Centring, Drilling and Counterboring / Countersinking − Course:

Techniques for Machining of Material. Instruction Examples for

Practical Vocational Training
 Table of Contents
Centring, Drilling and Counterboring / Countersinking − Course: Techniques for Machining of
Material. Instruction Examples for Practical Vocational Training................................................................1
Preface...................................................................................................................................................1
Instruction example 3.1.: Shaft...............................................................................................................1
Instruction example 3.2.: Die plate.........................................................................................................3
Instruction example 3.3.: Adapter...........................................................................................................5
Instruction example 3.4.: Draw−in bush.................................................................................................7

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Centring, Drilling and Counterboring / Countersinking − Course:
Techniques for Machining of Material. Instruction Examples for
Practical Vocational Training
Institut für berufliche Entwicklung e. V.
Berlin

Original title:

Lehrbeispiele für die berufspraktische Ausbildung "Zentrieren, Bohren und Senken"

Author: Detlev Krechlok

First edition © IBE

Institut für berufliche Entwicklung e.V.

Parkstraße23
13187 Berlin

Order No.: 90−33−3203/2

Preface

The present booklet contains 4 selected instruction examples which are intended to help practising and
consolidating knowledge and skills acquired in the working techniques "centring, drilling,
counterboring/countersinking".

In order to facilitate the preparation and execution of the work, the necessary materials, cutting and operating
tools, measuring and testing tools and accessories are stated for each training example.

For the instruction examples 1 and 3 the steel is specified according to the value of its tensile strength in the
unit "Megapascal" (MPa).

We also recommend knowledge required in addition to knowledge of centring, drilling,

counterboring/countersinking which should be repeated before starting with the work. The specified sequence
of operations gives the steps necessary for the production of the parts. This sequence of operations should be
strictly observed if good quality is to be achieved, For each instruction example a working drawing is attached
showing the required shapes and dimensions of the workpiece. The admissible deviations for sizes with no
indication of tole−rances may be taken from the table below.

Nominal size Admissible deviation in mm

0.5 − 6 ± 0.1

6 − 30 ± 0.2

30 − 120 ± 0.3

120 − 315 ± 0.5

The admissible surface roughness Rz is specified in µm (0.001 mm).

Instruction example 3.1.: Shaft

This example serves to practise centring with the centre drill on rotationally symmetrical parts held in a chuck.

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Material

GGL − 25 (GG = cast iron, L = flakes, GGL = grey cast iron, 25 = 250 MPa tensile strength)

Dimensions

dia. 60×250

Cutting and operating tools

Centre drill B 3.15; key

Measuring and testing tools

Vernier caliper

Accessories

Drill chuck, hard chuck jaws

Required previous knowledge

Reading of drawings, measuring and testing, scribing and prick−punching

Explanations to the working drawing

B 3.15: B = centre hole type B

3.15 = nominal size of the centre drill (d)

Surface finish: unmachined Rz 80, centre hole Rz 20

Sequence of operations Remarks

1. Dimensional inspection

2. Clamping of workpiece Type of clamping: "chucking" in hard chuck jaws. Clamp short. Consider
spindle capacity. For longer parts use spindle support.

3. Clamping of tool Chuck centre drill in drill chuck. If necessary, have drill chuck held in tailstock
spindle using taper sleeves.

4. Setting of cutting values Select speed rate as high as possible. Feed manually.

5. Positioning of tailstock Move tailstock in working position and lock it.

6. Switching on lathe

7. Tool to take first cut Ensure that tool is in central position when taking first cut. Adjust tailstock, if
necessary.

8. Centring Finish centring. Consider size specified.

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9. Returning of tool carrier Leave sufficient space for unloading.
(tailstock)

10. Switch off machine

11. Measuring

12. Re−chucking Turn part by 180° around its longitudinal axis and clamp it short.
For machining of the second side repeat operations 5. to 11. Operation 7. is not necessary since central
position of the centring tool has already been aligned.

Instruction example 3.2.: Die plate

This example serves to practise centring with the turning tool on rotationally symmetrical parts held in a chuck

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Material

100 Cr 6 (100 = 1 % carbon; Cr 6 = 1.5 % chromium)

Dimensions

dia. 32×47

Cutting and operating tools

Inside turning tool for corner work, key

Measuring and testing tools

Vernier caliper, dial gauge, protractor

Accessories

Stepped chuck jaws which can be turned out, supporting plates, coolant, Vee (for round cross section of
turning tool shaft)

Required previous knowledge

Reading of drawings, measuring and testing, scribing and prick−punching

Explanations to the working drawing

↑(0.04) = admissible true−running error of 0.04 mm not to be exceeded.

Surface finish: finished Rz 20

Sequence of operations Remarks

1. Dimensional inspection

2. Clamping of workpiece Type of clamping: "chucking" in stepped chuck jaws which can be turned out.
Chuck on dia. 30, measure on dia. 20, maintain admissible deviation. Check
for true running. If necessary, turn out chuck jaws. Interrupted cut! Wear safety
goggles I

3. Clamping of tool Clamp short. See to necessary clearance angle. Swivel top slide by 30
degrees.

4. Setting of cutting values

5. Tool to take first cut Set end stop. Let tool take first cut at interedge between end face and surface
of hole by means of top slide adjustment.

6. Centring Adjust cross slide to the left. Manually finish−turn centre hole by top slide
adjustment. Use coolant for tools without carbide tips.

7. Dimensional and surface

inspection

8. Unloading

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Instruction example 3.3.: Adapter

This example serves to practise drilling with the drill and boring with the boring tool on rotationally symmetrical
parts held in a chuck.

Material

St 60−2 (St = steel, 60 = 600 MPa tensile strength, 2 = grade)

Dimensions

dia. 55×70

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Cutting and operating tools

Drill dia. 20. internal roughing tool, centre drill A 3.15, right−hand side−cutting tool, key.

Measuring and testing tools

Vernier caliper, depth gauge, dial gauge

Accessories

Drill chuck, taper sleeves, supporting plates, coolant, block gauge 25 mm, chuck jaws which can be turned out

Required previous knowledge

Reading of drawings, measuring and testing, scribing and prick−punching, drilling and
counterboring/countersinking

Explanations to the working drawing

ø 32−0.1 means:

toleranced size −

upper deviation 32.00

lower deviation 31.90

Surface finish: finished Rz 20

Sequence of Remarks
operations

1. Dimensional
inspection

2. Clamping of Type of clamping: "chucking" in chuck jaws which can be turned out. Clamp short.
workpiece

3. Centring

4. Longitudinal Set live centre.

turning and facing

5. Clamping of tool Drill to be held in tailstock. Ensure firm fit of taper.

Clamp short considering blind hole length. (Use vee, if necessary).

6. Drilling ø 20 Drill through hole dia. 20 by manual adjustment of tail−stock sleeve. Use sleeve
scale.

7. Boring ø 32−0.1 Make sure the drill edge is sufficiently cooled. Set end stop. Insert block gauge 25
mm. Tool nose to take first cut on transition between end face and inner surface of
the workpiece. Remove block gauge. Set feed
Finish−bore ø 32−0.1
Utilize "0" position of cross−slide.

8. Deburring Use primary cutting edge.

9. Re−chucking

10. Facing to 60 mm
length

11. Deburring Thoroughly deburr inner and outer edges.

For batch production repeat sequence of operations until operation 3, re−chuck, centre and continue with
operation 4. Operation 8 is then deleted (earlier operation).

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Instruction example 3.4.: Draw−in bush

This example serves to practise countersinking with the counter−sink and turning tool (boring tool) of hollow
cylindrical parts.

Material

15 Cr 6 (15 = 0.15 % carbon. Cr 6 = 1.5 % chromium) case−hardening steel

Dimensions

dia. 52×82

(pre−machined dia. 50×80, hole dia. 20)

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Cutting and operating tools

Countersink 60°, inside turning (boring) tool for corner work, chuck key

Measuring and testing tools

Depth gauge, protractor, dial gauge

Accessories

Chuck jaws which can be turned out, taper sleeves, supporting plates, coolant

Required previous knowledge

Reading of drawings, measuring and testing, scribing and prick−punching, drilling and
counterboring/countersinking

Explanations to the working drawing

ø 20 H 7: ø − diameter, 20 − nominal size,

H − disposition of the tolerance

zone

7 − quality
↑0.02 − admissible true−running error 0.02 mm surface: finished Rz 20, Rz 6.3 fine−finished.

Sequence of operations Remarks

1. Dimensional inspection

2. Clamping of workpiece Type of clamping: "chucking" in stepped chuck jaws which can be turned
out. Chuck on dia. 50 (surface and end face pre−machined as per sketch
1). Check for true running (Turn out chuck jaws, if necessary).

3. Clamping of tool Locate tool in tailstock.

Ensure firm fit of taper.

4. Countersinking 2×60° Countersink 2×60° by means of manual sleeve adjustment. Select low
cutting speed.
Use coolant. Use sleeve scale. Visual inspection of size and surface finish.

5. Re−chucking Type of clamping: "Chucking". Check for true running (radial and axial
runout).

6. Clamping of tool Clamp inside turning tool short on top slide. Ensure clearance angle.
Swivel top slide by 45°.

7. Countersinking 10×45°
Set end stop. Take first cut on transition between inner surface and end
face. Set cross slide to "0". Set feed. Finish turning with several chips by
means of manual top slide adjustment. Use coolant for turning tool without
carbide tip.
Visual inspection of surface finish.

8. Dimensional and surface

inspection.

9. Unloading.

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