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Drilling: Workshop Technology MME 1103
Drilling: Workshop Technology MME 1103
DRILLING
TABLE OF CONTENTS
LIST OF FIGURES ....................................................................................III LIST OF TABLES ......................................................................................III 4.1 INTRODUCTION .............................................................................. 1
4.1.1 TYPES OF DRILLS............................................................................... 2 4.1.2 MACHINING OPERATION RELATED TO DRILLING .............................. 4 4.2 4.3 DRILLING MACHINES................................................................... 5 BASIC FORMULA FOR DRILLING OPERATION .................... 7
4.4.1 CUTTING FLUIDS ................................................................................ 9 4.5 4.6 4.7 4.8 GUIDELINES IN DESIGN ............................................................... 9 TROUBLESHOOTING................................................................... 10 SAFETY RULES .............................................................................. 11 PROJECT DRILLING .................................................................... 11
REFERENCES............................................................................................ 12
LIST OF FIGURES
Figure Figure Figure Figure 4.1 4.2 4.3 4.4 : : : :
Two holes types: (a) through hole and (b) blind hole Standard geometry of a twist drill Other operations related to drilling: (a) reaming, (b) tapping, (c)counterboring, (d)countersinking, (e) centre drilling, and (f) spot facing Sensitive bench drill press
LIST OF TABLES
: : :
The rules and principles of cutting speeds and RPM calculations in drilling operations List of cutting fluids for different materials List of problems and possible causes in drilling operation
4.1 INTRODUCTION
Drilling is the most common machining process whereby the operation involves making round holes in metallic and nonmetallic materials. Approximately 75% of all metalcutting process is of the drilling operation. Drills usually have a high length to diameter ratio that is capable of producing deep hole, however due to its flexibility, necessary precaution need to be taken to maintain accuracy and prevent drill from breaking. Drilled holes can be either through holes or blind holes (see Figure 4.1). A through holes is made when a drill exits the opposite side of the work; in blind hole the drill does not exit the workpiece (Groover, 1996).
Figure 4.1: Two holes types: (a) through hole and (b) blind hole (Groover, 1996)
During the operation, chips that are produced within the workpiece must exit through the flutes to the outside of the tool. As the chip is formed and extracted towards the surface, it will generate friction. Friction subsequently heat is also generated when the drill bit touch the workpiece during the holemaking process. Therefore, chip disposal and cutting fluids are among the most important elements need to be consider during this process. Normally, holes produced by drilling are bigger than the drill diameter and depending on its applications; the drilled holes will subjected to other operations such as reaming or honing to better surface finish and dimensional accuracy (Kalpakjian & Schmid, 2001).
There are also several apparatus needed during the drilling operation as shown below: Drilling machine Center punch Hammer Center drill Twist drills Coolant Vernier caliper Two flute drill set: i. Center drill ii. Countersink drill iii. Counter bore drill iv. Drill various diameter
spiral grooves. The grooves also serve as passage to the cutting fluid. In order that the cutting edges can cut off chips, two movements are required simultaneously; rotational speed and axial feed. In twist drill, there are various angles to be considered (see Figure 4.2):
Cutting angle (ca) or angle of : lip The two lips must be of same length and equal angle. For ordinary work, the cutting angle is 59 and vary with metal to metal.
If ca>= drill will not cut the metal easily and will not hold its position centrally because of being too flat. If ca<= more power is needed to turn the drill and drill will cut at slower rate due to the longer cutting edges.
The cone shaped cutting end is the point from the lips and varies from 12- 15 degrees. In drilling soft materials, the angle may be increased under heavy feeds. For hard materials, the recommended angle is 9 degrees. If reduced further the drill cannot cut into the metal and may break in the centre along the web. It is the angle between the flute and the workpiece that is usually 70-75 degrees. This helps to secure the lip over the correct space to curl the chips. If more there will be no edge for cutting and if less the cutting edge will be too thin and may break under strain.
Rake angle
The type of drill is selected according to the job upon several factors as follows (Kibble at. , 2002): a) b) c) d) e) type of machine used rigidity of workpiece setup size of hole to be drilled composition and hardness of workpiece
Figure 4.3: Other operations related to drilling: (a) reaming, (b) tapping, (c)counterboring, (d)countersinking, (e) centre drilling, and (f) spot facing. (Groover, 1996) 4
The types of drilling machine can range from a simple bench type units used to drill small diameter holes, to large radial drills, which can accommodate large workpieces. The drill head of a universal drilling machine can be swiveled to drill holes at an angle. For high production rate operations, a multiple spindles or also known as gang drilling can be used. This type of machine is capable of drilling in one step as many as 50 holes of varying sizes, depth and locations. Drill diam. Mm Up to 5 5 12 12 30 30 90 Spindle speed 3 3 9 18 Change method Belt Belt Gear box Gear box
Sensitive
Table 4.1: The rules and principles of cutting speeds and RPM calculations in drilling operations Drilled holes are used to take up screws, bolts, shafts, electrical wiring, steam pipes, fitting of furniture and equipment and further more to pass through gases, fluids etc. It is clear that the production of holes is a major part of al engineering manufacture. The drilled holes either have through or blind holes and the machine tool used to produce holes is usually the drilling machine. Drills are classified by material, length, shape, number, and type of helix or flute, shank, point characteristics, and size series. Drills are produced from high-speed steel (HSS), solid carbide, or with carbide brazed inserts. Most drills are made for right-hand rotation. Right-hand drills, as viewed from their point, with the shank facing away from our view, are rotated in a counterclockwise direction in order to cut. Left-hand drills cut when rotated clockwise in a similar manner. Because of the great force applied by the machine in drilling, it is essential to ensure the rigidity of both cutting tools and workpiece. The drill must be correctly held and the workpiece clamped to the table. There are three ways workpiece is usually held in drilling machine, by using: (a) vise, (b) fixtures and (c) jig. A vise is a general purpose workholding device possessing two jaws that grasp the workpiece. A fixture is a workholding device that is usually custom designed for the particular workpiece. A jig is a workholding device that is also specially design to the workpiece. The difference between a jig and a fixture is the jig provides a means of guiding the tool during drilling operation.
* Note that V is in m/min and D in mm Feed (f) is the distance the drill penetrate per revolution (mm/rev), the share of each cutting edge is = f/2 Depth of cut is taken as half the diameter for drilling = D/2 Drilling time (T) can be given by the equation; T = L / f N; where f is the feed (mm/rev) N is the rotational speed (rpm) L is the sum of hole depth, approach and over travel distances
*The approach is usually considered as 0.4D while over travel ranges from 1 to 3mm.
Material removal rate (MRR) in drilling is the volume of material removed by the drill per unit time. MRR = ( D / 4).(f).(N) 7
4.4.1
Cutting Fluids
A large number of coolant and cutting oils are used in drilling operations. A good cutting fluid will cool the workpiece and tool and will also act as a lubricant between the chip and the tool to reduce friction and heat buildup. Table 4.2 lists some of the cutting fluids for different materials. Materials Dry Aluminum Brass Bronze Cast iron Steels Low carbon Alloy Stainless Others x x x Type of cutting fluid Soluble Oil Kerosene Sulfurised Oil x x x x x x x x x x
Mineral oil x
Emulsifying or soluble oils : mixed in water Animal or mineral oils with : added sulfur or chlorine
For main requirement to use inexpensive cooling medium For operations that tend to create more friction and for reaming, counterboring, countersinking and tapping operations
d) Through holes are preferred over blind holes. If holes with large diameters are required, the parts should have a pre-existing hole. e) Part should be designed so that all drilling can be done with a minimum of fixturing and without repositioning the workpiece. f) It may be difficult to ream blind or intersecting holes because of the possibility of tool breakage. Extra hole depth should be provided. g) Blind holes must be drilled deeper than subsequent reaming or tapping operations that may be performed.
4.6 TROUBLESHOOTING
A general guideline to the probable causes of problems in drilling operations is listed below Kalpakjian & Schmid, 2001: Problem Drill breakage Excessive drill wear Tapered hole Oversized hole Poor hole surface finish : : : : :
Possible Causes Dull drill; seizing in hole because of chips clogging flutes; feed too high; lip relief angle too small Cutting speed too high; ineffective cutting fluid; rake angle too high; drill burned and strength lost when sharpened Drill misaligned or bend; lips not equal; web not central Same as above; machine spindle loose; chisel edge not central; side pressure on workpiece Dull drill; ineffective cutting fluid; welding of workpiece material on drill margin; improperly ground drill; improper alignment
Figure 4.4: Causes of oversize drilling: (a) drill lips ground to unequal lengths, (b) drill lips ground to unequal angles, and (c) unequal angles and lengths
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REFERENCES
Groover M.P., (1996), Fundamentals of Modern Manufacturing, Materials, Processes and Systems, International Editions, Prentice Hall. Gupta J.K. (1996), Basic Workshop Practice, S. Chand & Company Ltd. Kalpakian, S & Schmid, S.R. (2001), Manufacturing Engineering and Technology - 4th International Edition, Prentice Hall International. Kibble R.R, Neely J.E, Meyer R.O & White W.T. (2002). Machine Tool Practice7th Edition, Prentice Hall.
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