MKSSS’s

Cummins College of Engineering for Women, Pune

Department of Mechanical Engineering

Second Year of Engineering

Subject Name: Manufacturing Processes – I

Subject Code : ME 2103

Subject Teacher : Prof. Vishwanath Mali

Contact : vishwanath.mali@cumminscollege.in
 A
Presentation
On

UNIT IV

Drilling Machines
by

Prof. V. A. Mali
Department of Mechanical Engineering
Syllabus
• Introduction, types of drilling machines.

• Drilling and allied operation: drilling, reaming, tapping,

countersinking, counterboring, spot facing, deep hole drilling.

• Alignment tests of drilling machine.

• Boring machine: purpose and applications, horizontal boring

machines, precision boring machines
Introduction
• Drilling, is a machining operation used to create a round hole in a work part.
• This contrasts with boring, which can only be used to enlarge an existing hole.
• Most drilling operations are performed using a rotating cylindrical tool that has two cutting edges on its
working end.
• The tool is called a drill or drill bit, the most common form of which is the twist drill.
• The rotating drill feeds into the stationary work part to form a hole whose diameter is equal to the drill
diameter.
Types of Drilling Machines
1. Portable drilling machine
2. Sensitive drilling machine
3. Upright drilling machine
4. Radial drilling machine
5. Gang drilling machine
6. Multiple Spindle drilling machine
7. Automatic drilling machine
8. Deep Hole drilling machine
Portable drilling machine
• Can be operated with ease any where in the workshop.

• Used for drilling holes in workpieces in any position which can not be
drilled by standard drilling machines.

• The entire drilling mechanism including the motor is compact and

small in size.
Portable drilling machine

• Some of the portable machines are operated machines are operated by

hand power, but most of the machines are driven by individual motor.

• The motor is usually of universal type (AC and DC)

• The maximum size of the drill that it can accommodate is not more than 12
to 18 mm.

• The machines operated at high speed as smaller size drills are only used.
Sensitive drilling machine
• The sensitive drilling machine is a small machine designed for drilling
a small holes at high speed in light jobs
• Hand feed permits the operator to feel or sense the progress of the
drill into the work.

• So that if the drill becomes worn out or jams, the pressure on the drill
may be released immediately to prevent it from breaking.

• As the operator senses the cutting action at any instant it is called

sensitive drilling machine.

• Capable of rotating the diameter 1.5 to 15.5 mm.

Upright drilling machine
• This machine is designed for handling medium sized workpieces.

• Similar to sensitive drilling machine but this is larger and heavier.

• In an upright drilling machine a large number of spindle speeds and

feeds are available for drilling different types of work.
Radial drilling machine
• The radial drilling machine is intended for drilling medium to large and
heavy workpieces.

• The column supports the radial arm which can be raised and lowered to
accommodate workpieces of different heights.

• The arm of machine may be swung around to any position over the work
bed.

• The drill head containing mechanism for rotating and feeding the drill is
mounted on a raidial arm and can be moved horizontally.
Gang drilling machine
• When a number of single spindle drilling machine columns are placed
side by side on a common base and have a common worktable, the
machine is known as the gang drilling machine.
• In gang drilling four to six spindles may be mounted side by side.

• Each spindle may be set up properly with different tools for different
operations.

• A series of operations are performed on the work by simply shifting

the work by simply shifting the work from one position to another.

• The speed and feed of the spindles are controlled independently.

• This type of machine is specially adopted for production work.

Multiple Spindle drilling machine
• The function of a multiple spindle drilling machine is to drill a number of
holes in piece work simultaneously.

• To produce the same pattern of holes in a number of identical pieces in a

mass production work.

• Such a machines have several spindles driven by a single motor and fed
simultaneously.

• The spindles are so constructed that their centre distance may be adjusted
to any position as required.
Automatic drilling machine
• It performs a drilling operations automatically with computer numeric
control and transfer the work automatically.
Deep Hole drilling machine
• Special machines and drills are required for drilling deep holes in rifle
barrels, crank shafts, long shafts etc.

• The machine is operated at high speed and low feed.

• A long job is usually supported at several points to prevent any

deflection.
Drilling Machine Operations
1. Drilling
2. Boring
3. Reaming
4. Tapping
5. Countersinking
6. Counterboring
7. Spot Facing
8. Deep Hole Drilling
Drilling
• Drilling is the operation of producing cylindrical hole by removing
metal by the rotating edge of a cutting tool called drill.

• Before drilling the center of the hole is located on the workpiece by

drawing two lines at right angles to each other and then center punch
is used to produce an indentation at the center.
• Drilling does not produce an accurate hole in a workpiece.

• Holes generated by drilling are rough.

• The hole is always oversize than the drill used due to the vibration of
spindle and drill.
Boring
• To enlarge a hole by means of an adjustable cutting tool with only one
cutting edge.

• To finish hole accurately and to bring it to the required size.

• To machine the internal surface of a hole already produced in casting.

• To correct out roundness of hole.

• The cutter is held in a boring bar.
• For perfect finishing of hole, the job is drilled slightly undersize.
• Accuracy is as high as ± 0.00125 mm.
• Slow process than reaming.
• Requires several passes of the tool.
Reaming
• Reaming is an accurate way of sizing and finishing a hole which has
been previously drilled.
• The tool used for reaming is known as the reamer which has multiple
cutting edges.
• Reamer can not originate a hole.

• It simply follows the path which has previously drilled and removes a
very small amount of material.

• The material removed by this process is around 0.375 mm.

Tapping
• Tapping is the operation of producing internal threads by means of a
cutting tool called a tap.
• A tap may be considered as bolt with accurate threads cut on it.

• The threads acts as cutting edges which are hardened.

• When the tap is screwed into the hole it removes metal and cuts
internal threads which will fit into external threads of the same size
Countersinking
• Countersinking is the operation of making a cone-shaped
enlargement of the end of a hole to provide a recess for flat head
screw
• The tool used for countersinking is called a countersink.
• Standard countersinks have 60°, 82° and 90° included angle.
• Cutting edges of the tool are formed at conical surface.
• The cutting speed in countersinking is 25% less than that of drilling.
Counterboring
• Counterboring is the operation of enlarging the end of a hole
cylindrically.
• Enlarged hole forms a square shoulder with the original hole.
• This is necessary is some cases to accommodate the heads of bolts.
• The tool used for counterboring is called counterbore.
• The cutting edges may have straight or spiral teeth.
• The tool is guided by pilot which extends beyond the end of the
cutting edges.
• Counterboring can give an accuracy of about ±0.05 mm.
• The cutting speed in countersinking is 25% less than that of drilling.
Spot Facing
• Spot facing is the operation of smoothing and squaring the surface
around a hole for the seat for a nut or the head of bolt.
• A counterbore or a special facing tool may be employed for this
operation.
Deep Hole Drilling
• A straight-flute drill designed for deep-hole drilling is the gun drill, shown in Figure.
• Twist drill is usually limited to a depth-to-diameter ratio of 4:1, and the straight-flute drill to about 3:1, the
gun drill can cut holes up to 125 times its diameter.
• As shown in the figure, the gun drill has a carbide cutting edge, a single flute for chip removal, and a coolant
hole running its complete length.
• Gun drills range in diameter from 2 mm to about 50 mm.
Alignment tests of drilling machine
• The alignment test for drilling machine is carried out to check the
grade of manufacturing accuracy.

• Flatness of clamping surface of base

• True running of the spindle
• Parallelism of spindle with vertical movement
• Squareness of clamping surface of table to its axis
Flatness of clamping surface of base
• Straight edge is kept of base.

• Feeler gauges gives error.

• Error should not exceed 1 micro.

True running of the spindle
• Test mandrel is placed in the tapered hole of spindle

• Dial indicator is placed on worktable

• Spindle rotated slowly

• Error should not exceed 30 micron.

Parallelism of spindle with vertical movement
• Test is performed into two planes A & B

• Test mandrel and dial indicator are placed

• Spindle is adjusted in the middle position of its travel

• Permissible errors is 30 micron.

Squareness of clamping surface of table to its axis
• Dial indicator is placed in spindle.

• Table is slowly rotated

• Error should not exceed 50 micron.

Boring Machine
• The boring machine is used to bore holes in large and heavy parts
such as engine frames, steam engine cylinders, machine housing etc.,
which are practically impossible to hold and rotate in engine lathe or
drilling machine.
• The primary function of boring machine is to bore a hole.

• Along its primary function and due to the available range of speeds
and feeds, it allows drilling, milling and facing operation to be
performed.

• By fitting of simple attachments, the use of the machine can be

extended still further to include screw cutting, turning, grinding or
gear cutting.
Horizontal boring machine
• In a horizontal machine boring machine. The work is supported on a
table which is stationary and the tool revolves in a horizontal axis
• A horizontal boring machine can perform boring, reaming, turning
facing, milling etc. operations with using suitable tools.

• Workpieces which are heavy, irregular, unsymmetrical or bulky can be

conveniently held and machined.
Parts of a horizontal boring machine
• Bed
• Headstock supporting column
• End supporting column
• Headstock
• Saddle and table
• Boring bars
Bed
• The bed supports column, tables and other parts of machine.
Headstock supporting column
• The column provide supports to the headstock and guides it up and
down accurately.
End supporting column
• The end supporting column situated at he other end of the bed
houses the bearing block for supporting a long boring bar
Headstock
• The headstock mounted on the column supports, drives and feeds
the tool.
Saddle and table
• The table supports the work.
• The saddle permits the work to be moved longitudinally on the bed.
Boring bars
• The boring bar supports the cutter for boring operations on jobs
having larger diameters.
Precision boring machine
• The precision boring machine uses single point tools to machine
surfaces rapidly and accurately
• Cemented carbide and diamond tipped single point tools are
operated at a very high cutting speed to produce accurately sized
holes with a fine surface finish.

• The feeding movement may be provided by the tool or by the work.

• The machine may be horizontal or vertical.

Cutting Speed
Total length of travel
Time required for drilling the hole
Material Removal Rate (MRR)
A hole with 40 mm diameter and 50 mm depth is to be drilled in mild steel
component. The cutting speed can be taken as 65 m/min and feed rate as
0.25 mm/rev. Calculate the machining time and the material removal
rate.
Find the time required to drill 4 holes in a cast iron flange each of 2 cm
depth, if the hole diameter is 2 cm. Assume cutting speed as 21.9 m/min.
and feed as 0.02 cm/rev.
Calculate the machining time to drill four 8 mm dia holes and one 40 mm
dia central hole in the flange shown in Figure. 20 mm dia hole is drilled
first and then enlarged to 40 mm hole. Take cutting speed 10 m/min, feed
for 8 mm drill 0.1 mm/rev, for 20 mm drill feed is 0.2 mm/rev. and for 40
mm f drill feed is 0.4 mm/rev.