ME231: Materials and Manufacturing

II
 Drilling
•
Operation
Drilling is a machining operation used to create a round hole in a workpart.
• The hole is straight and circular.
• The hole can be a through hole or blind one.
• Drilling is usually performed with a rotating cylindrical tool (drill bit) that has
two cutting edges on its working end.
 Drill Operation
•
(cont.)
The most common drill bit is the twist drill.
• The rotating drill feeds into the stationary workpart to form a hole
whose
diameter is theoretically equal to the drill diameter.
• In practical, the diameter of the hole is slightly bigger than the diameter of
the drill bit.
• The surface of the hole is usually rough.
• Drilling is performed on a drill press (drilling machine), although other
machine tools also perform this operation.
 Twist
•
Drill
A twist drill is basically a cylindrical piece of steel
with special grooves. One end
of the cylinder is pointed and the other end is so shaped that it can be attached
to the drilling machine. The grooves are usually called flutes. The flutes formed
by twisting a flat piece of steel into a cylindrical shape and such types of
cylindrical shape drills are called twist drills.
Twist Drill
Nomenclature
Twist Drill
Nomenclature
 Operations performed on a drilling machine
Several operations are related to drilling, most of the operations follow drilling; a
hole must be made first by drilling, and then the hole is modified by one of the
other operations.
(a) Reaming: is used to slightly enlarge a hole, to provide a better tolerance on its
diameter, and to improve its surface finish. The tool is called a reamer, and it usually
has straight flutes.
 Operations performed on a drilling machine
(b) Tapping: This operation is performed by a tap and is used to provide internal
screw threads on an existing hole.
• A cylindrical tool with cutting teeth arranged in a spiral whose pitch is equal to
that of the screw threads, is simultaneously rotated and fed into a pre-existing
hole.
• The end of the tool is slightly conical to facilitate entry into the hole.
• The initial hole size is approximately equal to the minor diameter of the screw
thread.
 Operations performed on a drilling machine
(c) Counterboring: provides a stepped hole, in which a larger diameter follows a
smaller diameter partially into the hole. A counterbored hole is used to seat bolt
heads into a hole so the heads properly fits into the surface..
 Operations performed on a drilling machine
(d) Countersinking: This is similar to counterboring, except that the step in
the hole is cone-shaped for flat head screws and bolts.
 Operations performed on a drilling machine
(e) Centering: Also called center drilling, this operation drills a starting hole to
accurately establish its location for subsequent drilling. The tool is called a center
drill.
 Operations performed on a drilling machine
(f) Spot facing: Spot facing is the operation of smoothing and squaring the surface
around and at the end of a hole so as to provide a smooth seat for a nut or for the
head of a cap screw.
 Operations performed on a drilling machine
(g) Boring: is a type of drilling operation in which we increase the diameter
of previously drilled hole. The boring tool has only one cutting edge.
 Drilling
Machines
The standard machine tool for drilling is the drill press. The main parts of a
drilling machine are shown below:
• Base
• Column or Pillar
• Arm
• Worktable
• Drill head
• Feed Mechanism
• Spindle
• Drill jigs
• Chuck
• Electric Motor
• Pully or gears
 Types of Drilling
Machines
(a) Upright drilling machine: The upright drill stands on the floor and consists of
a table for holding the workpart, a drilling head with powered spindle for the drill
bit, and a base and column for support. It is also called pillar drilling machine. It is
used for making 20mm to 40mm holes in metal and wood.
 Types of Drilling
Machines
(b) Bench drilling machine: A similar to upright drill press, but smaller, is the
bench drill, which is mounted on a table or bench rather than the floor. This drilling
machine is capable of drilling holes up to 12.5 mm diameter in steel.
 Types of Drilling
Machines
(c) Portable drilling machine: A portable drilling machine is a small-size, hand-
operated power drill, mainly used for making small holes up to 12mm in an object
in any position. It can drill a hole through woods, plastic, metal, and concrete. Due
to their small size and mobility, portable drill machines are used by woodworkers,
house owners, plumbers, electricians, and industrial workers.
 Types of Drilling
(d) Radial
Machines
drilling machine: The radial drilling machine is a large drill press
designed to cut holes (up to 80mm in dia) in large parts. It has a radial arm along
which the drilling head can be moved and clamped. The head therefore can be
positioned along the arm at locations that are a significant distance from the
column to accommodate large work. The radial arm can also be swiveled about the
column to drill parts on either side of the worktable.
 Types of Drilling
Machines
(e) Gang drilling machine: The gang drill is a drill press consisting basically of two
to six upright drills connected together in an in-line arrangement. Each spindle is
powered and operated independently, and they share a common worktable, so that
a series of drilling and related operations can be accomplished in sequence (e.g.,
centering, drilling, reaming, tapping) simply by sliding the workpart along the
worktable from one spindle to the next.
 Types of Drilling
Machines
(f) Multi spindle drilling machine: Multiple-spindle drill, in which several drill
spindles are connected together to drill multiple holes simultaneously into the
workpart. The main purpose of the multi-spindle drilling machine is to increase
production and to reduce the operation time.
 Types of Drilling
Machines
(g) Deep hole drilling machine: This is a special breed of drilling machine mostly
used to make deeper holes in various parts like spindles, barrels, connecting rods,
and certain oil-well drilling equipment.
 Types of Drilling
Machines
(h) CNC drilling machine: are available to control the positioning of the holes in
the workparts. These drill presses are often equipped with turrets to hold multiple
tools that can be indexed under control of the CNC program. The term CNC turret
drill is used for these machine tools.
 Cutting Conditions in
Drilling
The cutting speed, v, in a drilling operation is the surface speed at the
outside diameter of the drill.
𝑣 = π𝐷𝑁
Where D is the diameter of drill in mm, N is the spindle revolutions per minute.
Feed in drilling is specified in mm/rev (in/rev) and it can be converted into
f
rate feed as:
(mm/min)
𝑓𝑟 = 𝑓𝑁
 Cutting Conditions in
Drilling
The machining time, 𝑇 , required to drill a through hole can be determined by
𝑚
the following formula:
𝑡+𝐴
𝑇𝑚 =
𝑓𝑟
Where A = an approach allowance that accounts for the drill point angle,
representing the distance the drill must feed into the work before reaching full
diameter.
𝜃
𝐴 = 0.5 𝐷 tan 90 −
2
t = workpiece thickness, 𝜃 = is drill point
angle.
 Cutting Conditions in
Drilling
The machining time, 𝑇 , required to drill a blind hole can be determined by
𝑚
the following formula:
𝑑+𝐴
𝑇𝑚 =
𝑓𝑟
Where d = is defined as the distance from the work surface to the depth of the full
diameter.
𝜃
𝐴 = 0.5 𝐷 tan 90 −
2
t = workpiece thickness, 𝜃 = is drill point
angle.
 Cutting Conditions in
Drilling 𝑚𝑚
3
The rate of metal removal, 𝑅 ) in drilling is determined as the
(
product of the 𝑀𝑅 𝑚 𝑖 𝑛
drill cross sectional area and the feed
rate:
The
End