Experiment No.

10 / Session 12

Title: To study and perform drilling operation using Upright drilling machine and
understanding the drill bit regrinding procedure

Objective: To make the students enable to perform drilling operation and drill bit regrinding

Introduction:
Drilling machine is one of the simplest, moderate and accurate machine tool used in production shop and
tool room. It consist of a spindle which imparts rotary motion to the drilling tool, a mechanism for
feeding the tool into the work, a table on which the work rests. It is considered as a single purpose
machine tool since its chief function is to make holes.
 Drill Press:
The standard machine tool for drilling is the drill press. There are various types of drill press, the
most basic of which is the upright drill, Figure22.15.The upright drill stands on the floor and consists
of a table for holding the work part, a drilling head with powered spindle for the drill bit, and a base
and column for support. A similar drill press, but smaller, is the bench drill, which is mounted on a
table or bench rather than the floor. The radial drill is a large drill press designed to cut holes in large
parts. It has a radial arm along which the drilling head can be moved and clamped. The head there
fore can be positioned along the arm at locations that are a significant distance from the column to
accommodate large work. The radial arm can also be swiveled about the column to drill parts on
either side of the worktable. .

Drilling Bit Material:

Many different materials are used for or on drill bits depending on
requirements. Many hard materials such as carbide are much more brittle than steel. Following is the list
of materials used in drillings;

 Low carbon steel

 high carbon steel
 high speed steel
 cobalt steel alloys
 Tungsten carbide
 Poly crystalline diamond
Coating:

 Black oxide
 Titanium
 Titanium nitride
 Titanium carbon nitride
 Diamond powder

Drilling Speeds and Feeds:

The speed of a drill is measured in terms of the rate at which the outside or periphery of the tool
moves in relation to the work being drilled. The common unit and term for this velocity is surface
feet per minute, abbreviated sfm. Every tool manufacturer has a recommended table of sfm values
for their tools. General sfm guidelines are found in resources such as the Machinery Handbook (see
Table 1 in this document for a condensed version). The peripheral and rotational velocities of the
tool are related as shown in the following equation:
V=π×D×N (Eq. 1)
Where
V is the recommended peripheral velocity for the tool being used
D is the diameter of the tool
N is the rotational velocity of the tool
Since the peripheral velocity is commonly expressed in units of feet/minute and tool diameter is
typically measured in units of inches, Equation 1 can be solved for the spindle or tool velocity, N in
the following manner:
N [rpm] = 12 [in/ft] × V [sfm] / (π × D [in/rev]) (Eq. 2)
Equation 2 will provide a guideline as to the maximum speed when drilling standard materials. The
optimum speed for a particular setup is affected by many factors, including the following:

1. Composition, hardness, and thermal conductivity (k) of material

2. Depth of hole
3. Efficiency of cutting fluid
4. Stiffness and condition of drilling machine
5. Stiffness of workpiece, fixture, and tooling (shorter is better)
6. Quality of holes desired
7. Life of tool before regrind or replacement
Table 2 contains recommended feed rates for various drill diameters. For each diameter range there
is a corresponding feed range. Use the smaller values for stronger/harder materials and the larger
values for weaker/softer materials. To calculate the feed rate, use the following formula:

f = N × fr (Eq. 3)

Where
f = calculated linear feed rate of the drill [in/min]
N = spindle speed [rpm]
fr = feed per revolution of the drill [in/rev]

In addition, the following rules of thumb should be observed when applicable:

• Always start with a slower speed (~50%) and build up to the maximum after trials indicate the job
can run faster.
• Overloading the drill bit by feeding too quickly in Z will result in an excessive chipload on each
drill lip, causing the cutting edges to fracture (chip).
• Peck drilling, or the practice of drilling a short distance, then withdrawing the drill, will reduce the
tendency of chips to collect in the bottom of the hole. The deeper the hole, the more frequent the
drill must be retracted (or pecked) to be effective.
• The deeper the hole, the greater the tendency is for chips to pack and clog the flutes of the drill.
This increases the amount of heat generated and prevents the cutting lubricant from conducting heat
away from the drill point (where all the cutting occurs). Excessive buildup of heat at the drill point
results in premature failure. Therefore, a reduction in speed and feed to reduce the amount of heat is
required in deep-hole applications where coolant cannot be effectively applied. Consequently, feeds
and speeds should be reduced up to 50% when drilling holes deeper than 3 drill diameters.
Final Notes:

• Remember that the speed and feed calculated using the manufacturer’s empirical data (i.e. Tables 1
& 2) are the optimum parameters. In other words, these are the maximum speed and feed rate that
could be used under perfect conditions. To promote their products, this published data is usually
optimistic (i.e. the speeds and feeds are typically on the high side). Manufacturers will generate the
data using the stiffest machines and workpiece setups available, very high pressure coolant (1000+
psi) or highly effective (and expensive) cutting oil, etc.
• Running a tool too slow will only decrease productivity; however, running a tool too fast with
regard to speed or feed rate will result in accelerated tool wear or outright failure. So always err on
the side of running too slow in a laboratory environment.

Example: Calculate the speed and feed for a ¼″ HSS drill bit in soft cast iron on a manual milling
machine in the lab.
First, lookup the recommended surface speed (peripheral velocity) in Table 1:

V ≈ 100 ft/min

Next, calculate the spindle speed from Equation 2:

N [rpm] = 12 × V / (π × D)
= 12 in/ft × 100 ft/min / (π × 0.25 in/rev)
≈ 1500 rpm (ans)
Now calculate the feed rate used for plunging in the Z axis:
From Table 2, lookup the recommended feed per revolution for a 1/4″ HSS drill bit:
fr ≈ 0.004 in/rev Finally, calculate the plunge feed rate using Equation 3:

f [in/min] = N [rpm] × fr [in/rev]

= 1500 rev/min × 0.004 in/rev
= 6.0 in/min (ans)
Note that these speed and feed values are guidelines assuming adequate (flooded) lubrication,
workpiece stiffness and drill depth less than 3 drill diameters (0.75″). When applying oil manually
(as in the lab), scale the feed and speed back to 60%, so N = 900 rpm and f = 3.6 in/min (final ans).

Equipment and Materials:

REQUIRED MATERIAL:

M.S. Flat of 45 x 45 x 10 mm3.

REQUIRED TOOLS:

 Vernier height gauge

 V-block
 Steel rule
  Dot punch
 Ball peen hammer
 Drill bits of diameters 5 mm, 10 mm & 16 mm

SEQUENCE OF OPERATIONS:

 Checking the raw material

 Marking and sawing
 Marking on the flat
 Drilling
 Grinding the corners
 Surface grinding

Procedure:
1. The surface of the given work piece is the first smoothened by filing.
2. Then chalk is applied on its surface and marking should be done as per
the required dimensions.
3. Cut the four corners of the work piece by using cold chisel.
4. Grind the four corners of the work piece to the required shape by using
bench grinder.
5. Grind the four sides of the work piece.
6. Drilling operation is performed to make different sizes of holes by using
drilling machine.
How to Sharpen Drill Bits, Step-by-Step:
Follow these steps to sharpen drill bits on
your grinding wheel:

1) Hold the drill bit so that the cutting face is

parallel to the grinding wheel surface. The
idea here is to remove only as much metal as
needed to clean up the cutting edge.

2) Slowly bring the bit into contact with the

wheel. Keep the bit as straight as possible,
without rotating it. We aren’t trying to
duplicate the original curvature of the factory
grind. Instead, we’re making a new, flatter cutting face.

3) The heel portion of the cutting face should be ground slightly more than the edge.
This will cause the cutting edge contact the drilled surface first, when in use.

4) When you sharpen drill bits, metal is removed and the steel will begin to heat up.
Dip the bit into water frequently to keep it cool. If it gets too hot to hold in your bare
hand, you’re either grinding too fast or not dipping and cooling often enough.

5) As soon as the cutting edge is sharp, spin the bit half a turn, and begin sharpening
the other cutting face. The more evenly you can grind the two edges, the better the bit
will perform.

6) When you’ve got both edges sharp, check to see if they are the same width. Look at
the drill end-on. The two cutting edges should almost meet to form a point in the
center of the bit diameter. There will be a short line centered between the two. If not,
no problem; just grind a little more on the wider side until the two even up.

Are both edges sharp, the same width, and centered?

Good!
For a quick check, hold the tip of the bit against a piece of scrap wood and simply turn
it slowly by hand (Clockwise, please). A properly sharpened bit will easily begin
making a hole, even with very little pressure.

For a real test, chuck the bit into your drill. Try drilling into a piece of wood pushing
just enough for the bit to “bite”. The bit should bite into the wood without you having
to force it. After drilling an inch or two, pull the bit back out. It should send chips
flying.

Precautions:
1. Follow the general instructions written in the manual.
2. The work piece should be held rigidly in the vise before operating the machine.
3. Before operating the machine see whether the job and tool is firmly secured in devices or not.
4. Optimum machining conditions should be maintained.
5. Do not wear any loose clothing or ties. ...
6. Do not wear gloves, rings, watches, or bracelets while working with a drill press.
7. Do not set speeds, adjust, or measure work until machine is completely stopped.
8. Do not force the drill with extra pressure.
9. Apply cutting fluids to the tool and work piece properly

WORKSHEET

USING DRILL TO MAKE HOLE OF GIVEN SHAPE

Name:_____________________ Reg. No:________________
Date:_____________________ Marks:_________________
Group:_______________
Observations and Calculations:
EQUIPMENT & MATERIALS USED

Equipment Material Dia of Drill bit Rpm Feed

1. Draw the sketch of component to be made with dimensions.

2. Make a process layout. (Steps to be performed)

Results/Conclusion

Applications: