Drill Machines and Drill Bits

Text : SF Krar
Units 38,39,40,41
 Objective
• To study various types of drill machines
• To study different accessories of drill
machines
• To study parts of a twist drill bit and its
different types
• Method to select cutting speeds and feeds
• safety and operation hints

2
 Drilling Operations
• Drilling – producing holes using twist
drills
• Countersinking – tapered or cone
shaped enlargement to the end of hole
• Reaming – sizing and producing smooth
round hole form a previously drilled hole
• Boring – Enlarge or true a hole by
means of a single point tool
• Spot facing – smoothing and squaring
the surface around the hole to provide a
seat for screw or nut
• Tapping – internal threads
• Counter boring – enlargement to
provide a square shoulder for head of
bolt or cap screw 3
Drilling Countersinking Reaming Boring

Spot-Facing Tapping Counterboring 4

 Types of Drilling Machines
• Portable drilling machine
• Bench drilling machine
• Radial drilling machine
• Gang drilling machine

5
 Sensitive Drill Press
• Hand feed lever
– Controls downfeed pressure
– Feel the pressure
• Manufactured in bench and floor
model
• Four main parts
– Base
– Column
– Table
– Drilling head
6
 Parts of Sensitive Drill Press
• Base – made up of cast
iron, for stability, has
holes/slots for bolting
• Column – cylindrical post
• Table – to support work
piece, raised or lowered, tilt,
holes/slots for clamping
fixtures
• Drilling head – mounted at
top of column, revolves tool
• Spindle – has drill chuck
7
Different Shapes

8
 Upright Drill Machine
• Similar to sensitive drill
press except that it is
larger and heavier
• Differences
– Fitted with gear box for
various speeds
– Spindle may be
advanced by hand
lever, hand wheel or
automatically
– Reservoir for coolant
9
10
 Radial Arm Drill Machine
• For handling larger work pieces
• Advantages
– Larger and heavier work
– Drilling head is easily raised or
lowered
– Work piece stays at one location;
movable head
– More powerful; larger cutting tools
– On universal models
• head may be rotated for drilling
holes at angles

11
 Parts of Radial Arm Drill
Machine
• Base
– Made of heavy box type ribbed
cast iron or welded steel
– Bolted to floor
– Reservoir for coolant
– Larger work pieces or table can
be bolted to base
• Column - Upright support
• Radial Arm
– May be raised , lowered or swung
and clamped
– Power driven elevating
• Drilling Head
– Mounted on Radial Arm
– Moved by means of transverse
hand wheel
– Contains controls and gears for
spindle speeds and feeds
– Automatic feed possible 12
13
 Gang Drill Machines
• More than one work /
head mounted on a
single table
• For series work
• Can be used for drilling,
reaming or counter
sinking
• Multi – Spindle head can
have 20 or more spindles
on single head

14
 NC Drill Machines
• Spindle and table movement
are controlled electronically
by means of a computer
• Tools are changed
accordingly
• Repeated job accuracy up to
0.001 inch (0.02mm)

15
Drilling Machine Accessories

UNIT 39
 Versatility of the Drill Press
• Greatly increased by various accessories
• Two categories
– Tool-holding devices
• Used to hold or drive cutting tool
– Work-holding devices
• Used to clamp or hold workpiece

17
 Tool-Holding Devices
• Drill press spindle provides means of
holding and driving cutting tool
• End may be tapered or threaded for
mounting drill chuck
• Most common
– Drill chucks
– Drill sleeves
– Drill sockets

18
 Drill Chucks
• Most common devices used for holding
straight-shank cutting tools
• Most contain three jaws that move
simultaneously when outer sleeve turned
– Hold straight shank of cutting tool securely
• Two common types
– Key
– Keyless

19
 Chucks
• Hold straight-shank drills
• Mounted on drill press spindle
– Taper

– Threads
• Held in spindle by self-
holding taper in larger
machines
• Four types of drill chucks 20
 Types of Drill Chucks
• Key-type
– Most common
– Three jaws move simultaneously
when outer sleeve turned
• Tighten with key
• Different size keys for different size chucks

21
 Types of Drill Chucks
• Keyless
– Chuck loosened or tightened by
hand without key
• Precision keyless
– Holds smaller drills accurately

22
 Types of Drill Chucks
• Jacobs impact keyless chuck
– Hold small or large drills
using Rubber-Flex
collets
– Gripped or released
quickly and easily by
means of built-in
impact device in chuck

23
 RUBBER-FLEX® COLLETS VS
CONVENTIONAL COLLETS
• Unique in design and operation, the Jacobs® Rubber-Flex® Collet can
generate two to three times the gripping power of a conventional split-steel
collet.

• Gripping force is uniform and parallel throughout the collet contact

length and not concentrated at the nose or back as is frequently in the
with split-steel collets

24
 Drill Sleeves and Sockets
• Drill Sleeves
– Used to adapt drill
shank to machine
spindle if taper on tool is
smaller than taper in spindle
• Drill Socket
– Used when hole in spindle
of drill press too small for
taper shank of drill
– Used often as
extension sockets
25
 Drill Drift
• Used to remove tapered-shank
drills or accessories from drill
press spindle
• Always place rounded edge up so
this edge will bear against round
slot in spindle
• Use hammer to tap drill drift and
loosen tapered drill shank
• Use board or piece of pressed-
wood to protect table or vise

26
Drill Drifts

27
 Work Holding Devices
Drill Vise
• Used to hold round,
square or odd-
shaped
rectangular pieces
• Clamp vise to table
for stability

28
 Angle Vise
• Angular adjustment
on base to allow
operator to drill
holes at an angle
without tilting table

29
Contour Vise

30
 V – Blocks and U - Clamps
• V-blocks
– Made of cast iron or hardened steel
– Used in pairs to support round work for drilling

31
 Step Blocks and Clamps
• Step blocks
– Used to provide support
for outer end of strap
clamps
– Various sizes and steps

32
 Angle Plates
• L-shaped piece of
cast iron or
hardened steel
machined to
accurate 90º
• May be bolted or
clamped to table
• Variety of sizes

33
 Drill Jigs
• Used in production for
drilling holes in large
number of identical
parts
• Eliminate need for
laying out a hole
location

34
 Clamps or Straps
• Clamps or straps
– Used to fasten work to table or angle plate for
drilling
– Various sizes
– Usually supported at
end by step block and
bolted to table by T-bolt
that fits into table T-slot

35
Types of Clamps

Finger clamp

U-clamp

Straight clamp
36
 Clamping Stresses
• Don’t want stresses to
cause springing or
distortion of
workpiece
• Clamping pressures
should be applied to
work, not step block
– Step block should
be slightly higher
than work
– Bolt close to work 37
Twist Drills

UNIT 40
 Twist Drill Bit
• Rough flutes are forged or milled then
twisted to get spiral shape
• Made up of carbon steel
• Now replaced by high speed steel drills
(can be operated at double cutting
speeds)-HSS or HS
• Carbide drills-up to 300% of HS drills

39
Three Main
Parts
of a Drill Point

Body

Shank

40
41
 Parts of a Twist Drill
• Shank
– Straight or tapered shank
– Straight shanks are held in chucks (up to ½ in or 13 mm dia)
– Tapered fit into spindle
• Body
– Flutes – helical groves, form cutting edges, allow fluids, admit
chips to escape

– Margin – narrow raised section on body of drill tool, full length,

provides full size to tool
– Land – body clearance, undercut between margin and flutes,
made smaller to reduce friction
– Web – partition in the center of the drill that extends the full
length and increases gradually in thickness towards tang
42
 Parts of a Twist Drill
• Drill Point
– Consists of chisel edge, lips, lip clearance,
and heel
– Chisel edge
• Chisel-shaped portion of drill point
– Lips
• Cutting edges formed by intersection of flutes
• Must be of equal length and have same angle
– So drill run true and not cut hole larger than drill

43
Drill Point

44
 Lip Clearance

• The relief ground on point of drill

extending from cutting lips back to the
heel

Shop Tools and Techniques 45

 Drill Point Angles Clearances
• Angle and clearance varied to suit
different materials
• Conventional Point(118º) - general
purpose drilling. 8-10º lip clearance
• Too much lip clearance weakens
the cutting edge (breakage and
chipping)
• Too little lip clearance, requires
heavy drilling pressure (quick wear)
47
 Drill Point Angles Clearances
• Long Angle Point (60 to 90º)
with 12 to 15º lip clearance
– Used on low helix drills for non
ferrous metals, soft cast iron,
plastics, fibers and wood
• Flat Angle Point (135 to 150º)
with lip clearance of 6 to 8º
– Used to drill hard materials
– Smaller clearance provides better
support to cutting edge
48
49
 System of Drill Sizes
• Diameter of the drill over the margins
• Fractional Sizes – 1/64 to 4 inch (step of 1/64 in)
• Number size - #1 (0.228in) to #97 (0.0059in)
• Letter size – A (0.234in) to Z (0.413in)
• Millimeters
– Miniature 0.04 mm to 0.09 mm step of 0.01 mm
– Straight shank standard 0.5 to 20 mm
– Taper shank 8 to 80 mm

50
Drill size checking

51
 Drilling Facts and Problems
• A properly ground drill should have
following characteristics:
– Length of both cutting lips should be
same- off center hole
– Angle of both lips should be same- cuts
oversize
– Lips should be free from nicks or wear
– There should be no sign of wear on the
margin

52
Conditions when Drill should be
Ground
• Drill should reground when:
– Colour & shape of the chips change
– More drilling pressure is required to force
drill into the work
– Drill turns blue due to excessive heat
generated
– Top of the hole is out of round
– Poor finish is produced in the hole
– Drill chatters when in contact with metal
– Drill squeals and may jam
– Excessive bur in the drilled hole
53
 Causes of Drill Failure
• Drill speed may be too high for the hardness of the
material
• Feed may be too heavy and overload the cutting lips
• Feed may be too light and cause the lips to scrape rather
than cut
• Hard spots or scale may be present on work surface
• Work or drill may not be supported properly, resulting in
springing and chatter
• Drill point is incorrect for the material being drilled
• Finish on the lips is poor
54
Cutting Speeds and Feeds

Unit 41
 Introduction
• Speed of a twist drill is generally referred to as
cutting speed, surface speed or peripheral
speed

• It is the distance that a point on the

circumference of a drill will travel in 1 min

• Recommended cutting speeds for drilling

various types of materials given in Table 41-1

56
 Cutting Speeds
• CS
– Surface feet per minute (sf/min)
– Meters per minute (m/min)

• Revolutions per minute (r/min)

– Number of revolutions of the drill necessary to attain
proper cutting speed for the material being
machined

• Small drill operating at same r/min will travel fewer feet

per min as compared to a larger drill

57
 Revolutions per Minute
• To determine correct number of r/min of a
drill press spindle for a given size drill,
following should be known:
– Recommended cutting speed of the material
being drilled

– Type of material from which the drill is made

– Table 41-1 for high speed drills

58
 Revolutions per Minute (cont’d)
• Formula (inch)
– r/min = CS * 12 / D = CS*4/D
• CS – Cutting speed in feet per min
• D – Drill dia in inches

• Formula (metric)
– r/min = CS*1000 / D = CS*320/D
• CS – Cutting speed in meter per min
• D – Drill dia in mm

59
 RPM Calculation
• Calculate RPM for drilling of ½ in
diameter hole in cast iron with high speed
drill
– RPM = CS*4/D = 80*4/0.5 = 640

• RPM for drilling a 1.5 mm diameter hole in

tool steel using high speed drill
– RPM = CS*320/D = 18*320/15 = 384

60
 Feed
• Feed – the distance that a drill advances into
work for each revolution
• Expressed in decimals, fractions of an inch or
millimetres
• Should be carefully chosen as it is a determining
factor in the rate of production and life of drill
• Generally governed by:
– Diameter of drill
– Material of work piece
– Condition of drilling machine

61
 Feed
• Feed rate increases as drill size increases

• ¼” (6 mm) drill should have a feed of only 0.002-0.004 in

(0.05-0.10 mm)

• 1” (25 mm) drill will have a feed of 0.010-0.025 in (0.25-

0.63 mm)

• Too coarse a feed may chip the cutting edges or break

drill

• Too light a feed causes chattering or scraping noise

which quickly dulls the cutting edges 62
• Table 41-2
 Feed
• When drilling alloy or hard steels use a
somewhat slower feed

• Softer metals such as aluminium, brass or cast

iron can usually be drilled with faster feed

• Blue chips from steel indicate too much heat at

cutting edges. Heat is caused by either a dull
cutting edge or too high a speed

63
 Cutting Fluids
• Purpose of the cutting fluid is to provide both cooling and
lubrication

• For a fluid to dissipate heat effectively:

– Must be able to absorb heat rapidly
– Have good resistance to evaporation
– Have high thermal conductivity

• Good cutting fluid should:

– Cool work piece & tool
– Reduce friction
– Improve cutting action
– Protect work against rusting
– Provide anti weld properties
– Wash away chips
64
 Summary
• Different types of drill machines
• Drill holding and work holding devices
• Construction of twist drills and selection of
required drill for different type of materials
• Drill speed, RPM and feed selection
• Cautions and important points for safe and
efficient drilling operation

65
Questions