Abstract: A method of through-hole drilling of metal workpieces having sufficient ductility to create hinged drill caps, which comprises: while carrying out through-hole drilling with low thrust drill tips, directing a fluid jet stream against the drill exit side of the workpiece with sufficient force to retain and resulting drill cap closed against the exit side until such drill cap is completely annularly severed from the workpiece, the jet stream being oriented substantially coincident with the revolving axis of the drill. The fluid of the jet stream may be a machining liquid coolant, a gas, or a water-based solution. The jet stream has a diameter upon impingement with the workpiece that is less than the diameter of the exit opening created by the drill.

Abstract: A method of drilling ductile materials with split-point drills includes the steps of placing a split-point drill above a ductile material having an entrance side, drilling a hole in the ductile material with the split-point drill from the entrance side to an exit side thereof, breaking through a surface of the exit side with the split-point drill a first predetermined distance to form a drill cap, retracting the split-point drill a second predetermined distance, and accelerating the split-point drill through the surface of the exit side to remove the drill cap from the ductile material.