Professional Documents
Culture Documents
Training Manual
Drilling Operation and Tools
Drilling
Drilling is a commonly employed hole‐making process that uses a drill as a cutting tool for producing
round holes of various sizes and depths. Drilled holes may be subjected to additional operations for
better surface finish and dimensional accuracy, such as reaming and honing.
Process
Drilling involve relative rotational and axial motion between drill and the work piece .usually the drill
rotates relative to work piece and advance into the work piece but some time opposite is true. Chips
are removed by flowing along the grooves or flutes of the drill
Drill Tooll Partts
Description
AXIS The longitudinal centre line of the drill.
BACK TAPER The slight decrease in diameter from the front to the back in the drill body.
BODY The portion of the drill extending from the cutting lips to the shank.
BODY CLEARANCE The portion of the land that has been cut away to provide diametrical clearance.
CHISEL EDGE The edge formed by the intersection of the cutting lips.
CHISEL EDGE ANGLE The included angle between the chisel edge and the cutting lip when viewed from the
point end of the drill.
CYLINDRICAL LAND (MARGIN) The cylindrical portion of the land that is not cut away to provide clearance.
CYLINDRICAL LAND WIDTH The distance between the leading edge and the heel of the land, measured at a
right angle (Margin Width) to the leading edge.
DIAMETER The measurement across the cylindrical lands (margin) at the outer corners of the drill.
FLANK The surface of the drill point extending behind the lip to follow the flute.
FLUTE LENGTH The axial length from the extreme end of the point to the termination of the flutes at the
shank end of the drill. As this includes the flute runout, flute length does not indicate the usable length of the
drill.
FLUTE RUNOUT The end of the flutes near the shank where they join the drill body.
FLUTES The grooves in the body of a drill which provide the cutting lips, allow swarf and chip
ejection, and permit cutting fluid to reach the cutting lips.
HEEL The edge formed by the intersection of th body clearance and the flute surface.
HELIX ANGLE The angle formed by the leading edge of the land and the plane containing the axis of the drill.
LAND The peripheral portion of the body between adjacent flutes.
LEAD OF HELIX The distance measured parallel to the axis between corresponding points on the leading
edge of the land in one turn of the drill.
LIPS The cutting edges of a two flute drill extending from the chisel edge to the periphery of the drill.
OVERALL LENGTH The total length measured from the extreme point to the end of the shank.
POINT The sharpened end of the drill comprising the cutting lips, chisel edge, lands and the web.
POINT ANGLE The included angle between the cutting lips. (brittle material Æ900…118) and
(1180…1350Æductile and hard material)
RELATIVE LIP HEIGHT The relative position of the lips measured at the outer corners in a direction parallel
to the drill axis.
RECESS The section of reduced diameter between the shank and the body of a drill.
SHANK The part of the drill by which it is held and driven
TANG The flattened end of a taper shank intended to fit into a driving slot in a socket.
WEB (CORE) The central portion of the drill that joins the land. The end of the web forms the chisel edge
Key System Components
Drills are classified by
• Material from which they are made
• Method of manufacturing
• Length
• Shape
• Number and type of helix or flute
• shank
• Point characteristics
• Size series
Selection of drill depends on several factors
• Hardness and composition of the work piece, with hardness being more important
• Rigidity of the tooling
• Hole dimensions
• Type of drilling machine
• Drill application — originating or enlarging holes
• Tolerances
• Cost
Types
Among the common types of drills are
• Combined drill and countersink or center drill
• Short drill used to center shafts before squaring and turning
• The step drill, with two or more diameters
• The spade drill which has a removable tip or bit clamped in a holder on the drill shank, used for
large and deep holes
• The trepanning tool used to cut a core from a piece of metal instead of reducing all the metal
removed to chips
• The gun drill, run at a high speed under a light feed, and used to drill small long holes
• The core drill used to bore out cored holes
• The oil‐hole drill, having holes or tubes in its body through which oil is forced to the cutting lips
• Three‐ and four‐fluted drills, used to enlarge holes after a leader hole has been cored, punched,
or drilled with a Drilling two‐fluted drill
• Twisted drills made from flat high‐speed steel or drop forged to desire shape and then twisted.
Drills are also made of solid carbide or of high‐speed steel with an insert of carbide to form the
chisel edge and both cutting edges. They are used primarily for drilling abrasive or very hard
materials.
Varieties of Classification for Drills
Effects and Consequences of Drill
features
Seleection
n of Drrill
Seleectingg Drilll Speeed
Speed reffers to the revvolutions per minute (RPM M) of the drilliing machine sspindle. For d drilling, the sp
pindle
should rottate at a set sspeed that is selected for tthe material b being drilled. Correct speeeds are essenttial
for satisfaactory drillingg. The speed a
at which a drilll turns and cuts is called tthe peripherall speed.
Peripheraal speed is thee speed of a ddrill at its circcumference eexpressed in ssurface feet p per minute
(SFPM). TThis speed is rrelated to thee distance a d drill would tra
avel if rolled on its side. FFor example, a
a
peripheral speed of 30 feet per minute means the drill would roll 30 feet in 1 minute if rolled on its
side.
It has been determined through experience and experiment that various metals machine best at certain
speeds; this best speed for any given metal is what is known as its cutting speed (CS)
Starting a Hole
The best method to align and start a hole is to use the combination countersink and drill, known as the
center drill. Set the drilling machine speed for the diameter of the tip of the center drill, start the
machine, and gently lower the center drill into contact with the work, using hand and eye coordination.
The revolving center drill will find the center punched mark on the work piece and properly align the
hole for drilling. The depth of the center‐drilled hole should be no deeper than two third the length of
the tapered portion of the center drill.
After the drill has been aligned and the hole started, then insert the proper size drill and continue
drilling into the work piece, while applying cutting fluid. The cutting fluid to use will depend on what
material is being machined. Use the cutting fluids freely as the drill size increases, both the size of the
web and the width of the chisel edge increase.
Large Holes
The chisel edge of drill does not have a sharp cutting action, scraping rather than cutting occurs. In
larger drills, this creates a considerable strain on the machine. To eliminate this strain when drilling a
large hole, a pilot hole is drilled first and then followed with the larger drill. A drill whose diameter is
wider than the web thickness of the large drill is used for the pilot hole. This hole should be drilled
accurately as the larger drill will follow the small hole.
A pilot drill can also be used when average‐sized. Holes are to be drilled on small drilling machines. The
small machine may not have enough power to drive the larger drill through the metal. Avoid making the
pilot drilled hole much wider than the web of the larger drill. Too wide of a pilot drilled hole may cause
the larger drill cutting lips to grab and snag which may cause excessive chatter or an out‐of‐round hole.
Angles
The helix angles of the flutes vary from 10 to 45°. The standard point angle is 118°. There are a number
of drill grinders on the market designed to give the proper angles. The point may be ground either in the
standard or the crankshaft geometry.
Material
The most common tool material for drills is high‐speed steel M1, M7, and M10. High speed steel is most
commonly used it provides strength, toughness and high temperature strength at comparatively low
cost. Carbide tripped drills are used for special applications such as abrasive material of low tensile
strength or heat resistance alloys. Solid carbide drills are used where extreme rigidity, accuracy and long
tool life is required
Machine ability Rating
Soft materials such as aluminum and plastics are rated well to excellent while cast iron and mild steel
have a fair to good machine ability rating. Stainless steel has a poor to fair rating because of its
roughness and its tendency to work harder when machined
Speeds and feeds
The optimal speed and feed for drilling depend on work piece material, tool material, depth of hole,
design of drill, rigidity of setup, tolerance, and cutting fluid.
Recommendations for speeds and feeds in drilling a variety of materials are given in Table
Coolant Use
Deflection Accuracy (Work rotating)
Deflection Accuracy (Tool rotating)
Uneven Work Surfaces
WORK CLAMPING AND SUPPORT
Drilling Problems and Causes
Common Reasons for Drill Failure
(pictorial form)
OVERSIZE HOLE
Lips of unequal length One lip doing all the work Suggest: Re‐grinding the drill
Chisel edge not central Suggest: re‐grinding the drill
Machine spindle out of true Check for damage to chuck or spindle
UNEQUAL CHIPS
Lips of unequal length as in 1a long chip from one side indicate that it is doing
all the work. Suggest: Re‐grinding the drill
Drill point angle is off; low on one side and high on the other consequently the
chisel edge will be off centre
Relative lip height; too great a difference
SPLITTING UP THE WEB
Insufficient lip clearance Suggest re‐grinding drill
Too high a feed rate. Check recommended conditions
Striking drill point with hard object
Ejecting drill onto machine base Both c. & d. cause bruising to the chisel edge,
which will show up under use as a fracture
Surface cracks on the flanks can be caused by overheating when grinding and
then quenching
BROKEN TANG
The tang is for ejection purposes only. Allowing the torque to be taken by the
tang will result in breakage's Always ensure that the taper socket is free from
foreign matter and damage, So that friction alone drives through the taper The
positive helix angle of the drill, will, when opening out an existing hole pull the
Morse taper out of contact, which will result in a broken tang. Pilot holes
should only be 1.5 times the chisel edge length
BREAKING OF DRILLS
Drill worn or improperly point ground
Drill slipping in drive and Work not rigid
Drill flutes choking in swarf and Insufficient lip clearance
Feed rate too high or drill pulling through on breakthrough
DRILLING MACHINE SAFETY
Drilling machines are one of the most dangerous hand operated pieces of equipment in the shop area.
Following safety procedures during drilling operations will help eliminate accidents, loss of time, and
materials. Listed below are safety procedures common to most types of drilling machines found in the
machine shop.
(Make Sure You Have Read Any Kind Of Instructions Placed on Machine or Shop Floor e.g. Safety
Instruction, Notice Board, Any Sort of Signs Board …………These things are for us so pay attention)
Personal Safety in the Workshop
• Wear proper protective clothing and button it up.
• If long sleeves, roll them up or button the cuffs.
• Wear proper safety shoes or boots.
• Put on safety goggles whenever the machine process involves sparks or chips flying out.
• Do not wear rings, wrist watches, gloves or anything that might be caught in the Machine.
• Do not run.
• Do not operate the machine unless all guards and safety devices are in position and working.
During Machinery Operation
• Do not support the work pieces by hand. Use a holding device to prevent the work piece from
being torn from the operator's hand.
• Never make any adjustments while the machine is operating.
• Never clean away chips with your hand. Use a brush.
• Make sure that the cutting tools are running straight before starting the operation.
• Never place tools or equipment on the drilling tables.
• Ease up on the feed as the drill breaks through the work to avoid damaged tools or work pieces.
• Remove all chuck keys and wrenches before operating.
• Remember to stop the machine first before walking away for any reason.
• Do not lean on a machine, especially if it is running.
• Learn how to stop your machine in an emergency
Use of Compressed Air
• Never direct compressed air towards yourself, or anyone else for cleaning.
• Never use compressed air for cleaning away chips and dust. Flying particles can be dangerous.