DRILLING

Drilling machine is one of the simplest machine tools used to produce holes in
solid objects. The process of making holes is termed as drilling. In drilling, work
is clamped to the table and the rotating cutting tool, called drill is fed into it.
TYPES OF DRILLING MACHINES :
They are broadly divided into the following groups.
1. Portable drilling machine
2. Sensitive drilling machine
(a) Bench mounting
(b) Floor mounting
3. Radial drilling machine
4. Upright drilling machine
(a) Round column section
(b) Box column section
5. Gang drilling
6. Multi-spindle drilling
7. Deep hole drilling machine
8. Automatic drilling machine
SENSITIVE DRILLING MACHINE:

It is a small drilling machine in which feed is hand operated, and the cutting
force applied is determined by sense or feel of the operator.
The parts are as follows
1.Base(Bed):
The base is made up of Cast Iron which has the capability of high compressive
strength, good wear resistance and good absorbing capability(i.e. absorb the
vibrations induced during working condition) and for these reasons, it acts as a
base to the drilling machine.

2.Column: It is exactly placed at the centre of the base which can act as a
support for rotating the Swivel table and holding the power transmission
system.
3.Swivel Table: It is attached to the column which can hold the machine vice in
the grips and thereby, the workpiece is fixed in the machine vice to carry out the
drilling operation.
The Swivel table can move up and down by means of rotational motion and can
be locked to the column by means of locking nut.

4.Power Transmission system:

It consists of motor, stepped pulley, V-belt and the Spindle. The power
transmission is explained in the working of the drilling machine.
5.Hand wheel:
By the rotation of hand-wheel, the spindle moves up and down in the vertical
direction in order to give the necessary amount of feed to the work.
Here, the rotational motion is converted into linear motion by means of a Rack
and Pinion mechanism which was explained below.

6.Chuck: It is used to hold the drill bit.

Working principle :
The work is mounted on the work table which may be raised or lowered by the
clamp to accommodate work pieces of different sizes.
The drive mechanism of sensitive drilling machine consists of V-belt drive from
machine spindle to drill spindle. Three or four stepped cone pulley is provided
to give a required speed range.
The spindle is designed and mounted in a sleeve such that the spindle rotates
and simultaneously move up and down to provide feed for drill. This is achieved
by a rack and pinion mechanism. It is provided with a separate motor which
drives the drill spindle.
Sensitive drilling machines are widely used for drilling, reaming, boring,
counter-boring and other similar operations.
SENSITIVE DRILLING MACHINE
Rack and pinion mechanism
Radial Drilling Machine :

➢Radial drilling machines are used for drilling heavy work, and specially for the
jobs where high degree of accuracy is required.

➢The arrangement of its parts is such that the spindle with the drill can easily
be moved to any point along the ways of arms swivelling the arm about
column. This feature enables the spindle to be positioned at any point above
the surface of the table.

➢A wide range of spindle speeds, together with automatic feed of the spindle,
makes the radial drilling machine suitable for large casting sand forgings.
Principals parts are :

1. Base

2. Column

3. Radial arm

4. Drill head

5. Spindle speed and feed mechanism.

Radial Drilling Machine
1. Base: It is a large rectangular casting and is made rigid to support column
and table. In certain cases, T-slots are provided on top surface for clamping the
work directly so that it will serve the function of table.

2. Column: It is a cylindrical casting mounted vertically to the base. It supports

radial arm which can slide vertically up and down.

3. Radial arm : Radial arm is mounted horizontally on column. It is provided

with accurate guideways on which drill head slides. The radial arm slides up
and down, and also swing around the column.
4. Drill head : It is mounted on the radial arm. It may be slide along the arm to
locate the drill spindle with respect to work. After proper adjustment of spindle
the drill head is locked on radial arm. It is provided with mechanism to drive the
drill at required speeds and feeds.

5. Spindle speed (drive) and feed mechanism : The drill spindle is driven by a
motor fitted directly over the drill head. Through the gear box multiple speeds
and feeds of the spindle can be obtained.
TOOL HOLDING DEVICES:
The following devices are used for holding the drills.

1. Drill chuck

2. Drilling machine spindle

3. Sleeve

4. Socket
1. Drill chuck : is designed to hold straight shank drills of different sizes. The jaws of
the chuck are tightened around the drill by means of drill chuck key. The drill
chucks have standard taper shanks which are fitted into the tapered hole of the
drill spindle.

Drill chuck
2. Drilling machine spindles have morse taper holes. Standard taper shank drills
are directly fitted in the spindle. The drill may be removed by driving the drift.

Drilling machine spindles

3. Sleeve is used to hold the taper shank drills whose taper is less than taper
hole of the spindle. The outside taper of the sleeve matches with spindle hole
taper.

4. Socket is used for the drills whose taper is larger than spindle hole taper. It is
much longer than sleeve. Its taper shank conforms to the spindle hole taper and
fits into it.

Sleeve Socket
TWIST DRILL NOMENCLATURE :
Drill nomenclature comprises the various parts and important geometric
parameters of cutting point.

Shank : The shank is the part of drill which is held in machine spindle and driven
by it.

Tang : Flattened end of a shank, intended to fit into a slot in the drill holder.

Neck : Reduced portion between body and shank.

Body : The fluted portion of a drill.

Flutes : Helical grooves formed in the body of drill.

Web: The central portion of the body which separates the flutes and runs
through entire length of drill.

lip or Cutting edge : The edge formed by intersection of flank and face, and
correspond to the cutting edge of a single point tool.

Land: The cylindrical ground surfaces on the leading edges of drill flutes.

Body Clearance : The portion of the body which is reduced in diameter to give
diametric clearance .
Margin : Narrow surface along the groove which keeps the drill aligned.

Heel : The edges formed by the intersection of flute surface and body clearance.

Chisel angle : The included angle between the chisel edge and the cutting lip.

Helix angle : The angle between the drill axis and the leading edge of the land.

Point angle : The angle formed by the cutting edges at the point (cone shaped
surface at the cutting end).

Rake angle : The angle between the face and line parallel to the drill axis and is
equal to helix angle at drill periphery.
Face : The portion of the flute surface adjacent to the lip on which the chip
impinges as it is cut from the work.

Flank : The surface on the drill point which extends behind the lip to the
following flute.
DRILL MATERIALS:

1. High carbon steel (tool steel) are used for slow speed drilling operation. The
amount of heat generated must be dissipated quickly, because overheating
causes the drill to soften and lose its cutting edges.

2. High speed steel drills can be used at high cutting speed. They retain cutting
edges at high speed and high temperature up to 600°C. Such drill, are used for
drilling ferrous, non-ferrous metals and other hard materials The addition of
cobalt to HSS produces excellent properties and are used for drilling tough
castings and forgings, Armor plates. Such drills may be operated at high
temperature than HSS drill.

3. Tungsten carbide drills are used for drilling abrasive materials. These drills are
sharpened on special grinding wheel (silicon carbide or diamond impregnated
wheels).
DRILLING MACHINE OPERATIONS :
The following operations are generally performed on drilling machine.

1. Drilling 5.Counter sinking

2. Reaming 6.Tapping

3. Boring 7.Spot-facing

4. Counter boring . 8.Trepanning

1. Drilling :
Drilling is the process of making a cylindrical hole by rotation of cutting tool,
called drill. Before drilling, the hole location should be marked out and centre
punched. This helps the drill to start at correct location.
2. Reaming :
Reaming is the process of making a hole smoothly and accurately to size. To
finish the hole to required size, it should be drilled under size and then reamer is
used. Material allowance left in the hole for hand reaming is usually 0.05 mm to
0.1 mm, and for machine reaming it ranges from 0.13 mm to 0.65 mm
3. Boring :
Boring is the operation of enlarging the hole by using single point cutting tool.
This makes the hole to size with good finish. Boring can only be performed on an
existing hole
4. Counter boring:
It is the operation of enlarging the hole for part of depth with cutting tool
called counter borer. This process is quite often used in order that the heads of
the bolts or screws can lay flush with the face of the job.
5. Counter sinking :
It is the operation of forming chamfers at the edge of a hole with counter
sinking tool. These are made with included angles of either 60° or 90°.
6. Spot-facing :
Spot-facing is the process of machining the surface around a hole. As a result of
this operation, the surface around the hole is trued up so that a flat circular
seating, at right angles existing hole, is provided for bolt heads.
7. Trepanning :
Trepanning is the operation of producing large holes by specially designed tool.
The tool has cutting edges at one end and a solid shank at the other end to fit
into the drill spindle. It is rotated in a drilling machine to cut out large holes
from solid metal by cutting a narrow groove along the circumference.
8. Tapping :
Tapping is the operation of cutting internal threads by using a cutting tool called
tap. The tap can fed into the hole by feed lever, and the cutting edges of tap
removes the metal to form internal threads.
 WORK HOLDING DEVICES :
For drilling, it is necessary to setup the work correctly and secure it rigidly to
work table.
The following devices are used for holding the work in a drilling machine.
1. Drill vices
2. Parallel bars
3. Step blocks
4. Angle plates
5. V-blocks
6. Clamps and T-bolts
7. Drill jigs.
Drill vice : A drill vice is a work holding device in which the workpiece is held
securely while drilling and other operations are performed. Before drilling, work
is aligned under the drill, and vice is securely fastened to the table by means of
T-bolts.
Parallel bars : Parallel bars are accurately machined and are used to raise the
workpiece so that the drilling may be carried without damaging the vice or
machine table. It also set the workpiece square and parallel with the base of the
vice.
Step blocks : Step block is used along with clamps and bolts. It provides support
for other end of clamp.
Clamps and T-bolts are used for clamping the work to the table to avoid
inaccuracy of work and also to avoid accidents. Clamps should always be
arranged to grip as near as possible to the drilling and free end of each clamp
should be packed.
Angle plate :
It has two faces with slots and holes so that work maybe securely attached to one
of its faces.
V-Block :
V-Block with U-clamp is used to hold round jobs.
Drill jig :
A drill jig locates the work piece in proper position and holds it securely. It also
guide the drill so that holes drilled on all the parts are in the same exact location.
These are employed for mass production.
CUTTING SPEED : it is defined as the peripheral speed of a drill surface which is
in contact with the work. It is expressed in meters/min.
If 'd' is the diameter of drill in mm
N speed of drill spindle in RPM,
then the cutting speed is given by the equation,
Cutting speed = (πdN/1000) m/min.
Feed : The feed of a drill is the distance that the drill enters the work per each
revolution of the drill spindle (drill). It is expressed in millimetres per revolution.

Depth of cut : It is the total amount of metal removed per pass of

the cutting tool. It is expressed in mm. Half the diameter of drill is the depth
of cut in drilling.