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Anil Dahiya
Q.1. (i) What is the difference between machine and machine tool? (ii) Write difference between shaper, planer & slotter. (iii)What is the difference between single purpose and special purpose machines? (iv) What is difference between generating and forming? (v) What are major differences between CNC lathe and conventional lathe? Q.2. (a) Explain the different cutting tool materials? Write applications of each. (b) With neat sketch explain single point cutting tool geometry. Q.3. (a )What do you mean by taper turning? Explain the different taper turning methods used on lathe? Anil Dahiya 3/22/2012 3:30 AM (b) Explain the major work holding devices used on lathe.
Drilling
Drilling machines are generally or mainly used to
originate through or blind straight cylindrical holes in solid rigid bodies and/or enlarge (coaxially) existing (premachined) holes.
Holes of different diameter ranging from about 1 mm
to 40 mm
Holes of varying length depending upon the
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Machining Video
Machining Video
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single spindle drilling machines are mounted (bolted) on rigid table and manually operated using usually small size ( 10 mm) drills.
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Drilling Head
Mechanism used to revolve cutting tool Spindle: round shaft holds cutting tool Quill: houses spindle
Sensitive Drill
drills, are quite similar to the table top drilling machines but of little larger size and higher capacity (0.55 ~ 1.1 kW) and are grouted on the floor (foundation).
Here also, the drill-feed and the work table
tubular columns and are generally used for Anil Dahiya jobs and light drilling. 3/22/2012 3:30 AM small
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are much more strong, rigid and powerful than the pillar drills. In column drills the feed gear box enables automatic and power feed of the rotating drill at different feed rates as desired. Blanks of various size and shape are rigidly clamped on the bed or table or in the vice fitted on that. Such drilling machines are most widely used and Anil Dahiya over wide range ( light to heavy) work. 3/22/2012 3:30 AM
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radial arm which along with the drilling head can swing and move vertically up and down.
The radial, vertical and swing movement of the
drilling head enables locating the drill spindle at any point within a very large space required by large and odd shaped jobs.
There are some more versatile radial drilling
machines where the drill spindle can be Anil Dahiya 3/22/2012 3:30 AM additionally swivelled and / or tilted.
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Radial Drill
Sometimes called radial-arm drill
Advantages of this machine
Larger and heavier work may be machined Drilling head raised or lowered Drilling head moves rapidly to any desired location
while work piece remains clamped More power Head may swivel so holes can be drilled on angle
Radial Drill
Radial Drill
Radial Drill
Radial Drill
Radial Drill
Radial Drill
high speed electric motor. In fire hazardous areas the drill is often rotated by compressed air.
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Hand drills
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machine a number (2 to 6) of spindles with drills (of same or different size) in a row are made to produce number of holes progressively or simultaneously through the jig.
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column type but are more productive like gang drill by having a pentagon or hexagon turret.
The turret bearing a number of drills and similar
tools is indexed and moved up and down to perform quickly the desired series of operations progressively.
These drilling machines are available with
varying degree of automation both fixed and flexible type. Anil Dahiya 3/22/2012 3:30 AM
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number of drills work simultaneously on a blank through a jig specially made for the particular job.
The entire drilling head works repeatedly using
main spindle and the central gear through a number of planetary gears in mesh with the Anil Dahiya 3/22/2012 central gear and the corresponding flexible 3:30 AM
drills are adjusted depending upon the locations of the holes to be made on the job.
Each shaft possesses a telescopic part and two
universal joints at its ends to allow its change in length and orientation respectively for adjustment of location of the drills of varying size and length.
In some heavy duty multispindle drilling machines,
the work-table is raised to give feed motion instead of moving the heavy drilling head.
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height within around 200 mm is placed or clamped on a table, and operated manually for drilling small holes of around 1 to 3 mm diameter in small work pieces.
rifle barrels, long spindles, oil holes in shafts, bearings, connecting rods etc, are very difficult to make for slenderness of the drills and difficulties in cutting fluid application and chip removal. It needs machines like deep hole drilling machine such as gun drilling machines with horizontal axis which are provided with high spindle speed high rigidity tool guide pressurised cutting oil for effective cooling, chip removal and lubrication at the drill tip. Deep hole drilling machines are available with both
the other parts Drilling head: this box type structure accommodates the power drive and the speed and feed gear boxes.
Spindle: holds the drill and transmits rotation and
axial translation to the tool for providing cutting motion and feed motion both to the drill.
Drilling machines are available in varying size and
configuration such as pillar drill, column drill, radial drill, micro-drill etc. but in working principle all are Anil Dahiya 3/22/2012 3:30 AM more or less the same.
Twist Drill
Classification of drill
According to type of shank they carry
Parallel shank Tapper shank According to type of flutes
flat drill twist drill According to length short series: 0.2mm-16mm stub series: 0.5mm-40mm long series: 1.5mm-26mm
According to application:
Core drill: carry 3 parallel flutes ,used for
enlarging drilled holes Drill for long hole drilling: heavy duty drill and larger helix angle Centre drill: Masonry drill :4mm-20mm, cutting anle:115used for drilling centre holes According to the tool material: High speed steel drill Carbide tipped drill
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does the cutting. It consists of the following: (A) dead centre: It is the sharp edge at the extreme tip of the drill. This should always be the exact centre of the drill. (B) Lips: these are the cutting edges of the drill. (C) Heel : It is the portion of the point back from the cutting edge. 2: Shank : It is the portion of the drill by which it is clamped in the spindle. The shank may be either straight or tapered. Straight shank drills are used with a chuck. Tapered shank drills have self-holding tapes that fit directly into the drill press spindle. On the taper shank is the another term is used which
3: Body : It is the portion between the point and the shank. The
body consists of the following parts: (A) Flutes : Two or more spiral grooves that run the length of the drill body are called flutes. The flutes do four thing. Help from the cutting edge of the drill point. Curl the chip tightly for easier removal. From channels through which chips can escape from the hole being drilled. Allow the coolant and lubricant to get down to the cutting edge. (B) Margin It is the narrow strip extending back the entire length of the flute. It is the full diameter of the drill. (C) Body Clearance: It is the part of the drill body that has been reduced in order to cut down friction between the drill and the wallAM Anil Dahiya 3/22/2012 3:30 of the hole
Angles of a drill:
Rake or helix angle: angle between a plane containing
the drill axis and leading edge of the land. It can have +ve, -ve or zero right hand flute have +ve, left hand flute have ve, parallel have zero. Angle varies 0-48 (16-32 is generally used). Higher angle for softer materials and lower for harder . Point angle (cutting angle) : angle between two opposite lips of the drill ( 80-140) ,118 for large variety of materials, smaller angle for brittle materials, larger for harder materials Lip clearance angle: angle between flank and plane normal to drill axis (8-15) ,12 is most common Chisel edge angle: angle formed between the cutting lip and chisel edge (120-135) greater this angle larger will be clearance.
Drill Materials
The two most common types are 1. HSS drill - Low cost 2. Carbide- tipped drills - high production and in CNC machines Other types are Solid Carbide drill, TiN coated drills, carbide coated masonry drills, parabolic drills, split point drill
Types of drills Twist drill: most common drill Step drill: produces holes of two or more different diameters Core drill: used to make an existing hole bigger
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Centre Hole
Drilling
Drilling
Deep Holes
Drilling
Drilling operations
Operations that can be performed in a drilling
machine are
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Standard Operations
Reaming
Boring
Truing and enlarging hole by means of single-point cutting tool
Standard Operations
Spot-Facing
Smoothing and squaring surface around hole to
provide seat for head of cap screw or nut Boring bar fitted with double-edged cutting too
Standard Operations
Tapping Cutting internal threads in hole with cutting tool called tap
Counterboring
Enlarging top of previously drilled hole to given depth to provide square shoulder for head of bolt or capscrew
Types of cutters
Combined Countersinks and central drill :Special drilling tool to start the hole accurately. At the end it makes countersinks in the work piece. Gun drill :Machining of lengthy holes with less feed rates.
To overcome the heating and short life of the normal drill tool
Types of cutters
Tapping:-
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particularly when the job is heavy and /or of odd shape and size.
In a vice which is clamped on the bed. In a suitable jig clamped on the bed. Anil Dahiya
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Drill socket for mounting drill chuck and taper shank drills in spindle
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Drill
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Drilling
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cylindrical holes)
Occasionally for boring, counter boring,