How to Remove a Broken Drill Bit from Metal?

Are you stuck with a broken drill bit in your metal project? Don’t worry; it happens!

Removing a broken drill bit from metal typically involves using a screw extractor or specialized drill bits. Heat or penetrating oil can also help loosen the broken piece. The method depends on the bit’s size, material, and how deeply it’s stuck.

Dealing with a broken drill bit¹ can be frustrating, but knowing the right steps and tools² can save you time and material. Keep reading, and I’ll walk you through the best methods³.

Can a Broken Drill Bit be Drilled Out?

Ever felt like you’re making things worse trying to fix a simple problem? That’s how it feels with a broken drill bit!

Yes, a broken drill bit can be drilled out, but it needs a careful approach. Use a smaller, high-quality drill bit, go slowly, and apply cutting oil to avoid damaging the surrounding metal. This method works best when the broken bit isn’t deeply embedded.

Now, let’s get into the details. Drilling out a broken drill bit is not always straightforward. Here’s what you should consider:

Choosing the Right Drill Bit for the Job

When drilling out a broken drill bit, the type of drill bit you use is very important. You should choose a drill bit that is smaller than the broken one. Using a smaller size can help you create a pilot hole⁴, which guides further drilling without damaging the surrounding metal. Also, you should choose a high-quality drill bit⁵, because these are less likely to break during the process. If you are drilling hard metal, a cobalt drill bit⁶ may be a good choice.

Step-by-Step Method for Drilling

First, center-punch the broken bit. Next, start drilling slowly with the smaller drill bit to make a pilot hole. Use oil to keep things cool and reduce friction. Gradually increase the size of the drill bit, and be very careful not to damage the threads or the surrounding material. If you meet any resistance, stop and reassess. Sometimes, alternating between drilling and using a screw extractor can be helpful.

Risks to Consider

Even if you are careful, there are risks. You could damage the surrounding metal, or you could push the broken bit further into the hole. You should always wear safety glasses to protect your eyes from flying metal shards. If you are not comfortable with this process, it may be best to consult a professional machinist.

What Tool is Used to Remove a Drill Bit?

Do you know which tool can save the day when a drill bit snaps? It’s not always obvious!

A screw extractor is often the go-to tool for removing a broken drill bit. You may also need penetrating oil, heat, a center punch, or specialized drill bits designed for hard materials. The best tool depends on the situation.

Let’s look at how each of these tools can help and what situations they’re best suited for:

How Screw Extractors Work

Screw extractors, sometimes called easy-outs, are designed to grip the inside of a broken screw or bolt. First, you drill a pilot hole into the broken drill bit. Then, you insert the extractor and turn it counterclockwise. The extractor’s threads will bite into the metal. With continued turning, the broken bit should unscrew itself from the hole. It’s important to use the right size extractor for the pilot hole you’ve drilled. If the extractor is too big, it can damage the threads in the hole.

Using Penetrating Oil Effectively

Penetrating oil can be very useful. It works by seeping into the small spaces between the broken bit and the surrounding metal. This can loosen rust and corrosion⁷, making it easier to remove the bit⁸. You should apply the oil and let it sit for a few hours, or even overnight, before trying to remove the bit.

When to Apply Heat

Heat can help to expand the metal around the broken drill bit. This expansion can loosen the bit. You can use a heat gun or a torch to apply heat. Be careful not to overheat the metal, because this can change its properties or even cause it to warp. After heating, let the metal cool down slightly. As it cools, it will contract, which can further loosen the broken bit.

Specialized Drill Bits for Tough Materials

For very hard metals, you might need specialized drill bits. Cobalt drill bits and carbide-tipped drill bits are good choices. These bits are designed to cut through tough materials without breaking. They can be used to carefully drill around the broken bit. This will weaken it enough that it can be removed with pliers or a screw extractor.

Is it Common to Break a Drill Bit?

Ever wonder if you’re the only one breaking drill bits all the time? Let’s find out!

Yes, it is common to break a drill bit, especially when working with hard materials or using the wrong technique. Factors like drilling speed, applied pressure, the material’s hardness, and the drill bit’s quality all contribute to breakage.

Breaking drill bits is a common problem, but you can reduce the chances of it happening. Here’s a more detailed look at why drill bits break and what you can do about it:

Matching the Bit to the Material

The hardness of the material you’re drilling affects the likelihood of breaking a drill bit. Harder materials, like stainless steel or hardened alloys, need more force and can cause the bit to overheat. Overheating can weaken the bit and cause it to snap. Using the correct type of drill bit for the material is key. For example, cobalt or titanium-coated bits are better for hard metals.

Finding the Right Drilling Speed and Pressure

Drilling speed and pressure can also lead to broken bits. Drilling too fast can create too much heat, and applying too much pressure can cause the bit to bind and break. The ideal speed and pressure depend on the material and the size of the drill bit. Softer materials like wood need higher speeds and less pressure, while harder materials need lower speeds and more pressure.

The Importance of Drill Bit Quality

The quality of the drill bit is very important. Cheaper drill bits are made from lower-quality materials, so they are more likely to break. Investing in high-quality drill bits⁹ from brands like tenyu can save you money in the long run. Better drill bits stay sharp longer, and they can withstand higher temperatures and pressures.

Perfecting Your Drilling Technique

Technique is very important in preventing drill bit breakage. Always start with a pilot hole to guide the drill bit. Keep the drill straight and apply steady pressure. Clear away chips often to prevent the bit from binding. Using cutting oil or lubricant can reduce friction and heat. This helps the bit to cut more smoothly and last longer.

How Often Should I Replace Drill Bits?

Are you using dull drill bits and making your work harder? Time for a change?

Replace drill bits when they become dull, chipped, or show signs of wear. Regularly inspect your bits and replace them as needed to maintain efficiency, precision, and prevent breakage. How often depends on usage and material.

To know when to replace your drill bits, here’s what to look for and how to extend their life:

Recognizing Signs of Wear and Tear

One clear sign is dullness. If the bit is not cutting as cleanly or quickly as it used to, it’s likely dull. You might notice that it takes more pressure to drill a hole, or that the bit is producing more heat and friction. Also, check for visible damage, like chips or cracks on the cutting edges. Any of these issues can affect the bit’s performance, and it can also increase the risk of breakage.

Considering Usage Frequency

If you use your drill bits often, they will wear out faster. Heavy use can cause the cutting edges to dull more quickly. If you use your bits daily, inspect them more often. People who only use their bits occasionally might not need to replace them as often.

The Impact of Material Type on Bit Life

The type of material you’re drilling also affects how often you need to replace your bits. Drilling hard materials, like steel or tile, will wear down bits more quickly than drilling soft materials, like wood or plastic. When working with harder materials, you should check your bits more often.

Best Practices for Maintenance

Proper maintenance can extend the life of your drill bits. Always clean your bits after each use to remove debris and prevent rust¹⁰. Store them in a dry place to avoid corrosion. Using cutting oil¹¹ or lubricant when drilling can reduce friction and heat. This will help to keep the bits sharper for longer. If you notice a bit is getting dull, you can sharpen it with a drill bit sharpener to restore the cutting edge and extend its life.

Conclusion

Dealing with a broken drill bit in metal doesn’t have to be a project-killer. With the right tools and techniques, like using screw extractors or penetrating oil, you can get that broken bit out and get back to work. Remember to maintain your drill bits, use the right speeds, and choose quality bits from tenyu for the best results.