DRILLING MACHINE

Drilling
Drilling is easily the most common machining
process. One estimate is that 75% of all metal-cutting
material removed comes from drilling operations.
Drilling involves the creation of holes that are right
circular cylinders. This is accomplished most typically
by using a twist drill, something most readers will
have seen before.
The chips must exit through the flutes to the
outside of the tool.
As can be seen in the figure, the cutting front
is embedded within the work piece, making
cooling difficult.
The cutting area can be flooded, coolant spray
mist can be applied, or coolant can be
delivered through the drill bit shaft.
The majority of drilling work is carried out on
pillar drilling machines, so called because the
machine elements are arranged on a vertical
pillar.
The machines in the heavy-duty range have
power feed, are driven from the motor through
a gearbox, and have a drilling capacity in steel
up to 50 mm diameter.
Smaller sensitive machines, have a hand
feed, giving the sensitivity, are belt driven
from the motor through pulleys, and have
a maximum drilling capacity in steel
ranging from 5mm up to 25mm diameter.
These machines may be bench- or floor-
mounted.
Drilling operation
This is the operation of making a circular hole
by removing a volume of metal from the job by
a rotating cutting tool called drill as shown .
Drilling removes solid metal from the job to
produce a circular hole.
Before drilling, the hole is located by drawing
two lines at right angle and a center punch is
used to make an indentation for the drill point
at the center to help the drill in getting started.
A suitable drill is held in the drill machine and
the drill machine is adjusted to operate at the
correct cutting speed.
The drill machine is started and the drill starts
rotating. Cutting fluid is made to flow liberally
and the cut is started.
The rotating drill is made to feed into the job.
The hole, depending upon its length, may be
drilled in one or more steps. After the drilling
operation is complete, the drill is removed from
the hole and the power is turned off.
The Sensitive Drilling
Machine
1.Base – provides a solid foundation
for the machine, into which the pillar
is securely clamped.
2.Pillar – provides a solid support for
the drill head and worktable.
3.Worktable – provides a flat surface
in correct alignment with the drill
spindle upon which the work piece
can be positioned. Tee slots are
provided for clamping purposes. The
worktable can be raised, lowered and
swung about the pillar and be
securely clamped in the required
position.
4.Motor – provides the drive to
the spindle through a five-step
pulley system and a two-speed
gearbox.
5.Handwheel – provides feed to
the drill by means of a rack and
pinion on the quill.
6.Quill – this is the housing
inside which the spindle rotates.
Only the longitudinal movement
is transmitted by the quill, which
itself does not rotate.
7.Spindle – provides the means of
locating, holding and driving the
cutting tools and obtains its drive
through the pulley.
8.Depth stop – provides a means of
drilling a number of holes to a
constant depth.
9.Stop/start – the machine shown is
switched on by a shrouded
pushbutton starter with a cover plate
which can be padlocked to prevent
unauthorized access. A mushroom-
headed stop button is situated on the
starter, and the machine can also be
switched off using the emergency
kick-stop switch at the front of the
base.
10. Drill guard – provided to
protect the operator from
contact with the revolving chuck
and drill while still retaining
visibility of the operation.
These guards range from simple
acrylic shields to a fully
telescopic metal construction
with acrylic windows. A typical
pedestal drill guard is shown.
DRIIL BIT
 Tool holding
 Drills and similar tools with
parallel shanks are held in a drill
chuck, Many different types of
chuck are available, each being
adjustable over its complete
range, and give good gripping
power.
Safety chuck key
 By rotating the outer sleeve, the
jaws can be opened and closed.
To ensure maximum grip, the
chuck should be tightened using
the correct size of chuck key.
 This prevents the drill from
spinning during use and chewing
Drill chuck up the drill shank.
Clamping
 Work is held on a drilling
machine by clamping to the
worktable, in a vice or, in the
case of production work, in a
jig.
 It is sufficient to say here that
work held in a jig will be
accurately drilled more
quickly than by the other
methods, but large quantities
of the work piece must be
required to justify the
additional cost of the
equipment.
 Cutting tools on drilling
machines
Various cutting tools besides twist drills are used on a
drilling machine, and some of them are described below.

1. Twist drill
Twist drills are available with parallel shanks up to
16mm diameter band with taper shanks up to 100 mm
diameter and are made from high-speed steel.
Standard lengths are known as jobber-series twist drills,
short drills are known as stub series, and long drills as
long series and extra long series. Different helix angles
are available for drilling a range of materials.
 The nomenclature of the twist
drill is shown. The helix angle of
the twist drill is the equivalent of
the rake angle on other cutting
tools and is established during
manufacture.
 The standard helix angle is 30°,
which, together with a point
angle of 118°, is suitable for
drilling steel and cast iron.
 Drills with a helix angle of 20° –
known as slow-helix drills – are
available with a point angle of
118° for cutting brass and
bronze, and with a point angle of
90° for cutting plastics materials.
 Quick-helix drills, with a helix
angle of 40° and a point angle of
100°, are suitable for drilling the
softer materials such as
aluminium alloys and copper.
 Determination of size drill
Number sizes
In metric system, the drill is generally manufactured
from 0.2 to 100 mm.
In British system the drills sizes range from No. 1 to
No. 80. Number 80 is the smallest having diameter
equal to 0.0135 inch and the number 1 is the largest
having diameter equal to 0.228 inch.
Number 1 to number 60 is the standard sets of drills.
The numbers 61 to 80 sizes drills are not so
commonly used.
The diameter of drills increases in steps of
approximately by 0.002 inch.
Letter sizes
The drill sizes range from A to Z, A being the smallest
having diameter equal to 0.234 inch and Z being the
largest having diameter equal to 0.413 inch, increasing
in steps of approximately O.010 inch fractional sizes:
The drill sizes range from 1/64" inch to 5 inch in steps
of 1/64 inches up to 1.75 inches, then the steps
gradually increase.
The drill sizes range from A to Z, A being the smallest
having diameter equal to 0.234 inch and Z being the
largest having diameter equal to 0.413 inch, increasing
in steps of approximately O.010 inch fractional sizes:
The drill sizes range from 1/64" inch to 5 inch in steps
of 1/64 inches up to 1.75 inches, then the steps
gradually increase.
 Cutting speed
The cutting speed in a drilling operation refers to the
peripheral speed of a point on the surface of the drill in
contact with the work. It is usually expressed in meters/min.
The cutting speed (Cs) may be calculated as:

Cs = ((22/7) × D × N)/1000

Where, D is the diameter of the drill in mm and

N is the rpm of the drill spindle.
 Feed
The feed of a drill is the distance the drill moves into the job
at each revolution of the spindle.
It is expressed in millimeter. The feed may also be expressed
as feed per minute.
The feed per minute may be defined as the axial distance
moved by the drill into the work per minute. The feed per
minute may be calculated as:

F = Fr × N

Where, F = Feed per minute in mm.

Fr = Feed per revolution in mm.
N = R.P.M. of the drill.
 Cutting fluids
During metal cutting, the metal immediately ahead
of the cutting tool is severely compressed, which
results in heat being generated.
The metal then slides along the tool face, friction
between the two surfaces generating additional
heat. Any rubbing between the tool and the cut
surface, which would occur with tool wear when
the clearance angle is reduced, also produces heat.
This heat is usually detrimental, especially to high-
speed-steel cutting tools. Some metals, as they are cut,
have a tendency to produce a chip which sticks or
welds to the tool face, due chiefly to the high pressure
between the metal and the tool.
This has the effect of increasing the power required for
cutting, increasing the friction and therefore heat, and
finally, as the chip breaks away from the tool face and
reforms, it creates wear on the tool face and a bad
surface finish on the work.
Excessive heat generated during the cutting may be
sufficient to cause the work to expand. Work measured
under these conditions may be undersize when it
cools.
To benefit from the advantages of each, they can be
mixed together with various additives to give a
required measure of cooling and lubrication.
With the high cost of oil, the cost of savings of water-
based fluids are so great that a great deal of
development is being carried out to provide fluids
which have good lubricating properties when mixed
with water.
In general, the use of cutting fluids can result in
• less wear on cutting tools,
• the use of higher cutting speeds and feeds,
• improved surface finish,
 • reduced power consumption,
• improved control of dimensional accuracy.

The ideal cutting fluid, in achieving the above,

should
• not corrode the work or machine,
• have a low evaporation rate,
• be stable and not foam or fume,
• not injure or irritate the operator.
 Types of cutting fluid
1. Neat cutting oils
 These oils are neat in so much as they are not mixed
with water for the cutting operation. They are
usually a blend of a number of different types of
mineral oil, together with additives for extreme-
pressure applications.
 Neat cutting oils are used where severe cutting
conditions exist, usually when slow speeds and
feeds are used or with extremely tough and
difficult-to-machine steels.
 These conditions require lubrication beyond that
which can be achieved with soluble oils.
2. Soluble oils
 Water is the cheapest cooling medium, but it is
unsuitable by itself, mainly because it rusts ferrous
metals.
 In soluble oils, or more correctly emulsifiable oils, the
excellent cooling property of water is combined with
the lubricating and protective qualities of mineral oil.
 Oil is, of course, not soluble in water, but with the aid
of an agent known as an emulsifier it can be broken
down and dispersed as fine particles throughout the
water to form an emulsion.
 These are often referred to as ‘suds’ or coolant.
3. Synthetic fluids
 Sometimes called chemical solutions, these fluids
contain no oil but are a mixture of chemicals
dissolved in water to give lubricating and
anticorrosion properties.
 They form a clear transparent solution with water,
and are sometimes artificially coloured.
 They are very useful in grinding operations, where,
being non-oily, they minimize clogging of the grinding
wheel and are used at dilutions up to 1 in 80.
 As they are transparent, the operator can see the
work, which is also important during grinding
operations.
4. Semi-synthetic fluids

 Unlike synthetic fluids, these fluids, sometimes

referred to as chemical emulsions, do have a small
amount of oil emulsified in water.
 When mixed with water they form extremely stable
transparent fluids, with the oil in very small droplets.
 Like the synthetic types, they are often artificially
coloured for easy recognition.
5. Vegetable oils
 This range of oils are based on specially refined
vegetable oils and are used for light and medium duty
turning, milling, honing, lapping and high-speed
grinding operations on a wide range of materials.
 Being oil, it is a natural lubricant which contributes to
a good tool life and improved surface finish of the
machined work piece.
 It is claimed to produce lower mist levels than the
mineral cutting oils and does not stain yellow metals,
e.g. brass.
 The product is non-toxic and is biodegradable making
it environmentally friendly.
 STANDARD OPERATING
PROCEDURE
1. S.O.P DRILLING MACHINE
2. VIDEO DRILLING MACHINE