert ranges from 0.05 to 0.12 mm. The starting value is 0.06 mm; then gradually increase the feed while monitoring the chips.
| Workpiece material | Cutting speed vc [m/min] | Spindle speed [rpm] | Feed f [mm/rev] | Feed rate [mm/min] |
|---|---|---|---|---|
| P Low-carbon steel (up to 0.3% C) | 160 | 2120 | 0.06 | 127 |
| P Carbon steel (from 0.3% C) | 150 | 1980 | 0.06 | 118 |
| P Alloy steel up to 300 HB | 120 | 1590 | 0.06 | 95 |
| P Alloy steel above 300 HB | 100 | 1320 | 0.06 | 79 |
| M Stainless steel | 80 | 1060 | 0.06 | 63 |
| K Gray cast iron | 130 | 1720 | 0.06 | 103 |
| K Ductile cast iron | 100 | 1320 | 0.06 | 79 |
Spindle speed and feed calculation – alloy steel up to 300 HB
Spindle speed = 1000 × cutting speed 120 m/min ÷ (3.14 × diameter 24 mm) ≈ 1592 rpm – set the machine to 1590. Feed rate = 1590 rpm × feed 0.06 mm/rev ≈ 95 mm/min. A hole 120 mm deep takes approximately 1.3 minutes (120 ÷ 95). When entering an inclined surface, reduce the feed to approximately 0.02 mm/rev.
Ø24 indexable drill Varel drills holes with a diameter of 24 mm and a depth of up to 120 mm without spot drilling. It uses two WCMT 040208 inserts, each with three cutting edges. Coolant flows through the drill directly beneath the inserts and flushes out chips. At a depth of 5×D, through-tool coolant is supplied at a pressure of at least 6 bar, and the hole bottom is nearly flat. The body with a 25 mm shank operates on machining centers and CNC lathes.
Questions about inserts, spot drilling and the hole bottom
Included items, centering, lathe use, bottom shape and coolant
Two WCMT 040208 inserts – the same insert in the center and peripheral pockets. Our store offers the Horn WCMT 040208 insert for indexable drills. The body comes with a Torx T8 key and two M2.5x6.5 screws.
The drill centers itself using two inserts, so drilling starts directly in solid material. A pilot hole in the workpiece must not exceed 6 mm. A larger hole pulls the drill off-axis.
Yes, the drill remains stationary in the turret while the workpiece rotates. The drill axis must align with the spindle axis within 0.03 mm. A disc of material is ejected at breakthrough, so keep the lathe guard closed.
The bottom is nearly flat, without the 118° cone left by a twist drill. The two inserts leave slight undulations. A low cone remains at the center.
At least 6 bar, supplied through the spindle and the drill's two channels. With external coolant, the drill can drill up to 36 mm in a single pass. For deeper holes, retract the drill every few millimeters.
Product accessories
Carbide insert WCMX 040208 H6310 Horn
Reference: 0000009390 In stock > 10 items
€3.16
€3.88 brutto
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| Courier GLS | Cash on delivery | 17,26 zł gross | Lead time 1 working day |
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