DJJ 1043

WORKSHOP TECHNOLOGY
 INTRODUCTION
 Drilling is the operation of producing circular
hole in the work-piece by using a rotating cutter
called DRILL.

 The machine used for drilling is called drilling

machine.

 The drilling operation can also be accomplished

in lathe, in which the drill is held in tailstock and
the work is held by the chuck.

 The most common drill used is the twist drill.

BENCH DRILL MACHINE
Radial Arm Drilling Machine
TWIST DRILL
 GLOSSARY OF TWIST DRILL
 POINT – The cutting end of a drill, made up of the
ends of the lands and the web. In form it resembles a
cone, but departs from a true cone to furnish
clearance behind the cutting lips.
 POINT ANGLE – The angle included between the
lips projected upon a plane parallel to the drill axis
and parallel to the cutting lips.
 LIPS – The cutting edges of a two flute drill
extending from the chisel edqe to the periphery.
 GLOSSARY OF TWIST DRILL
 FLUTES – Helical or straight grooves cut or
formed in the body of the drill to provide cutting
lips, to permit removal of chips, and to allow
cutting fluid to reach the cutting lips.
 WEB -The central portion of the body that joins
the lands. The extreme end of the web forms the
chisel edge on a two-flute drill.
 GLOSSARY OF TWIST 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
 TWIST DRILL SIZE
Twist Drill sizes are designated under four systems;
1. Fractional
• The Fractional Drill sizes range from 1/64 inch to 1 inch and
over.
2. Number
• Numerical drill sizes, corresponding to wire gauge (the larger
the number, the smaller the drill). Example: Starting with a #
80 drill and a #1 drill.
3. Letter
• Drill size designed by letter range from letter “A” (measures .234
inch) to letter “Z” (measures .431 inch).
4. Metric
 The metric sizes range from 0.4mm (measures .015 inch) to
50mm (measures 1.968 inch).
MEASURING THE SIZE OF A DRILL
By using two methods :
1. With a drill gauge

2. With a micrometers
(taken measurements across the margin of the drill)
 MATERIAL
 The two most common types are
1. High Speed Steel (HSS) drill
- Low cost
2. Carbide- tipped drills
- high production and in CNC machines

 Other types are:

Solid Carbide drill, TiN (titanium nitrate) coated
drills, carbide coated masonry drills, parabolic drills,
split point drill.
 STEPS OF MARKING OUT BEFORE DRILLING
1. A small dent is marked at centre of the hole by using
prick punch.
2. Draw two circles by using divider; one circle has same
diameter with the hole and another one is smaller.
3. Punch the small dent by using centre punch.
4. Switch ON the machine and make sure the drill point
is pointed to the centre of the hole.
5. Check either the drill bit spinning at the centre of the
hole or not.
6. The location of the centre of the hole need to adjust if
the drill bit is slide away from the centre. A groove is
marked by using round chisel to indicate that the new
adjustment has been made.
 METHODS OF HOLDING A DRILL BIT
 The different methods used for holding drill
in a drill spindle are
By directly fitting in the spindle hole.

By using drill sleeve

By using drill socket

By using drill chuck

 DIFFERENT TYPES OF DRILL BIT
1. COMBINATION AND COUNTERSINK:
These double ended drills are also called centre
drills. They are designed for drilling centre holes in
the end of work pieces to be held between standard
60º centres. Also available in bell type with 120°
chamfer to protect the centre hole.
 DIFFERENT TYPES OF DRILL BIT
2. TWIST DRILL:
A twist drill bit is a metallic cylinder with helical
grooves that spiral up the bit. Drills are used in a wide
variety of projects and fields, from home repair to arts
to large-scale construction projects.
DRILLS OPERATION
 DRILL BIT GEOMETRY
Point angle:
 The larger the point angle on a drill bit with a
specific diameter, the shorter its cutting edges.
Reducing the length of the cutting edges improves
the drill bit guidance and reduces the required
contact pressure.
 The smaller the point angle on a drill bit with a
specific diameter, the longer its cutting edges.
Increasing the length of the cutting edge makes
drill bit guidance more difficult and increases the
required contact pressure.
 DRILL BIT GEOMETRY
Lip Angle Clearance:
 Excessive clearance results in lack of support behind
cutting edge with quick dulling and poor tool life.
 Clearance angle behind cutting lip for general
purposes is 8º to 12º.
 DRILL BIT GEOMETRY
Helix Angle:
 The helix angle on a bit is the angle between the
cutting edge and a vertical line along the centre of the
bit.
 Bits with a moderate helix angle aid in chip ejection
and are recommended for drilling of plastics.
 Small helix angles interfere with chip ejection,
increasing melting.
 Helix angles, which are too large, can cause cracking
around the hole edges.
 Typically a helix angle of 15-30° is recommended.
 DEFINITIONS AND CALCULATION
 Cutting Speed (v):
It’s the peripheral speed of the drill
v = Π*D*N
where D = diameter of the drill in m
N = Speed of rotation in rpm
 Feed Rate (f):
It’s the movement of drill along the axis (rpm)
 Depth of Cut (d):
The distance from the machined surface to the
drill axis
d=D/2
 DEFINITIONS AND CALCULATION
 Material Removal Rate :
It’s the volume of material removed by the drill
per unit time
MRR = ( D2 / 4) * f * N mm3 / min

 Machining Time (T) :

It depends upon the length (L) of the hole to be
drilled , to the Speed (N) and feed (f) of the drill
t = L /( f * N) min
 SELECTION OF CUTTING SPEED
AND CUTTING FEED
 The selection of cutting speed and cutting feed is
influenced by:
Types and condition of machine.
Accuracy and work finishing.
Toughness of work holding device.
Usage of coolant
Drill bit material
 COOLANT
 Cutting fluids are very important in machining
processes.
 They are used to reduce the effects of friction.
 They are also used to carry away heat in machining
operations.
 Excessive heat can damage the microstructure of
metals.
 Proper use of coolants can make higher metal removal
rates possible.
 Coolants can also help improve part quality and
dimensional accuracy.
 TYPES OF COOLANTS
 Straight Cutting Oils
 Active Straight Cutting Oils
 Inactive Straight Cutting Oils
 Chemical Fluids
 Emulsions
 Special coolant
 FUNCTIONS OF COOLANT
 to cool the tool
 to cool the work piece
 reduce friction at the sliding contacts,
 prevent or reduce the adhesion on the
contact edges.
 to flush chips away.
 BENEFITS OF USING CUTTING FLUID
 Improve part productivity.
The use of cutting fluids reduces friction and heat.
The removal of the heat prevents the work piece from
expanding during the machining operation, which
would cause size variation as well as damage to the
material’s microstructure.

• Reduce tooling cost.

Proper use of cutting fluids increases tool life, which
reduces the tooling costs. Increased tool life also
reduces tool changes and downtime which decreases
labour costs.
 BENEFITS OF USING CUTTING FLUID
 Increase Cutting Speeds and Feeds
Cutting tools reduce friction and heating a
machining operation. This allows high speeds and
feeds to be used to achieve optimal cutting
conditions

 Improved Surface Finishes

Effective use of cutting fluids helps remove the
chips. This prevents the chip from being caught
between the tool and work piece where it causes
scratches and a poor surface finish
 BENEFITS OF USING CUTTING FLUID
 Reduces Bacterial Growth
Bacteria can drastically affect cutting oils. Bacteria
growth can turn a cutting fluid rancid. Additives in
coolants help reduce the effects of bacteria, but it is
important that pure water is used for coolant
mixing.

• Rust and Corrosion Prevention

Cutting fluids should protect the tooling, machine,
and work piece against rust and corrosion. Cutting
fluids should leave a small residual film that
remains after the water has evaporated.
 MACHINE AND DRILL BIT
MAINTENANCE
 Machines should be cleaned after use.
 Chips should be removed using brush.
 T-slots, grooves, spindles sleeves, belts, pulley should
be cleaned.
 Machines should be lightly oiled to prevent from
rusting.
 Use suitable cutting speed.
SAFETY DURING DRILLING OPERATION
 Do not support the work piece by hand – use work
holding device.
 Use brush to clean the chip
 No adjustments while the machine is operating
 Ensure for the cutting tools running straight before
starting the operation.
 Never place tools on the drilling table
 Avoid loose clothing and protect the eyes.
 Ease the feed if drill breaks inside the work piece.
 WHY THE WORKPIECE IS NEEDED TO
CLAMP SECURELY?
1. Workpiece will loose from workholding
device.
2. The hole drilled become large.
3. Drill bit will broken.
4. Hole drilled will not meet specification.
5. Waste material and drill bit.
6. Waste time to replace the new material
and drill bit.
 WORKHOLDING DEVICES
• Machine table vice
WORKHOLDING DEVICES
 METHOD TO DRILL A LARGE HOLE
 Drill a small pilot hole on the spot with a smaller
bit if you will be drilling a large hole. This will help
ensure that the hole will be straight when you use
the larger bit.
 THE IMPORTANCE OF PILOT DRILL
 Pilot hole will allow you to centre the tip of
the larger diameter tool and then accurately
drill your final size hole.
 This often keeps the larger tool from
jumping all over the surface when it first
touches the material.
THE IMPORTANCE OF CENTRE DRILL
 Centre drills are an progression to improve
productivity.
 They combine the countersink with a small pilot drill.
 Centre drills are intended for putting in centres for
turning on a lathe.
 TYPES OF JIGS
 Plate jigs or channel jig.
 Angle plate jig.
 Box jig.
 Leaf or latch jig.
 Sandwich jig.
 Trunnion jig.
 Template jig
 Universal Jig
 FUNCTIONS OF DRILL JIGS
 A drill jig is a type of jig that expedites repetitive hole
centre location on multiple interchangeable parts by
acting as a template to guide the twist drill or other
boring device into the precise location of each
intended hole centre.
End of Chapter [Assignment 1]
QUESTION 1

 a) List TWO (2) tools that are used as marking tool.

(2 marks)
 b) List FIVE (5) types of hammer. (5 marks)
 c) State THREE (3) major hazards which may arise from the
use of electrical equipment and their causes (6 marks)
 d) List SIX (6) ways on how to care for a file. (6 marks)
 e) i) Draw a chisel (2 marks)
ii) State the uses of a chisel (2 marks)
iii) Explain the differences between a hot chisel and a cold chisel
(2 marks)
QUESTION 2

 a) State FIVE (5) procedures of maintaining a

micrometer. (5 marks)
 b) Name THREE (3) types of micrometer and their
uses. (6 marks)
 c) State THREE (3) disadvantages of using a
micrometer. (6 marks)
 d) Draw a vernier calliper and label SIX (6) main parts.
(8 marks)
QUESTION 3

 a) Define of mandrel. (2 marks)

 b) Name THREE (3) important parts of a lathe
machine. (3 marks)
 c) State THREE (3) effects on a drill bit and a work
piece if the work is carried out without using any
coolant. (6 marks)
 d) Calculate the cutting speed if the twist drill
diameter is 18 mm and the rotation per minute is 993.
(6 marks)
 e) State FOUR (4) types of manufacturing lathe
machines and their functions. (8 marks)