Production Technologies and

Automation Engineering
TEL12S Spring 2014, Juha Sipilä
Production Technologies…
Forming and Shaping Process and Equipment

Drilling

Juha Sipilä
Production Technologies…
Forming and Shaping Process and Equipment

Drilling

http://www.youtube.com/watch?v=om6GQKfoS1g

Juha Sipilä
Production Technologies…
Drilling
Main parts of a drill (Kalpakjian et al 2010, p. 643)

Explanations also later in this

presentation….

Juha Sipilä
Production Technologies…
Drilling
Various types of drills and drilling and reaming operations (Kalpakjian et al .2010, p. 645)

Juha Sipilä
Production Technologies…
Drilling

General Capabilities of Drilling and Boring Operations

Cutting tool Diameter range Hole depth/diameter
(mm) Typical Maximum
Twist drill 0,5 … 150 8 50

Spade drill 25 … 150 30 100

Gun drill 2 … 50 100 300

Trepanning tool 40 … 250 10 100

Boring tool 3 … 1200 5 8

Juha Sipilä
Production Technologies…
Drilling, drill types
• The conventional standard-point twist drill is the most common drill
• The geometry of the drill is such that the normal rake angle
(leikkuukulma) and velocity of the cutting edge vary with the distance
from the center of the drill.
• Main features
• Point angle 118o … 135o
• Lip-relief angle 7o … 15o
• Chisel edge angle 125o … 135o
• Helix angle 15o … 30o
• The various angles are available for minimizing drilling forces and torque
and optimizing drill life
• Two spiral grooves (flutes) run the length of the drill  the chips are
guided upward through these grooves
• The grooves enables also the cutting fluid to reach the cutting edges
• Drills also available with chip-breaker feature (important with automated
machinery)
Juha Sipilä
Production Technologies…
Drilling, drill types

• A step drill produces holes with two or more different diameters

• A core drill is used to make an existing hole larger
• Counterboring and countersinking drills produce depression on the
surface to accommodate the heads of screws and bolts below the
workpiece surface
• A center drill is short and it is used to produce a hole at the end of a piece
of stock
• Used so, that the workingpiece may be mounted between centers of the
headstock and the tailstock of a lathe (turning machine)

Juha Sipilä
Production Technologies…
Drilling, drill types

• A spot drill is used to start a hole at the desired location on a surface (a

conventional drill is “wandering” or “walking” without a starting hole)
• A spade drill has removable or brazed (kovajuotos) tips or bits
• Used to produce large-diameter or deep holes
• Higher stiffness (jäykkyys)
• Rather cost effective

Various types of drills

(Kalpakjian et al .2010, p. 645)

Carbide inserts

Juha Sipilä
Production Technologies…
Drlling parameters (Kalpakjian et al 2010, p. 649)

General Recommendations for Spees and Feede is Drilling

Workpiece Surface speed Drill diameter
material (m/min)
Feed, mm/rev Speed, rpm
1,5 mm 12,5 mm 1,5 mm 12,5 mm
Aluminium alloys 30 … 120 0,025 0,30 6400 … 25 000 800 … 3 000

Magnesium alloys 45 … 120 0,025 0,30 9 600 … 25 000 1 100 … 3 000

Copper alloys 15 … 60 0,025 0,25 3 200 … 12 000 400 … 1 500

Steels 20 … 30 0,025 0,30 4 300 … 6 400 500 … 800

Cont.

Juha Sipilä
Production Technologies…
Drlling parameters (Kalpakjian et al 2010, p. 649)

General Recommendations for Spees and Feede is Drilling

Workpiece Surface speed Drill diameter
material (m/min)
Feed, mm/rev Speed, rpm
1,5 mm 12,5 mm 1,5 mm 12,5 mm
Stainless steels 10 … 20 0,025 0,18 2 100 … 4 300 250 … 500

Tianium alloys 6 … 20 0,010 0,15 1 300 … 4 300 150 … 500

Cast irons 20 … 60 0,025 0,30 4 300 … 12 000 500 … 1 500

Thermoplastics 30 … 60 0,025 0,13 6 400 … 12 000 800 … 1 500

Thermosets 20 … 60 0,025 0,10 4 300 … 12 000 500 … 1 500

Note: As hole depth increases, speeds and feeds should be reduced, selection depends on surface finish
required

Juha Sipilä
Production Technologies…
Drlling parameters

• Material-removal Rate in Drilling (MRR)

• MRR = (π D2/4) f N
where
D = diameter of drill
N = rotational speed of the drill (N = V / π D)
f = feed (the distance the drill penetrates per unit revolution)

MRR unit is (mm2)(mm/rev)(rev/min) = mm3/min

Example Excel

(Kalpakjian et al 2010, p. 648…649)

Juha Sipilä
Production Technologies…
Drilling…

• The speed in Table is surface speed of the drill and its periphery (kehä).

• Thus, an example

• Φ 12,7 mm drill
• Rotation speed 300 rpm

• Has a surface speed of

V = (12,7/2 mm) (300 rev/min) (2 π rad/rev)(1/1000 m/mm) = 12 m/min

Juha Sipilä
Production Technologies…
Drilling, recommendations

Drill conditioning
• Grinding either manually or with special fixtures
• Manual is difficult and requires skill (experience)
• Computer-controlled grinders are available
• Coated drills can be recoated

• See http://www.sawcenter.fi/fi/huolto/jth

Measuring drill life

• Usually measured by the number of holes drilled
• Monitoring vibration
• Acoustic emission (voice lever gets higher)

Juha Sipilä