LECTURE-03

DRILLING & RELATED OPERATIONS

NIKHIL R. DHAR, Ph. D.

DEPARTMENT OF INDUSTRIAL & PRODUCTION
ENGINEERING
BUET BANGLADESH
Introduction

Drilling is most common single

machining operation
Drilling makes up 25% of machining
Drilling occurs at the end of a tool
within the material, four actions take
place a the drill tip
 A small hole is formed by the web—
chips are not cut here in the normal
sense.
 Chips are formed by the rotating lips.
 Chips are removed from the hole by the
screw action of the helical flutes.
 The drill is guided by lands or margins
that rub against the walls of the hole

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Definition
Drill can be defined as a
rotary end cutting tool
having one or more
cutting lips, and having
one or more helical or
straight flutes for the
passage of chips and the
admission of a cutting
fluid.

Nomenclature and geometry of conventional twist drill

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Nomenclature and Geometry of a Twist Drill
Three main components are the:
 Shank
 Body
 Point

 Shank - This is the portion which is

“clamped” to provide the drive. Straight
shank for drill up to ½”. Shank is equal to
body diameter. Above ½”, shank can be
tapered or reduced.
 Body
 Flutes - Helical grooves cut around the
body which form the cutting edges
Allow coolant to flow to the cutting
edge
Allow chips to be withdrawn
 Margin- Narrow raised section of the
body. Provides full body to hole support
to help keep it aligned as it drills.
 Body clearance - Reduced section of the
drill between the flutes and margin.
Used to reduce friction between drill and
workpiece
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  Web- Thin section in the center of
the drill which forms a “core” for
the drill. This feature increases as
it extends to the shank. Forms the
chisel edge of the drill.
Point - Chisel edge of the drill.
 The spiral, or rate of twist in the
drill, controls the rate of chip
removal in a drill. A fast spiral drill
is used in high feed rate
applications under low spindle
speeds, where removal of a large
volume of swarf is required. Low
spiral drills are used in cutting
applications where high cutting
speeds are traditionally used, and
where the material has a tendency
to gall on the drill or otherwise clog
the hole, such as aluminum or
copper.
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  The point angle is determined by
the material the drill will be operating
in. Harder materials require a larger
point angle, and softer materials
require a sharper angle. The correct
point angle for the hardness of the
material controls wandering, chatter,
hole shape, wear rate, and other
characteristics.
 The lip angle determines the
amount of support provided to the
cutting edge. A greater lip angle will
cause the drill to cut more
aggressively under the same amount
of point pressure as a drill with a
smaller lip angle. Both conditions can
cause binding, wear, and eventual
catastrophic failure of the tool. The
proper amount of lip clearance is
determined by the point angle.

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Classifications
Classification Based on Construction
 Solid Drills: Those made of one piece of material such as high speed steel
 Tipped Solid Drills: Those having a body of one material with cutting lips made of
another material brazed or otherwise bonded in place
 Composite Drills: Those having cutting portions mechanically held in place
Classification Based on Methods of Holding or Driving
 Straight Shank Drills: Those having cylindrical shanks which may be the same or
different diameter than the body of the drill; the shanks may be made with or
without driving flats, tang, grooves or threads
 Taper Shank Drills: Those having conical shanks suitable for direct fitting into
tapered holes in machine spindles, driving sleeves or sockets; tapered shanks
generally have a driving tang
 Taper Shank Square Drills: Those having tapered shanks with four flat sides for
fitting a rachet or brace
 Shell Core Drills: Core drills mountable on arbors specifically designed for the
purpose; commonly used with shell reamer arbors

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  Threaded Shank Drills: Those made with threaded shanks generally used in close
center multiple spindle applications or portable angle drilling tools
 Beaded Shank Bits: Drills with flat shanks having raised beads parallel to the axis
Classification Based on Number of Flutes
 Two-Flute Drills: The conventional type of twist drill used for originating holes
 Single-Flute Drills: Those having only one flute commonly used for originating
holes
 Three-Flute Drills (Core Drills): Drills commonly used for enlarging and finishing,
drilled, cast, or punched holes; they will not produce original holes
 Four-Flute Drills (Core Drills): Used interchangeably with three-flute drills; they
are of similar construction except for the number of flutes
Classification Based on Hand of Cut
 Right-Hand Cut: When viewed from the cutting point the counterclockwise
rotation of a drill in order to cut; the great majority of drills are made right hand
 Left-Hand Cut: When viewed from the cutting point the clockwise rotation of a
drill in order to cut

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Cutting Tools for Drilling Operations
Twist Drill: The twist drill is the most common type of drill. It has two
cutting edges and two helical flutes that continue over the length of the
drill body. The drill also consists of a neck and a shank that can be either
straight or tapered. A tapered shank id fitted by the wedge action into the
tapered socket of the spindle and has a tang that goes into a slot in the
spindle socket, thus acting as a solid means for transmitting rotation.
Straight shank drills are held in a drill chuck that is, in turn, fitted into the
spindle socket in the same way as tapered shank drills.
Twist drill

 Core Drill: A core drill consists of the chamfer, body, neck and
shank. This type of drill may have three or four flutes and an
equal number of margins, which ensures superior guidance,
thus resulting in high machining accuracy.

 Spade Drill: A spade drill is used for drilling

large holes of 90 mm or more. The design of
Core drilling: to
this type of drill results in a marked saving in increase diameter of
tool cost as well as in tangible reduction in tool existing holes
weight that facilitates its ease of handling.
Moreover, this drill is easy to grind.
Spade drill: for large,
deep holes
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Cutting Tools for Drilling Operations
Step Drill: A multiple diameter drill with one
set of drill lands which are ground to different
diameters
Step drill: for stepped holes

 Gun Drill: A gun drill is used for drilling deep

hole. All gun drills are straight-fluted, and
each has a single cutting edge. A hole in the
body acts as a conduit to transmit coolant
under considerable pressure to the tip of the
Gun drill with holes for coolant
drill.

 Center Drill: Center drill bits are used in metalworking to

provide a starting hole for a larger-sized drill bit or to make
a conical indentation in the end of a workpiece in which to
mount a lathe center. In either use, as the drill is either
establishing the center of a hole or making a conical hole
for a lathe center. However, the true purpose of a center
drill is the latter task, while the former task is best done
with a spotting drill.

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Operations Related to Drilling

Reaming: Reaming is used to slightly enlarge a hole, to

provide a better tolerance on its diameter and to improve its
surface finish. The tool is called a reamer and it usually has
straight flutes.

 Tapping: This operation is performed

by an tap and is used to provide
internal screw threads on an existing
hole.

 Counterboring: Counterboring provides a stepped hole, in

which a larger diameter follows a smaller diameter partially
into the hole. A counterboring hole is used to seat bolt heads
into a hole so the heads do not protrude above the surface.

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Operations Related to Drilling

Countersinking: This is similar to Counterboring, except

that the step in the hole is cone-shaped for flat head screws
and bolts.

 Centering: Also called center drilling,

this operation drills a starting hole to
accurately establish its location for
subsequent drilling. This tool is called a
centerdrill.

 Spotfacing: Spotfacing is similar to milling. It is used to

provide a flat machined surface on the workpart in a localized
area.

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Drills and Drilling Operations

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Drill Press
A drill press is preferable to a hand drill
when the location and orientation of the
hole must be controlled accurately. A
drill press is composed of a base that
supports a column, the column in turn
supports a table. Work can be supported
on the table with a vise or hold down
clamps, or the table can be swiveled out
of the way to allow tall work to be
supported directly on the base. Height of
the table can be adjusted with a table lift
crank than locked in place with a table
lock. The column also supports a head
containing a motor. The motor turns the
spindle at a speed controlled by a
variable speed control dial. The spindle
holds a drill chuck to hold the cutting
tools (drill bits, center drills, deburring
tools, etc.).
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Specialized Drill Presses
Gang-drilling machines: independent columns, each with different drilling
operation, work piece slid from one column to next
Turret-type, upright drilling machines: used when numerous drilling operation
are required in rapid succession, turret rotates needed tool into position for each
operation

Gang-drilling machines Turret-type, upright drilling machines

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Specialized Drill Presses
Radial drilling machines: used on large workpieces, spindle mounts on radial arm,
allowing drilling operations anywhere along the arm length
Multiple-spindle drilling machines: Single powerhead operates multiple spindles
enabling multiple holes at one time, each hole can be unique

Radial drilling machines Multiple-spindle drilling machines

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Summary

Drilling is the most common machining operation

Drilling can be performed on a number of machine tools,
drill presses are specialized machine tools for drilling
only
Drills come in a wide variety of types and tip geometries
depending upon production rate and accuracy needed
Hole geometries can be adjusted through the use of
counterboring, countersinking and reaming

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 Questions

?
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