Abu Dhabi Men’s College

Mechanical Engineering Department

Manufacturing Technology II

MCE 3303

Lab: Drilling and threading by tap & die

Section CRN

Submitted by ID

Submitted to: Dr. Yasser El-Okda

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Table of Contents
Table of Contents:............................................................................................................................2

Introduction......................................................................................................................................3

Drilling.........................................................................................................................................3

Threading.....................................................................................................................................3

Drilling and threading tools.............................................................................................................4

Different types of drill bits...........................................................................................................5

Twist drill bit............................................................................................................................5

Masonry tool bit.......................................................................................................................6

Spade bits.................................................................................................................................6

Figure 6: Spade drill bit............................................................................................................6

Auger bits.................................................................................................................................6

Thread tools for making different threads....................................................................................6

Materials of the drilling and threading tools with material properties.........................................7

Materials for drilling tools........................................................................................................7

Materials for threading tools....................................................................................................7

1. High-Speed Steel. This material is used to make threading tools because it has high
hardness and high abrasion resistance relative to other materials for example common steel....7

Applications of drilling and threading tool materials for different work materials.....................7

Work and thread tool holding..........................................................................................................8

Method for holding the work piece during drilling process.........................................................8

Methods for holding the work piece during threading process....................................................8

Drilling operation.............................................................................................................................9

Working principle of drilling process..........................................................................................9

Drilling machine construction....................................................................................................10

Types of drilling machines.........................................................................................................11

Portable drilling machine.......................................................................................................11

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 Sensitive drilling machines....................................................................................................12

Upright drilling machine........................................................................................................13

Radial drilling machine..........................................................................................................13

Gang drilling machine............................................................................................................13

Turret drilling machine...........................................................................................................14

Automatic drilling machines..................................................................................................14

Drilling operations.....................................................................................................................15

Cutting conditions in Drilling....................................................................................................15

Threading operation.......................................................................................................................16

Internal threading/ how to use a hand tap..................................................................................16

External threading/ how to use dies...........................................................................................16

Conclusions....................................................................................................................................17

References......................................................................................................................................18

Figure 1: Drilling operation elements (El-Hofy, 2006)...................................................................4

Figure 2: Parts of standard tap.........................................................................................................5
Figure 3: Common die shapes (Dixon, 2010)..................................................................................5
Figure 4: Twist drill and its point (El-Hofy, 2006).........................................................................6
Figure 5: twist drill bit.....................................................................................................................6
Figure 6: Masonry drill bit...............................................................................................................7
Figure 7: Spade drill bit...................................................................................................................7
Figure 8: Tap handle in use on lathe..............................................................................................10
Figure 9: Parts of drilling machine................................................................................................12
Figure 10: Portable drilling machine (Rajput, 2015).....................................................................13
Figure 11: Sensitive drilling machine (Rajput, 2015)...................................................................13
Figure 12: Radial drilling machine (Rajput, 2015)........................................................................14
Figure 13: Gang drilling machinev (Rajput, 2015).......................................................................15
Figure 14: Turret drilling machine (Rajput, 2015)........................................................................15

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Figure 15: Die stock (Gill & Krar, 2002)......................................................................................17
Figure 16: Die stock used to cut threads (Gill & Krar, 2002).......................................................18

Table 1: Typical cutting conditions in drilling (Bangalore, 2004.)............................................................22

Introduction

Drilling

Drilling is the process of machining by cutting to make a hole by use of drill tool. The drilling

process entails two main motions which are primary rotary motion and auxiliary feed motion.

For a drilling operation in horizontal drilling process, the work being drilled is given the rotary

motion and the tool is given the linear feed motion. Such drilling process is often used to drill

long holes by use of automatic, center and turret lathes. When performing drilling in vertical

arrangement, the drilling tool does both feed and rotary motion at the same time by use of

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drilling standard machines. This is the most commonly used and important drilling type and is

shown in the figure below. In drilling operations some holes are made through the hole this is

known as through-hole drilling. In other cases, the drilled hole reaches some depth in the work

piece and this is known as blind hole drilling.

Figure 1: Drilling operation elements (El-Hofy, 2006).

Depending drill cutting edge engagement, the drilling process is done in a solid material whereas

in secondary drilling that is enlarging process, the cutting edge parts are the only ones working in

the cutting process (El-Hofy, 2006).

Threading

Threading is the process of cutting screw threads on a work piece. The tools used for cutting

threads are known as taps and dies. The process of creating the threads is known as threading.

Some of the tools are forming tools and others are cutting tools. A tap tool is used to form or cut

the female part of the mating pair for example a nut. Die tool is used to form or cut male part of

the mating pair for example bolt. Tapping is the process of forming or cutting threads using a tap

while threading is the process of forming or cutting using a die. Dies are kept in holders known

as die stocks. The figure below shows the die stock and a threading tap (Dixon, 2010).

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 Figure 2: Parts of standard tap.

Figure 3: Common die shapes (Dixon, 2010).

Drilling and threading tools

Drill bit is the cutting tool used to perform the drilling operation and is known as twist drill

shown in the figure below. The drills are classified in terms of materials they are made of,

manufacturing method, shape, length, type and number of helix or flute, point charateristics,

shank, and size series.

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 Figure 4: Twist drill and its point (El-Hofy, 2006).

Different types of drill bits

Drill bit is the part of drilling tool that is used to perform the drilling operation that is to do the

cutting. There are various types of drill bit used in different areas. Some of the types of the drill

bits are twist drill, spade bits, masonry bits, auger bits.

Twist drill bit

This is a general purpose drill bit used for drilling plastics, wood, steel among other materials.

They are made with angles suitable for drilling steel materials but their geometry and cutting

angles are not suitable for cutting many other types of materials. They can drill other materials

but not particularly good. Standard twist drill is made using high speed steel (HSS) and their tips

are 118o. There are also 90o bits that can be bought from engineering suppliers and these can drill

soft materials faster, and cut more holes with cordless tool.

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 Figure 5: twist drill bit.

Masonry tool bit

These drill bits are made of steel and tungsten carbide brazed or welded into the tip. The tunsten

carbide tipped (TCT) masonry bits can easily be recognised because their tips are wider. This tip

is blunt and can cut by crushing small section of the work. They areused to drill block, bricks,

mortar and stones (Huth, 2016).

Figure 6: Masonry drill bit.

Spade bits

These bits have a spade-shaped tip. With this tip they are able to bore softwoods. They are to cut

holes for example running cables.

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 Figure 7: Spade drill bit.

Auger bits

These bits are used for drilling dry and thick wood. When drilling using these bits one does not

need to apply a lot of pressure because of their good design. They are made with a screw tip that

helps create initial hole where the rest of the bit falls. As such, auger bits cut holes that are

precise and clean (Huth, 2016).

Thread tools for making different threads

There are three sets of hand taps. They are plug tap, tapered tap, and bottoming tap. Plug tap is

made with taper from tap end to fourth or third thread and is used for finishing rough work piece

after threading by use of tapered tap. Tapered tap is made with tapers from tap end to its sixth

thread. It is sued get started into the work for the first time. Bottoming tap is made with one

tapered thread at the end of the tap. It is used for finishing cutting of threads. There are different

tools for cutting different threads using a tap. These include (El-Hofy, 2006):

i. Straight flute tap. This is a tapping tool used by hand and threads cut are straight. It is

simple and most affordable.

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 ii. Gun taps. This tool is made with angular cutting face and straight flutes at their ends. It

offers exact and close cut because of its angular cutting face can boost material’s pieces

in front of the tap and thus cannot interfere with tap while in use.

iii. Pipe taps. This type of tool can be used on a machine or operated manually. They are

smaller than other most common taps.

iv. Spiral pointed taps. It is often used in high speed production areas. They are used made

with one lead flute grounded at a certain angle to access of the tap.

Materials of the drilling and threading tools with material properties

Materials for drilling tools

There are various materials used to make drilling tools based on drilling application of the tool.

Some of the materials are:

 Carbo steels. Both high and low carbon steels are used to make drill bit. The low carbon

steel can be used to make tools for cutting soft materials like wood. The high carbon steel

is used to make hard tools that can work in both wood and metals as they have higher

tempers.

 High speed steel. This material can withstand high temperatures as it maintains its

integrity that is hardness. With this material there is no work damage when the

temperatures are too high because this material can overcome such high temperatures.

 Titanium coatings. The tools made of this titanium coatings are very strong and have high

resistance to wear.

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Materials for threading tools

1. High-Speed Steel. This material is used to make threading tools because it has high

hardness and high abrasion resistance relative to other materials for example common

steel.

2. Solid carbide. This material is used because of its high temperature when compared to

steel. It is able to overcome more friction compared to steel. It helps make threads that

are clean and smooth.

Applications of drilling and threading tool materials for different work materials

Drilling tools are made of different materials because they are used in different areas of

application. The drilling tools for example are used in:

 Drilling holes in wood

 Drilling holes on construction materials like bricks

 Cutting holes on electronic equipment

 Cutting holes on steel sheets

 Cutting holes on fabric materials

Threading tools are used to make threads on different materials for example:

 To make threads on plastic materials

 Make threads in multi-core processors

 Make threads on steel rods/tubes

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Work and thread tool holding

Method for holding the work piece during drilling process

There are devices used to hold the work piece safely and firmly to enhance drilling. These are

vise mounting and base mounting.

Vise mounting. In this case the work piece is secured firmly on the machine table vise and is

swung to make the vise tail contact drill press column. The hole is centered by use of hand and

center drill placed directly above the center punch mark.

Base mounting. The work piece is mounted on base or table and strap clamps are used parallel to

the base or table. Straps and bolts are short as possible to enhance rigidity and allow drilling

clearance.

Methods for holding the work piece during threading process

a) Holding work piece on a tap Handle. This method used to hold the work piece and cut

threads by turning the handle. The work is placed on lathe chuck, spring loaded center or

dead center at the tailstock of the lathe machine. Threads are then cut by rotating the tap

handle.

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 Figure 8: Tap handle in use on lathe.

b) By use of die handle. In this method the work piece is placed on a chuck and the die tool

rotated on the die handle (Moltrecht, 1981).

Drilling operation

Working principle of drilling process

Drilling process is performed by use of a drilling machine. This machine is also known as drill

press. It helps in cutting holes through or into different materials such as metal, wood and many

others that can be worked on. This machine works when power supply is on. With this power the

machine spindle that gets power from motor starts to run. Radial arm is then adjusted as per the

drilling operation and work piece height. A chuck is connected to spindle. This helps to hold the

drill bit tool in its jaws. Drill head is set and adjusted on the at the work piece point of

application and then a suitable feed is given. The machine works by rotating drill bit edge that

exerts force on the work and the point where hole is to be drilled. A V-belt is attached to the

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electric motor that drives a pulley and which in turn drives the spindle which finally drives the

drill bit into the work. Next a handle wheel is rotated to converting rotary motion into linear

motion by use of rack and pinion mechanism. This then cuts the required hole. The hole is made

by removing chips by use of extrusion and shearing (Rajput, 2015).

Drilling machine construction

The drilling machine consists of several parts that work to ensure drilling is done well and also

others that help in ensuring safety of the operator. Some of the main parts of the drilling machine

are (Rajput, 2015):

1. Base. This is the part that is used to support the drilling machine structure. This part is

often made of gray iron. It is made with slots that support the structures that cannot fit on

the table.

2. Table. The table provides space for moving the work along the column. It is made such

that it can be swiveled to reach needed positions of the work piece. Most of the work

table are made with holes, slots and other accessories to help in holding the work piece.

3. Column. This is the part that is made round in shape and is also made of gray cast iron

steel tubing or ductile iron. It helps in giving support to the top half and table of the

machine.

4. Head. This is the part that is sued to house the quill, spindle, motor and pulleys. A V-belt

is attached to the electric motor that drives the pulley and which in turn drives the spindle

which finally drives the drill bit to cut the required hole.

5. Drill jigs. These are parts used in multi-tasking applications that is when several holes are

needed in one place. Also, this parts are used when locating the work piece to the

favorable position to be drilled. It also, helps in guiding drill straight with help of

bushings.

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 6. Angle plates. These are used to support the drilling action by the edge. The plates involve

slots and holes that assist when clamping the work to the table and hold it together.

Figure 9: Parts of drilling machine.

Types of drilling machines

Portable drilling machine

This is a drilling machine that is compact, very small, and self-contained unit that carries its

small electric motor. It is commonly used to drill holes in:

i. When the component that needs hole is big such that it cannot be lifted.

ii. The space is small such that big drilling machine cannot be used.

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This machine is made to drill holes of up to 12 mm in diameter. However, there portable drills

that can produce up to 18 mm diameter holes (Rajput, 2015).

Figure 10: Portable drilling machine (Rajput, 2015).

Sensitive drilling machines

These are drilling machines that are light in weight and used in workshops. They are usually

mounted on work benches. The operator is able to feel cutting process as he/she applies pressure

by using lever, thus the machine is known as sensitive drilling machine. This machine consists of

a base made of cast iron with vertical column. The column is of hollow steel pipe where the table

slides up and down. A table clamp is used to fix the table to the needed position. This machine

can make holes of 1.5 mm to 15 mm diameter. The speed ranges between 800 -9000 rpm. The

figure below shows this machine.

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 Figure 11: Sensitive drilling machine (Rajput, 2015).

Upright drilling machine

This machine is similar to the sensitive drilling machine. It is made with power feed mechanism

that is used to rotate the drill bit and used for heavy jobs.

Radial drilling machine

This machine is used make holes on work that is too heavy and very large to be mounted on

worktable of a vertical spindle drilling machine. It is made with a verticla column and heavy

base and long horizontal radial arm that extends from it and can be lowered, raised and swung in

horizotal plane about the column to the needed location. This machine is used in large scale and

tool rooms die manufacturing units.

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 Figure 12: Radial drilling machine (Rajput, 2015).

Gang drilling machine

This is drilling machine where several drilling spindles are mounted on one table. In this case

each of fthe drilling spindle is such that it can be set for different depth and speed of cut

independently. This machine is used when severla holes with different sizes are required on the

same work piece. Alos, other machining opertaions such as counter boring, reaming, tapping and

others can be done at the same time using this machine.

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 Figure 13: Gang drilling machinev (Rajput, 2015).

Turret drilling machine

This drilling machine helps reduce the floor space that can be used by gang drilling machine. It

has six turrets. The stations are set with various tools. Numerical control is also performed. Two

fixtures are located side by side on the table and this allows loading or unloading of one part as

the other part gets machined.

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 Figure 14: Turret drilling machine (Rajput, 2015).

Automatic drilling machines

These are drilling machines used in production and arranged in series to do different drilling

operations in sequence at successive work stations. After the work piece completes one operation

in a given station, it is automatically moved to the next station to be worked on. As such, it

works as transfer line (Rajput, 2015).

Drilling operations

After the work piece is set out and mounted properly, the drilling process starts. The drilling

operation entails selection of the right twist drill for the work to be done. The drill is properly

installed in the machine spindle. The machine speed and feed are set. The hole cutting starts at

the center and hole is drilled as per the drilling specifications and tolerance given. The drilling

operation should have tolerance provisions because in drilling there occurs oversizing naturally.

Oversizing occurs due to some factors in drilling that is drill point accuracy, twist drill actual

size, machine sleeve and chuck accuracy, drilling machine spindle accuracy and rigidity, rigidity

of the work piece and set up, and drilling machine rigidity. Maintenance and field shop drilling

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operations enhance some tolerance. However, oversizing should be kept to minimum by the

drilling machine operator (El-Hofy, 2006).

Cutting conditions in Drilling

Before drilling operation starts, one is required to find out the wear limits and machinability

properties of the materials to be drilled. As such there are some cutting conditions that one will

have to work out on. The factors that are needed to be determined before drilling include hole

depth, work surface condition, cutting fluid to be used, machine fixtures and rigidity among

others. Also, the torque, power, and thrust values are necessary when determining the cutting

conditions. The table below given common cutting conditions for drilling operation (Bangalore,

2004.).

Table 1: Typical cutting conditions in drilling (Bangalore, 2004.).

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Threading operation

Internal threading/ how to use a hand tap

The steps followed when cutting threads using a tap are (Dixon, 2010):

1. A pilot hole larger than the minor diameter of the needed thread is drilled. Diameter of

the drill bit is 75 -80% of the thread diameter.

2. The tap is set into the tap wrench and positioned at 90o to the work piece.

3. The tap is turned clockwise slowly. The work piece is held by use of a vise or another

tool that can assist in similar manner.

4. After the tap threads in one or two turns, the tap is taken back a quarter to half turn so as

to break the chip. The process is repeated as the tapping goes on.

5. Cutting oil is used to frequently lubricate the tap to reduce friction and heat.

6. It may happen that the hole sometimes clogs with metal chips making tap to blind. As

such, the tap will need to be extracted to clean off the filings. If this is not done, then it

could result to tap breaking.

7. When the threads are made to the required depth, the handle is turned clockwise to help

remove the tap.

8. The tap is cleaned and some oil sprayed on it before it is placed in respective storage box.

External threading/ how to use dies

The steps followed when cutting external threads are (Gill & Krar, 2002):

1. Work piece end is chamfered with a grinder or file.

2. The work is fastened safely on a vise. The small-diameter work piece is held short to

prevent it from bending.

3. The proper dies and die stock are selected.

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4. The tapered end of the die is lubricated with a right cutting lubricant.

5. The die tapered end is placed on squarely on the work piece.

6. The die stock is pressed down on the handles and turned clockwise for some several

turns. This is illustrated as shown in the figure below.

Figure 15: Die stock (Gill & Krar, 2002).

Figure 16: Die stock used to cut threads (Gill & Krar, 2002).

7. The die is checked to confirm that it has started squarely with the work piece.

8. In case it is not square, the die is removed from the work and started again when it is

square and some pressure is applied as the die is turned.

9. The die is turned forward one turn and then reversed around one-half turn to help break

the chip.

10. Cutting fluid is applied as frequent as possible when doing the cutting.

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Conclusions

From this lab report drilling process has been studied. Drilling has been found to be a process of

cutting a circular hole on solid material. The tool used to cut hole by use of drilling machine is

known as the drill bit and the drilling machine is known as drill press. There are different types

of drilling machines. The machines are used to cut holes in different scenarios. For example,

there are drilling machines that are portable and used in areas where there is limited space or

where a drilling machine cannot be lifted to make the hole. The drilling machine works by using

electric motor to provide mechanical power that is sued to run pulley and belts. These pulley and

belts transmit the power to the spindle. This power on the spindle is used to do work on the work

piece by cutting the required hole. The drilling machine is used in different areas for example in

wood industry to make holes, in metal industry for example to cut holes in steel sheet metal

among others. The drill press is made of different parts which include the electric motor, pulleys

and belts, spindle, column, base, working table among other. Each of these parts are essential in

one way or the other as they help in enhancing the drilling operation as well as enhancing safety

of the machine and the operator.

In addition, the threading machining process has been studied. The methods of manually cutting

threads was studied. There are internal threads and external threads. The respective procedures

for cutting both internal and externals threads were studied. The internal threads are cut by use of

tap threading tools while the externals threads are cut by use of die stock tool. The threading

tools are made of strong material that can withstand friction generated due to rotation as the

threads are being cut. Such materials are known for their high hardness and resistance to wear.

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References

Bangalore, H. M. (2004.). Production technology. New Delhi : Tata McGraw-Hill, .

Dixon, J. (2010). Modern Diesel Technology: Preventive Maintenance and Inspection . Toronto:

Delmar cengage learning.

El-Hofy, H. A.-G. (2006). Fundamentals of machining processes . CRC press.

Gill, A., & Krar, S. F. (2002). Machine tool technology basics. New York: Industrial Press, .

Huth, M. W. (2016). Basic principles for construction . Cengage learning.

Moltrecht, K. H. (1981). Machine shop practice. New York: Industrial Press.

Rajput, R. K. (2015). A textbook of manufacturing technology = manufacturing processes : for

B.E./B. Tech., A.M.I.E.-Section B, and competitive examinations. Bengaluru : Laxmi

Publications (P) LTD .

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