TABLE OF CONTENTS There is no one answer to what is the best countersink tool. The exceptionally wide variety of tools shown in Chapter 3 provides some insight into why it is so difficult to find the best tool. "Best" may mean "most convenient at hand" for many small shops. Aerospace engineer and machinists' needs entail a much more detailed list of what constitutes "best." Automotive plants will have a shorter list, but cost and long life will clearly be a major issue.
The following 10-step sequence will help any user define what is "best" for an operation. It is simple and practical. It also emphasizes talking with others to garner their insight and ideas.
Define "best" for your operation.
Search existing company data.
Discuss potentially better designs with experts and shop staff.
Explore alternatives to traditional machining approaches.
Experiment with proposed better tools/conditions.
Measure and record results.
Perform statistical design of experiments (DOE) if several conditions need to be explored.
Use formal optimization ("hill climbing") techniques if warranted.
Review results with experts and staff before implementing changes.
Validate performance over time.
"Best" actually has two attributes:
Best tool from machining/cost characteristics and
Best (or at least adequate) quality of part produced.
Table 9-1 provides some common attributes of "best" that users may need to consider. Users may add to the list or severely reduce it. Users multiply the score by the weighting factor to determine an impact number. Few companies will need to consider all the items listed.
