Drilling

Drilling Machines

• Hand drilling machine

• Sensitive drilling machine
• Upright drilling machine
• Radial drilling machine
• Gang drilling machine
• Multiple spindle drilling machine
• Turret drilling machine
• …
 Sensitive Drilling Machine
• Vertical slide for coarse positioning and the quill is used for
feed motion.

• Feed control is by hand feel.

 Upright Drilling Machine
Feed control is by hand wheel as well automatic.
 Radial Drilling Machine
• More rugged.
• The job need not move as the tool head can move around it in (r, θ) space.
• Feed control is by hand wheel as well as automatic.
 Gang Drilling Machine

This is a transfer line of drilling machines, mostly of the sensitive

drilling type.
 Multiple Spindle Drilling Machine
• Several drills can be mounted on the same Tool head.
• Each tool gets its drive through gear arrangement from the main
spindle.
• These heads have to be ordered specific to the parts as the distances
and drill sizes are specific to the geometry of each part.
• Useful only in mass peoduction.
 Turret Drilling Machine
• Usage is similar to gang drilling; but here, tool is indexed rather than moving
the job from one station to the other.
• Suitable for heavy jobs.
Note: In transfer lines, job moves from one station to the other;
 Drilling operations…
• Operations that can be performed in a
drilling machine are
 Drilling
 Reaming
 Boring
 Counter boring
 Countersinking
 Tapping
Operations in drilling machine
Operations in drilling machine
 Types of cutters
Countersinks :-
Special angled cone shaped enlargement at the end of
the hole
Cutting edges at the end of conical surface.
Cone angles of 60°, 82°, 90°, 100°, 110°, 120°

Counter Bore Tool:-

Special cutters uses a pilot to guide the cutting action .
Accommodates the heads of bolts.
 Types of cutters
Combined Countersinks and
central drill :-
Special drilling tool to start
the hole accurately.
At the end it makes
countersinks in the work
piece.
Gun drill :-
Machining of lengthy holes
with less feed rates.
To overcome the heating and
short life of the normal drill
tool
 Types of cutters
Tapping:-
For cutting internal thread
Multi cutting edge tool.
Tapping is performed
either by hand or by
machine.
Minor dia of the thread is
drilled and then tapping is
done.
 Classification of Drills
Criteria Types
Material HSS drills
Solid carbide drills
Carbide tipped HSS drills (brazed tips)
Insert type drills
Coated drills (TiN on HSS, TiN/ TiC/ Al2O3 on WC)
Number of flutes (Geometry) Two flute (most common)
Three flute (popular for composites)
Type (Geometry) Centre drill
Spade drill
D-bit drill
Twist drill
Step drill
Deep hole drills (with coolant ducts)
Shank Parallel shank
Taper shank
Twist Drill - Nomenclature
 Twist Drill
Taper and parallel shank types
 Centre Drill

• This has very short cutting edge.

• It is used only for creating the centre point.
• This is essential for good positioning accuracy.
• Also required while drilling on slant or non-planar surfaces.
 Spade Drill

• Spade drill does not require a pilot hole.

• Tool is weak.
• Suitable for soft materials.
 D-bit Drill

• D-bit drill does not require a pilot hole.

• Tool is strong
 Cutting Edges of Twist Drill
i. Major cutting edges (lip)
• These are at an angle called point angle which is 118 normally.
• Cutting velocity and rake angle and hence cutting efficiency is
high at periphery and reduces inward.
ii. Minor cutting edge (helical edge)
• Cutting velocity is constant.
• This gives finishing touch to the surface. Its quality decides the
surface finish of the hole.

iii. Chisel edge (bottom edge)

• This is between the two major cutting edges.
• Chisel edge is essential to give strength to the drill and keep both
flutes together.
• Cutting velocity and rake angle are too low. In fact, it partly cuts
and partly extrudes. It forces its way through the material
effectively pushing the material outward for subsequent removal
by the major cutting edges.
 Common Point Angles

• For soft materials, a point angle of 90 to 100 is used.

• For general purpose drilling, a point angle of 118 is
used.
• For hard materials, a point angle of 130 to 150 is used.
Chip Formation in Drilling
 Tool Holding devices
• The different methods used for holding drill
in a drill spindle are
• By directly fitting in the spindle hole.
• By using drill sleeve
• By using drill socket
• By using drill chuck
Tool Holding Devices
Work Holding Devices

1. Machine Table Vice

Work Holding Devices

• Step Blocks
• Clamps
• V-Blocks
• Angles
• Jigs
• T- Slots Bolt
 Definitions
• Cutting Speed (v):-
It’s the peripheral speed of the drill

v = *D*N/1000 m/min
Where, D = dia of the drill in mm
N = Speed of rotation in rpm
Feed Rate (f):-
it is the distance drill moves into the work at each
revolution per min.
Depth of Cut (d):-
it is equal to half the drill diameter
d=D/2
Material Removal Rate:-
It’s the volume of material removed by the drill per unit time
MRR = ( D2 / 4) * f * N mm3 / min

Machining Time (T) :-

It depends upon the length (l) of the hole to be drilled , to the
Speed (N) and feed (f) of the drill
t = L / f N min
Precautions for Drilling machine

• Lubrication is important to remove heat and friction.

• Machines should be cleaned after use
• Chips should be removed using brush.
• T-slots, grooves, spindles sleeves, belts, pulley should
be cleaned.
• Machines should be lightly oiled to prevent from rusting
Reaming
 Reaming
• Reaming is a finishing operation for circular holes.
• It requires a pre-drilled hole. The diameter of the pre-drill for any reamer is
available in the form of a chart.
• Reaming can give an accuracy of as high as IT5. IT8 to IT5 reamers are very
common.
• Reaming cannot correct the axis of the hole. It simply follows the drilled hole.
• Reaming uses low speed and high feed. This is in contrast to other tools to
get better finish where high speed and low feed are desirable. Reasons:
- Low speed avoids chatter which is detrimental to surface finish.
- High feed causes crisscrossing of the cutting marks leading to better
finish.
 Classification of Reamers
Criteria Types
Material Same as drills
(Carbide reamers give only marginal increase in speed over HSS is
possible so as to avoid chatter. However, the rigidity of the tool and high
resistance to abrasion improves finish and helps in centre correction)
By way of use Hand reamer
Machine reamer
Shape of hole Cylindrical reamers
produced Taper reamers
End cutting reamers (for blind holes)
Number of flutes Straight
RH
LH
RH + LH
Special types Block reamers
PERA reamer
Adjustable reamers
-Single point carbide reamer
-Floating reamer
-Typical expanding reamer
-Dihart expanding reamer
Shank Parallel shank
Taper shank
 Hand Reamer

• It has a small bevel at the end for easy entry.

• It has a long tapered portion in the beginning which cuts. This
is followed by a calibrating portion which burnishes.
• The shank end has a square end with a pip. A wrench can be
used for holding it. The pip can be used to guide it using a
centre.
Parameters of Reamer

[HMT, Fig. 5.71]

Helices Used in Reamers
 Helices Used in Reamers
Straight helix

• Easy to manufacture and re-sharpen

• Works satisfactorily for low strength steels and bronzes

LH vs. RH helices

• Helix gives smooth engagement in any type of cutting.

• For the normal rotation, LH cutter has a tendency to go up where as RH cutter
has a tendency go down due to the resultant reaction force.
• However, the feed force required is higher in LH and lower in RH. Therefore, it is
preferable to have a low helix value in either case.
• In LH, the chips are not carried away and hence move ahead of the cutting edge.
• The rake is –ve in LH whereas it is +ve in RH. Hence, RH requires less cutting
force.
LH + RH helices

• Alternately LH and RH flutes are used. This reduces the chances of chatter.
• These are difficult to regrind.
• Used only for stainless steel and other difficult-to-machine alloys.