Technology of Machine Tools: Drilling Machines

PowerPoint to accompany
Technology of Machine Tools

6th Edition
Krar Gill Smid
Drilling Machines
Section 10
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
38-2
Drilling Machines
Probably first mechanical device developed Principle of rotating tool to make hole One of most common and useful machines in industry Come in several types and sizes
From hand-fed to computer-controlled

6th Edition
Krar Gill Smid
Drill Presses
Unit 38
38-4
Objectives
Identify six standard operations that may be performed on a drill press
Identify four types of drill presses and their purposes Name and state the purpose of the main parts of an upright and a radial drill
38-5
Drilling Press
Drilling machine
Spindle
Turns drill to advance into work (hand or automatically)
Work table
Holds workpiece rigidly in place as hole drilled
Used primarily to produce holes in metal Other operations: tapping, reaming, boring, counterboring, countersinking, spot-facing
38-6
Standard Operations
Drilling
Operation of producing hole by removing metal from solid mass using twist drill
Countersinking
Operation of producing tapered or cone-shaped enlargement to end of hole
38-7
Standard Operations
Reaming
Operation of sizing and producing smooth, round hole from previously drilled or bored hole
Boring
Truing and enlarging hole by means of single-point cutting tool
38-8
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
38-9
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 tool
Pilot section on end to fit into existing hole
38-10
Principal Types of Drilling Machines

Wide variety of drill presses Size of drill press may be designated in different ways by different companies
Some state size as distance from center of spindle to column of machine Others state size by diameter of largest circular piece that can be drilled in center
38-11
Sensitive Drill Press Parts

Only hand feed mechanism
Control downfeed pressure
Manufactured in bench and floor model Four main parts

Base, column, table and drilling head
38-12
Radial Drilling Machine

6th Edition
Krar Gill Smid
Drilling Machine Accessories

Unit 39
39-14
Objectives
Identify and use three types of drillholding devices Identify and use work-holding devices for drilling Set up and clamp work properly for drilling
39-15
Versatility of the Drill Press

Greatly increased by various accessories
Two categories
Tool-holding devices
Used to hold or drive cutting tool
Work-holding devices
Used to clamp or hold workpiece
39-16
Tool-Holding Devices
Drill press spindle provides means of holding and driving cutting tool End may be tapered or threaded for mounting drill chuck Most common
Drill chucks Drill sleeves Drill sockets
39-17
Drill Chucks
Most common devices used for holding straight-shank cutting tools Most contain three jaws that move simultaneously when outer sleeve turned
Hold straight shank of cutting tool securely
Two common types

Key Keyless
39-18
Chucks
Hold straight-shank drills Mounted on drill press spindle
Taper Threads
Held in spindle by self-holding taper in larger machines Four types of drill chucks
39-19
Types of Drill Chucks

Key-type
Most common Three jaws move simultaneously when outer sleeve turned
Tighten with key
Keyless
Chuck loosened or tightened by hand without key
Precision keyless
Holds smaller drills accurately
39-20
Types of Drill Chucks

Jacobs impact keyless chuck
Hold small or large drills accurately using Rubber-Flex collets Gripped or released quickly and easily by means of built-in impact device in chuck
39-21
Drill Sleeves and Sockets

Drill Sleeves
Used to adapt cutting tool shank to machine spindle if taper on tool is smaller than tapered hole in spindle
Drill Socket
Used when hole in spindle of drill press to small for taper shank of drill Used also as extension sockets
39-22
Drill Drift
Used to remove tapered-shank drills or accessories from drill press spindle Always place rounded edge up so this edge will bear against round slot in spindle Use hammer to tap drill drift and loosen tapered drill shank Use board or piece of masonite to protect table
39-23
Work-Holding Devices
Angle vise
Angular adjustment on base to allow operator to drill holes at an angle without tilting table
Drill vise
Used to hold round, square or odd-shaped rectangular, pieces Bolt vise to table for stability
39-24
Contour vise
Has special movable jaws that automatically adjust to shape of odd-shaped workpiece
V-blocks
Made of cast iron or hardened steel Used in pairs to support round work for drilling
Step blocks
Used to provide support for outer end of strap clamps Various sizes and steps
39-25
Angle plate
L-shaped piece of cast iron or hardened steel machined to accurate 90 May be bolted or clamped to table Variety of sizes
Drill jigs
Used in production for drilling holes in large number of identical parts Eliminate need for laying out a hole location
39-26
Clamps or straps
Used to fasten work to drill table or an angle plate for drilling Various sizes Finger clamp Usually supported at end by step block and bolted to table by T-bolt U-clamp that fits into table T-slot
Modifications are doublefinger and gooseneck clamps

Straight clamp
39-27
Clamping Stresses
Dont want stresses to cause springing or distortion of workpiece Clamping pressures should be applied to work, not step block
Step block should be slightly higher than work Bolt close to work
39-28
Clamping Hints
1. Always place bolt close to workpiece 2. Have packing block slightly higher than work surface being clamped 3. Insert piece of paper between machine table the workpiece to prevent shifting 4. Place metal shim between clamp and workpiece 5. Use sub-base or liner under rough casting 6. Shim parts that do not lie flat to prevent rocking

6th Edition
Krar Gill Smid
Twist Drills
Unit 40
40-30
Objectives
Identify the parts of a twist drill
Identify four systems of drill sizes and know where each is used Grind the proper angles and clearances on a twist drill
40-31
Twist Drills
End-cutting tools Used to produce holes in most types of materials Two helical grooves, or flutes, are cut lengthwise around body of drill
Provide cutting edges and space for cuttings to escape during drilling process
40-32
Twist Drill Parts

Most made of high-speed steel
Replaced carbon-steel drills for two reasons
Can be operated at double the cutting speed Cutting edge lasts longer
Stamped with letters H.S or H.S.S.
Carbide-tipped drills
Speeds for production have increased up to 300% over high-speed drills
40-33
Three Main Parts of a Drill
Point
Body
Shank
40-34
Shank
Straight-shank drills
Held in drill chuck Up to in. in diameter
Tapered-shank drills
Fit into internal taper of drill press spindle Tang provided on end to prevent drill from slipping
40-35
Body
Portion of drill between shank and point Consists of number of parts for cutting Flutes
Two or more helical grooves cut around body of drill Form cutting edges, admit cutting fluid, allow chips to escape hole
Body Clearance
Undercut portion of body between margin and flutes
40-36
Body, cont.
Margin
Narrow, raised section on body of drill Next to flutes and extends entire length of flutes Provides full size to drill body and cutting edges
Web
Thin partition in center of drill, extends full length of flutes Forms chisel edge at cutting end of drill
40-37
Point
40-38
Lip Clearance
Is the relief ground on point of drill extending from cutting lips back to the heel
40-39
Drill Point Characteristics

The use of various point angles and lip clearances, in conjunction with thinning of the drill web, will allow:
1. Control size, quality and straightness of drilled hole 2. Control size, shape and formation of chip 3. Control chip flow up flutes
40-40
4. Increase strength of drill's cutting edges 5. Reduce rate of wear at cutting edges 6. Reduce amount of drilling pressure required
7. Control amount of burr produced

8. Reduce amount of heat generated 9. Permit use of various speeds and feeds for more efficient drilling
40-41
Conventional Point (118)

Most commonly used drill point Gives satisfactory results for most generalpurpose drilling Lip clearance of 8 to 12 for best results
Too much weakens cutting edge and causes drill to chip Too little results in use of heavy drilling pressure
40-42
Long Angle Point (60 to 90)

Used on low helix drills for drilling of nonferrous metals, soft cast irons, plastics, fibers, and wood Lip clearance generally from 12 to 15 Flat may be ground on face of lips to prevent drill from drawing itself into the soft material
40-43
Flat Angle Point (135 to 150)

Used to drill hard and tough materials Lip clearance on flat angle point drills only 6 to 8 to provide as much support as possible for cutting edges Shorter cutting edge tends to reduce friction and heat during drilling
40-44
Four Systems of Drill Sizes

Fractional
Range from 1/64 to 4 in. (steps of 1/64th )
Number
Range from #1 (.228 in.) to #97 (.0059 in.)
Letter
Range from A to Z (A = .234 in., Z = .413 in.)
Millimeter (Metric)
Miniature (0.04 to 0.09 mm, steps of 0.01 mm) Straight-shank standard (0.5 to 20 mm) Taper-shank (8 up to 80 mm)
40-45
Types of Drills
Wide variety manufactured to suit specific drilling operations and materials Design of drills vary
Number and width of flutes Amount of helix or rake angle of flutes Shape of land or margin Shape of flute: straight or helical Whether helix is right-hand or left-hand
40-46
Twist Drills
Manufactured from three main materials
Carbon-steel drills
Used in hobby shops not for machine shop work Cutting edges wear down quickly
High-speed steel drills

Used in machine shop work Cutting edges withstand more heat and wear
Cemented-carbide drills
Operated at high speeds, withstand higher heat, and can drill hard materials
40-47
General-Purpose Drill
Has two Helical flutes Designed to perform well on wide variety of materials, equipment and job conditions Can be made to suit different conditions and materials by varying point angle, speeds and feeds Straight-shank drills called general-purpose jobbers length drills
40-48
Oil Hole Drills

Have one or two oil holes running from shank to cutting point
Compressed air, oil, or cutting fluid can be forced through when deep holes being drilled
Used on turret lathes and screw machines Cutting fluid cools drill's cutting edges and flushes chips out of hole
40-49
Step Drills
Used to drill and countersink or drill and counterbore different sizes of holes in one operation May have two or more diameters ground Each size or step separated by square or angular shoulder
40-50
Saw-Type Hole Cutter

Cylindrical-diameter cutter with twist drill in center to provide guide for cutting teeth on hole cutter Made in various diameters Used for drilling holes in thin materials Little burr produced
40-51
Drilling Facts and Problems

Excessive speed Excessive clearance Examples of each Excessive feed on following slides Insufficient clearance Cutting lips with unequal angles Cutting lips with unequal in length Loading and galling
40-52
Excessive speed will cause wear at outer corners of drill. This permits fewer regrinds of drill due to amount of stock to be removed in reconditioning. Discoloration is warning sign of excess speed.
40-53
Excessive clearance results in lack of support behind cutting edge with quick dulling and poor tool life. Despite initial free cutting action. Clearance angle behind cutting lip for general purposes is 8 to 12.
40-54
Excessive feed sets up abnormal end thrust, which causes breakdown of chisel point and cutting lips. Failure induced by this cause will be broken or split drill.
40-55
Insufficient clearance causes the drill to rub behind the cutting edge. It will make the drill work hard, generate heat, and increase end thrust. This results in poor holes and drill breakage.
40-56
The web is the tapered central portion of the body that joins the lands.
40-57
Cutting lips with unequal angles will cause one cutting edge to work harder than the other. This causes torsion strain, bellmouth holes, rapid dulling, and poor tool life.
40-58
Cutting lips unequal in length cause chisel point to be off center axis and will drill holes oversize by approximately twice the amount of eccentricity.
40-59
Loading and galling is caused by poor chip removal with insufficient dissipation of heat so that material anneals itself to the cutting edge and flute. This condition frequently results from using wrong drills for the job or inadequate cutting fluid application.
40-60
Characteristics of a Properly Ground Drill

Length of both cutting lips equal Angle of both cutting lips be the same Lips should be free from nicks or wear No sign of wear on margin
Note: Resharpen drill if it does not meet all of these requirements.
40-61
Conditions That Indicate Drill Be Examined and Reground

Color and shape of chips change More drilling pressure required Drill turns blue because of excessive heat Top of hole out of round Poor finish produced in hole Drill chatters when it contacts metal Drill squeals and may jam in hole Excessive burr left around drilled hole
40-62
Factors Causing Premature Dulling of Drill

Drill speed may be too high for hardness of material being cut Feed may be too heavy and overload cutting lips Feed may be too light and cause lips to scrape rather than cut May be hard spots or scale on work surface
40-63
More Factors
Work or drill may not be supported properly, resulting in springing and chatter Drill point may be incorrect for material being drilled Finish on lips may be poor
40-64
Procedure to Grind a Drill

1. Wear approved safety glasses
2. Check grinding wheel and dress it to sharpen and/or straighten wheel face 3. Adjust grinder tool rest so it is within .060 in. of wheel face
4. Examine drill point and margins for wear
40-65
5. Hold drill near point with one hand, other hand hold shank of drill slightly lower than point 6. Move drill so it is approximately 59 to face of grinding wheel 7. Hold lip or cutting edge of drill parallel to grinder toolrest
8. Bring lip of drill against grinding wheel and slowly lower drill shank
40-66
9. Remove drill from wheel without moving position of body or hands, rotate drill onehalf turn, and grind the other cutting edge 10. Check angle of drill point and length of lips with drill point gage 11. Repeat operations 6-10 until cutting edges are sharp and lands are free from wear nicks

6th Edition
Krar Gill Smid
Cutting Speeds and Feeds

Unit 41
41-68
Objectives
Calculate the revolutions per minute (r/min) for inch and metric size drills
Select the feed to be used for various operations Calculate the revolutions per minute for the reaming operation
41-69
Cutting Speeds and Feeds

Two important factors
Diameter and material of cutting tool Type of material being cut
Speed of twist drill referred to as cutting speed, surface speed or peripheral speed
Distance point on circumference of drill will travel in 1 min
41-70
Recommended Cutting Speeds

For every job, choose the drill speed that will result in the best production rates! Steel Casting Tool Steel
Drill Size Cutting Speeds in Feet per Min or Meters per Min in mm 40 ft/min 12 m/min 60 ft/min 18 m/min 1/16 2 2445 1910 3665 2865 1/8 3 1220 1275 1835 1910 3/16 4 815 955 1220 1430 Portion of Table 41.1 from text
41-71
Economical Drilling Speed Variables

Type and hardness of material Most important! Diameter and material of drill Depth of hole Type and condition of drill press Efficiency of cutting fluid employed Accuracy and quality of hole required Rigidity of work setup
41-72
Revolutions per Minute

Compute correct number of r/min of drill press spindle for given size drill
Type of material to be drilled Recommended cutting speed of material Type of material from which drill is made
41-73
Formula (Inch)
CS (feet per minute) x12 r / min D(drill circumfere nce in inches)
where CS = recommended cutting speed in feet per minute for the material being drilled D = diameter of drill being used Revolution per minute = number of revolutions of the drill necessary to attain proper cutting speed for metal being machined.
41-74
Simplified Formula
Since not all machines can be set to exact calculated speed, pi () divided into 12 to simplify formula
CS x 4 r / min D
Example: Calculate r/min required to drill a in hole in cast iron (CS 80) with a high-speed steel drill.
80 x 4 320 r / min 640 1/ 2 1/ 2
41-75
Feed
Distance drill advances into work for each revolution May be expressed in decimals, fractions of an inch, or millimeters Three factors govern rate of feed
Diameter of drill Material of workpiece Condition of drilling machine
41-76
Drill Feeds
General purpose Work Drill Size in. 18 to to mm 3 to 6 6 to 13 25 to 38 Feed per Revolution in. .002 to .004 .004 to .007 mm 0.05 to 0.1 0.1 to 0.18
18 and smaller 3 and smaller .001 to .002
0.02 to 0.05
to 1
1 to 1
13 to 25
.007 to .015
0.18
.015 to .025
0.38 to 0.63
Table 41.2 Drill feeds
41-77
Drill Feeds
General rule: feed rate increases as drill size increases
Too coarse chip cutting edges Too light chattering noise, dulls cutting edge
Hard steels or alloys use slower feed Softer metals drilled with faster feed Blue steel chips indicate too much heat at cutting edge
Dull cutting edge or too high speed
41-78
Cutting Fluids
Provide both cooling and lubrication Properties of an effective liquid in dissipating heat
Able to absorb heat rapidly Have good resistance to evaporation Have high thermal conductivity
Oil: good lubricant, poor coolant Water: best coolant, no lubricating value (promotes rust)

6th Edition
Krar Gill Smid
Drilling Holes
Unit 42
42-80
Objectives
Measure the size of inch and metric drills
Drill the correct size center holes in workpieces Drill small and large holes to an accurate location
42-81
Drill Press Safety

1. Do not operate before understanding mechanism and how to stop 2. Always were approved safety glasses 3. Never attempt to hold work by hand 4. Keep your head back from revolving parts 5. As drill begins to break through work, ease up on drill pressure
42-82
6. Always remove burrs from drilled hole with file or deburring tool 7. Never leave chuck key in drill chuck 8. Never attempt to grab work that may have caught in drill
Stop machine first
9. Always keep floor around drill press clean and free of tools, chips, and oil
42-83
Drilling Hints
1. Treat cutting tools with care 2. Always examine condition of drill point before use do not use dull tools 3. Make sure drill point angle correct for type of material to be drilled 4. Set correct revolutions per minute for size of drill and workpiece material
42-84
5. Set up work so drill will not cut into machine as it breaks through workpiece 6. Work should always be clamped securely 7. End of workpiece farthest from hole should be placed on left-hand side of table so it will not swing toward operator 8. Always clean tapered drill shank, sleeve, and machine spindle before inserting drill 9. Use shortest drill length possible and/or hold it short in chuck
42-85
10. Good practice to start each hole with center drill

Provides guide for drill to follow
11. Thin workpieces should be clamped to hardwood block for drilling 12. Chips from each flute should be same shape; if blue during drilling, check drill point condition 13. Drill squeak usually indicates dull drill 14. When increased pressure must be applied during drilling, reason usually dull drill or chip caught in hole between drill and work
42-86
Measuring Size of a Drill

Good practice to always check drill for size before drilling Check for size
Drill gage Micrometer
Most accurate Check measurement across margin of drill
42-87
Lathe Center Holes

Use a combination drill and countersink
Commonly called center drill
Must be drilled to correct size and depth

Too shallow or deep, poor support for work
42-88
Spotting Hole Location With a Center Drill

Chisel end on drill wider than center-punch mark on work
Spot center-punch mark with center drill
Small point on center drill will accurately follow center-punch mark and provide guide for larger drill
42-89
Spotting Hole Location With a Center Drill

1. Mount small-size center drill in drill chuck 2. Mount work in vise
Do not clamp
3. Set drill speed to 1500 r/min 4. Bring point of center drill into centerpunch mark and allow work to center itself with drill point 5. Continue drill until one-third of tapered section of center drill has entered work 6. Spot all holes to be drilled
42-90
Spotting Hole
42-91
Drilling Work Held in a Vise

1. Spot hole location with center drill 2. Mount correct-size drill in drill chuck 3. Set drill press to proper speed for size of drill and type of material to be drilled 4. Fasten clamp or stop on left side of table 5. Mount work on parallels in drill vise and tighten it securely
42-92
6. With vise against table stop, locate spotted hole under center of drill 7. Start drill press spindle and begin to drill
Holes up to 12 in. hold vise against table Holes over 12 in. Clamp vise to table
Drill until full drill point into work With drill revolving, deep drill point in work and tighten clamp holding vise
8. Raise drill occasionally and apply cutting fluid during drilling 9. Ease up on drilling pressure as drill starts to break through workpiece
42-93
Drilling to an Accurate Layout

1. Clean and coat surface with layout dye 2. Locate position of hole from two machined edges of workpiece and scribe lines 3. Lightly prick-punch where two lines intersect 4. Check accuracy of punch mark
42-94
5. Scribe circle to indicate diameter of hole
6. Scribe test circle .060 in. smaller than hole 7. Punch four witness marks on circles up to .750 in. in diameter and eight witness marks on larger circles 8. Deepen center of hole location with center punch to provide larger indentation for drill to follow
42-95
9. Center drill work to just beyond depth of drill point
10. Mount proper size drill in machine and drill hole to depth equal to one-half to twothirds drill diameter
11. Examine drill indentation; should be concentric with inner proof circle
42-96
12. If spotting off center, cut shallow V-grooves with cape or diamond-point chisel on side toward which drill must be moved 13. Start drill in spotted and grooved hole Drill will be drawn toward direction of grooves 14. Continue cutting grooves into spotted hole until drill point drawn to center 15. Continue to drill hole to desired depth
42-97
Drilling Large Holes

Drills increase in size; thickness of web also increases to give drill strength
Thicker web, thicker point of drill Thick web not follow center-punch mark easily
Two methods to overcome poor cutting action of thick web on large drills
Web is thinned Lead, or pilot, hole is drilled
42-98
Using Pilot Hole with Large Holes

Drill pilot hole diameter which is slightly larger than thickness of web Care must be taken to drill pilot hole on center Pilot hole then followed with larger drill Problems when pilot hole too large
Cause chattering Drill hole out-of-round Spoil top (mouth) of hole
42-99
Procedure for Drilling Large Holes with Pilot Hole

1. Check print and select proper drill 2. Measure thickness of web at point
Select pilot drill with diameter slightly larger than web thickness
3. Mount workpiece on table 4. Adjust height and position of table so drill chuck can be removed and larger drill placed in spindle after pilot hole drilled and lock table
42-100
5. Place center drill in drill chuck, set proper spindle speed, accurately drill center hole 6. Using proper-size pilot drill, drill pilot hole 7. Shut off machine, leaving pilot drill in hole 8. Clamp work securely to table 9. Raise drill spindle, remove drill and chuck 10. Clean taper shank of drill and spindle hole 11. Mount large drill in spindle 12. Set spindle speed, feed and drill hole to required depth
42-101
Drilling Round Work in V-Block

1. Select V-block to suit diameter of work 2. Mount work in V-block and rotate it until center-punch mark is in center of work
Check distance from both sides equal
3. Tighten U-clamp securely or hold work in vise 4. Spot hole location with center drill 5. Mount proper drill size and set speed 6. Dill hole (do not hit V-block or vise when drill breaks through work)

6th Edition
Krar Gill Smid
Reaming
Unit 43
43-103
Objectives
Identify and state the purpose of hand reamers and machine reamers Explain the advantages of carbide-tipped reamers Calculate the reaming allowance required for each reamer Ream a hole by hand in a drill press Machine ream a hole
43-104
Reamers
Rotary cutting tool with several straight or helical cutting edges along body Used to accurately size and finish hole previously formed by drilling Two classifications
Hand Machine
43-105
Reamer Parts
Three main parts 1. Shank 2. Body 3. Angle of chamfer

43-106
Hand Reamers
Finishing tools Holes bored to .003-.005 in. Square on shank for wrench Teeth on end tapered so can enter hole easily Never turn backwards Taper hand reamers
Remove frequently to clean
43-107
Machine Reamers
Used in any machine tool for both roughing and finishing hole Called chucking reamers for holding method Wide variety of types and styles
Rose reamers Fluted reamers Carbide-tipped reamers
43-108
Fluted Reamers
Have more teeth than rose reamers for comparable diameter Lands relieved for entire length Fluted reamers cut along side as well as at chamfer on end Considered finishing tools and used to bring hole to size
43-109
Carbide-tipped Reamers
Similar to rose or fluted reamers, except carbide tips been brazed to cutting edges
Resist abrasion and maintain sharp cutting edges even in high temperatures
Outlast high-speed steel reamers Can run at higher speeds and still maintain their size
43-110
Shell Reamers
Reamer heads mounted on driving arbor Shank of driving arbor may be straight or tapered Two slots in end of reamer fit into lugs on driving arbor Sometimes locking screw in arbor
43-111
More Reamers
Adjustable reamers
Have inserted blades that can be adjusted approximately at .015 in over or under nominal reamer size
Adjusting nuts on either end
Emergency reamers
Drills whose corners have been slightly rounded and honed if reamer of particular size not available
43-112
Another Reamer
Expansion reamers
Amount expanded limited Body slotted and tapered, threaded plug fitted into end Turning this plug will allow 1 in. reamer to expand up to .005 in.
43-113
Reamer Care
1. Never turn reamer backward; ruin edges 2. Always store reamers in separate containers to prevent cutting edges from being nicked 3. Never roll or drop reamers on metal surfaces 4. When not in use, reamer should be oiled 5. Fine, free-cutting grinding wheel should be used for resharpening reamers
43-114
Reaming Allowances
Amount of material left in hole for reaming operation depends on number of factors
Type of machining operation prior to reaming Hole punched, rough-drilled, bored
General rules for amount of material to leave in hole for machine reaming
Holes up to .500 in. diameter, allow .015 in. Holes over .500 in. diameter, allow .030 in.
43-115
Reaming Speeds
Factors for determining most efficient speed
Type of material being reamed Rigidity of setup Tolerance and finish required in hole
Generally reaming speed 1/2 to 2/3 speed used for drilling same material High speed used when setup rigid Lower speed used when setup less rigid Coolants improve surface finish and allow speed
43-116
Reaming Feeds
Feed used for reaming usually two to three times greater than that used for drilling Rate varies with material reamed Generally .001 to .004 in. per flute per rev Feed too low: glazing, excessive reamer wear, chatter Feed too fast: reduce hole accuracy, poor surface finish Exception: tapered holes need light feed
43-117
Reaming Hints
1. Examine reamer and remove all burrs from cutting edges with hone 2. Cutting fluid should be used in reaming operation to improve hole finish and prolong life of reamer 3. Helical-fluted reamers should always be used when long holes and those with keyways or oil grooves are reamed
43-118
5. Straight-fluted reamers generally used when extreme accuracy required 6. Use roughing reamer first and then finishing reamer to obtain hole accuracy and good surface finish 7. Never turn reamer backwards 8. Never attempt to start reamer on uneven surface 9. Select reamer with incremental cut to avoid chatter 10. Always use stub center in drill press spindle to keep reamer aligned
43-119
Hand Reaming a Straight Hole
43-120
Procedure for Hand Reaming a Straight Hole

1. Mount work on parallels in vise and clamp it securely to table 2. Drill hole to proper size, leaving allowance for hand reamer to be used 3. Do not move location of work or table; remove drill and mount stub center in drill chuck 4. Start end of reamer in drilled hole
43-121
5. Fasten tap wrench on reamer 6. Engage stub center in center hole on end of reamer 7. With downfeed lever, apply slight pressure while turning reamer clockwise by hand 8. Apply cutting fluid and ream hole 9. When removing reamer, turn it clockwise, never counterclockwise
43-122
Machine Reaming a Straight Hole

1. Mount work on parallels in vise and fasten securely to table 2. Select proper-size drill for reaming allowance required and drill hole 3. Mount proper reamer in drill press 4. Adjust spindle speed to suit reamer and work material
43-123
5. Start drill press and carefully lower spindle until chamfer on reamer starts to cut 6. Apply cutting fluid and feed reamer by applying enough pressure to keep reamer cutting 7. Remove reamer from hole by raising downfeed handle 8. Shut off machine and remove burr from edge of hole

6th Edition
Krar Gill Smid
Drill Press Operations

Unit 44
44-125
Objectives
Counterbore and countersink holes
Select and use the proper tap to thread a hole in a drill press Use three methods to transfer hole locations
44-126
Counterboring
Operation of enlarging end of hole that has been drilled previously
Depth slightly greater than head of bolt, cap screw or pin it is to accommodate
Supplied in variety of styles

Each have pilot in end to keep tool in line with hole
Some interchangeable pilots to suit variety of holes
44-127
Procedure to Counterbore a Hole

1. Set up and fasten work securely 2. Drill proper size of hole in workpiece to suit body of pin or screw 3. Mount correct size of counterbore in drill press 4. Set drill press speed to approximately one-quarter that used for drilling 5. Bring counterbore close to work to see that the pilot turns freely in drilled hole 6. Start machine, apply cutting fluid and counterbore
44-128
Countersinking
Process of enlarging top end of hole to shape of cone to accommodate conicalshaped heads of fasteners
Head will be flush with or below surface
Countersinks available with various included angles

60, 82, 90, 100, 110, and 120
44-129
Countersinking
82 countersink used to enlarge top of hole so it will accommodate a flat-head machine screw Holes to be threaded countersunk slightly larger than tap diameter Speed is approximately 1/4th of drilling speed
44-130
Procedure to Countersink a Hole for a Machine Screw

1. Mount an 82 countersink in drill chuck 2. Adjust spindle speed to about that used for drilling 3. Place workpiece on drill table 4. With spindle stopped, lower countersink into hole
Clamp work if necessary
44-131
5. Raise countersink slightly, start machine, and feed countersink by hand until proper depth is reached.
Diameter checked by placing inverted screw in countersunk hole
6. If several holes to do, set depth stop 7. Countersink all holes to depth set on gage
44-132
Tapping
Performed by hand or under power with tapping attachment Done immediately after drilling operation Hand taps
In sets containing taper, plug, bottoming tap
Machine taps
Designed to withstand torque required to thread hole and clear chips
44-133
Set of Hand Taps
Taper
Plug
Bottoming
44-134
Types of Machine Taps
Gun Stub-flute
Spiral-flute
44-135
Fluteless Tap
Actually a forming tool used to produce internal threads in ductile material
Copper, brass, aluminum, and leaded steels
Fluteless tap Lobes of the tap

44-136
Procedure to Tap a Hole by Hand in a Drill Press

1. Mount work on parallels with centerpunch mark on work in line with spindle and clamp work securely to drill press table 2. Adjust drill press table height so drill may be removed after hole has been drilled without moving table or work 3. Center drill hole location
44-137
4. Drill hole to correct tap drill size for tap to be used 5. Mount stub center in drill chuck
Or remove drill chuck and mount special center in drill press spindle
6. Fasten suitable tap wrench on end of tap 7. Place tap in drilled hole, lower drill press spindle until center fits into center hole in tap shank 8. Turn tap wrench clockwise to start tap 9. Continue to tap hole, applying light pressure
44-138
Tapping Attachment
Mounted in a drill press spindle to rotate tap by power
Built-in friction clutch that drives tap clockwise when drill press spindle fed downward Reversing mechanism to back tap out of hole
Two- , three-fluted machine or gun taps used for power

Ability to clear chips
Tapping speed ranges from 60 100 r/min

Technology of Machine Tools: Drilling Machines

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Technology of Machine Tools: Drilling Machines

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Technology of Machine Tools

Krar Gill Smid

Technology of Machine Tools

Krar Gill Smid

Principal Types of Drilling Machines

Sensitive Drill Press Parts

Manufactured in bench and floor model Four main parts

Radial Drilling Machine

Technology of Machine Tools

Krar Gill Smid

Drilling Machine Accessories

Versatility of the Drill Press

Two common types

Types of Drill Chucks

Types of Drill Chucks

Drill Sleeves and Sockets

Modifications are doublefinger and gooseneck clamps

Technology of Machine Tools

Krar Gill Smid

Twist Drill Parts

Stamped with letters H.S or H.S.S.

Three Main Parts of a Drill

Drill Point Characteristics

7. Control amount of burr produced

Conventional Point (118)

Long Angle Point (60 to 90)

Flat Angle Point (135 to 150)

Four Systems of Drill Sizes

High-speed steel drills

Oil Hole Drills

Saw-Type Hole Cutter

Drilling Facts and Problems

Characteristics of a Properly Ground Drill

Note: Resharpen drill if it does not meet all of these requirements.

Conditions That Indicate Drill Be Examined and Reground

Factors Causing Premature Dulling of Drill

Procedure to Grind a Drill

4. Examine drill point and margins for wear

Technology of Machine Tools

Krar Gill Smid

Cutting Speeds and Feeds

Cutting Speeds and Feeds

Recommended Cutting Speeds

Economical Drilling Speed Variables

Revolutions per Minute

80 x 4 320 r / min 640 1/ 2 1/ 2

18 and smaller 3 and smaller .001 to .002

Table 41.2 Drill feeds

Technology of Machine Tools

Krar Gill Smid

Drill Press Safety

10. Good practice to start each hole with center drill

Measuring Size of a Drill

Lathe Center Holes

Must be drilled to correct size and depth

Spotting Hole Location With a Center Drill

Spotting Hole Location With a Center Drill

Drilling Work Held in a Vise

Drilling to an Accurate Layout

5. Scribe circle to indicate diameter of hole

9. Center drill work to just beyond depth of drill point

Drilling Large Holes