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à
 1.1 Introduction to drilling machine
1.2 Brief history

! ! "#à$$% 
 2.1 Basic definition of drilling machine
2.2 Types of drilling machine
2.3 Construction
2.4 Types of drills

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 3.1 Working Principle
3.2 Types of drilling operation
3.3 Work holding devices
3.4 Drilling parameters

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 4.1 Problem statement
 
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 5.1 Problems Faced

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5.2 Need for Multi axis arm type drilling machine

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6.1 Base
6.2 Arms
6.3 Cross Slide
6.4 Drilling machine

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7.1 Arm design
7.2 Base design
7.3 Cross slide
7.4 3D Model

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 8.1 Future scope of base
8.2 Future scope of machine

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›ver since mankind has made tools or machine to minimize his work he has been in a
continuous mission to find easier alternatives hence led the invention of many machines like
lathe , milling machine , drilling machine , etc. The invention of 1st electric drill is credited to be
Arthur James Arnot & William Blanch Brain in 1889.The 1st Portable drilling machine was
created in the year 1895 in Melbourne and then came the other types of drilling machines«

In the increasingly competitive environment, production technology is the key to industrial

prosperity. Rapid advances in the field of metal working, particularly in the past half century, are
responsible for evolving not only new machining techniques but also for refining many of the
earlier known basic processes.

Hence there was a need for innovation and implementation of newer and better designs in almost
every possible field in every possible way. World is in the constant process and the need for
change in every field everyone is in search of a better or economical solutions to the already
present technology or machineries.

Drilling is a machining process in which a hole is produced or enlarged by the use of a specific
type of end cutting tool called the drill. It is usually the most effective and economical method of
producing holes in solid materials. Drilling of holes can be regarded as one of man¶s earliest
machining achievements and it is one of the most widely used manufacturing processes.
However in spite of its economic significance, not much changes were made in the geometrical
shape of a drill point. It is only in recent years that considerable development has taken place to
evolve more efficient drill designs, newer tool materials, productive methods of manufacturing
drills and better methods of sharpening drill points.

As the name itself explains it is a manually controlled machine which has been
designed with multi axis so as to achieve the required drilling action in many complex degrees
which were difficult to achieve initially. In this machine the arm acts similar to a robotic arm
but in a manual way. There is a cross slide which gives the linear movement to the drilling
machine which takes care of the depth of the hole required and a stroke length of 125mm can
be achieved using the slide. Since the|machine|
|manually set, the accuracy of the hole or point
at which the hole can be drilled depends on the|accuracy with which the machinist sets the end
drill bit to the point. Once the drill bit is made to| touch the point| pre-marked on the work

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piece, then the machine is to be started, set to the|required speed|and the|depth is given using
the slide, which gives a linear motion to the drilling machine. The flexibility achieved using|
this machine| is an added advantage to the machine. With multiple axes available we aim to
achieve drilling at any position known to us or required in the given design. The measuring and
accuracy in order to maintain perpendicularity of the drill is obtained using angular measuring
instruments like spirit levels, protractors etc. The linear measurements are done using linear
scales.

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The drilling machine (drill press) is a single purpose machine for the production of
holes. Drilling is generally the best method of producing holes with the use of tool called drill
generally called drill bit. The drill bit is a cylindrical bar with helical flutes and radial cutting
edges at one end. The drilling operation simply consists of rotating the drill and feeding it into
the work piece being drilled at a specified speed and feed as per the requirement varying to the
size and depth of the hole. The process is simple and reasonably accurate and the drill is easily
controlled both in cutting speed and feed rate the cutting speed depends purely on the gear
settings in the machine in order to set the speed i.e. lower speed for larger size drills and higher
speed for the smaller size drills. The drill is probably one of the original and conventional
machining processes and is the most widely used.

Drilling machine -important features/dimensions

A drill press (also known as pedestal drill, pillar drill, or bench drill) is a fixed style of drill that
may be mounted on a stand or bolted to the floor or workbench. A drill press consists of a base, column
(or pillar), table,spindle (or quill), and drill head, usually driven by an induction motor. The head has a set
of handles (usually 3) radiating from a central hub that, when turned, move the spindle and chuck
vertically, parallel to the axis of the column. The table can be adjusted vertically and is generally moved
by a rack & pinion; however, some older models rely on the operator to lift and reclamp the table in
position. The table may also be offset from the spindle's axis and in some cases rotated to a position
perpendicular to the column. The size of a drill press is typically measured in terms of
 . Swing is
defined as twice the 
|

 , which is the distance from the center of the spindle to the closest

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edge of the pillar. For example, a 16-inch (410 mm) drill press will have an 8-inch (200 mm) throat
distance.

A drill press has a number of advantages over a hand-held drill:

´| ess effort is required to apply the drill to the work piece. The movement of the chuck

and spindle is by a lever working on a rack and pinion, which gives the operator
considerable mechanical advantage
´| The table allows a vise or clamp to be used to position and restrain the work, making the

operation much more secure

´| The angle of the spindle is fixed relative to the table, allowing holes to be drilled

accurately and consistently

´| Drill presses are almost always equipped with more powerful motors compared to hand-

held drills. This enables larger drill bits to be used and also speeds up drilling with
smaller bits.

Speed change is achieved by manually moving a belt across a stepped pulley arrangement. Some
drill presses add a third stepped pulley to increase the speed range. Modern drill presses can,
however, use a variable-speed motor in conjunction with the stepped-pulley system. Some
machine shop (tool room) drill presses are equipped with a continuously variable transmission,
giving a wide speed range, as well as the ability to change speed while the machine is running.

Drill presses are often used for miscellaneous workshop tasks such as sanding, honing or
polishing, by mounting sanding drums, honing wheels and various other rotating accessories in
the chuck. This can be unsafe in some cases, as the chuck arbor, which may be retained in the
spindle solely by the friction of a taper fit, may dislodge during operation.

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1.2 BRI›F HISTORY

The earliest drills were bow drills which date back to the ancient Harappans and ›gyptians. The
drill press as a machine tool evolved from the bow drill and is many centuries old. It was powered by
various power sources over the centuries, such as human effort, water wheels, and windmills, often with
the use of belts. With the coming of the electric motor in the late 19th century, there was a great rush to
power machine tools with such motors, and drills were among them. The invention of the first electric
drill is credited to Arthur James Arnot and William Blanch Brain, in 1889, at Melbourne, Australia.
Wilhelm Fein invented the portable electric drill in 1895, at Stuttgart, Germany. In 1917, Black & Decker
patented a trigger-like switch mounted on a pistol-grip handle.

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  14 



Drilling is an operation of making a circular hole by removing a volume of metal from

the job by cutting tool called drill. A drill is a rotary end-cutting tool with one or more cutting
lips and usually one or more flutes for the passage of chips and the admission of cutting fluid.
A drilling machine is a machine tool designed for drilling holes in metals. It is one of the most
important and versatile machine tools in a workshop. Besides drilling round holes, many
other operations can also be performed on the drilling machine such as counter- boring,
countersinking, honing, reaming, lapping, sanding etc.

  7
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´| Bench Drill
The most common form of drilling machine is the bench drill. As the name implies this machine
is normally bolted down to a bench. The workpiece can be clamped onto the worktable or onto
the base. Tee slots are normally provided for this function. The worktable can be moved up and
down the vertical column. The worktable can be clamped at the selected height. The drill is
normally located in a three jaw chuck which is rotated by the drive system. The figure below
shows a belt drive. Modern bench drills are driven by more sophisticated arrangements. The
chuck is moved up and down by a feed handle which drives rotating spindle via a rack and
pinion mechanism.

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´| Pillar Drill
The pillar drill has the same features as the bench drill. This drill is however free standing and is
of a far heavier construction able to take larger drills. The larger drills normally have taper
shanks which are located within a taper bore in the spindle end. These tapers are standardized as
morse tapers.

´| Radial Arm Drill

The radial drill is a free standing and the work piece is clamped in position on the base. The
drill head is positioned using motorized drives.

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´| CNC controlled drilling machine

This CNC controlled drilling system is the highest capacity machine for drilling steel beams. With its 3
drilling units it is possible to drill profiles simultaneous vertically as well as horizontally. This system is
the top level machine out of the drilling range. The most advanced, the highest capacity and the most
efficient.

´| Hand Drilling Machines

Hand drilling machines are one of most commonly used hand tools for domestic as well as
industrial works. ›lectrician to plumber, carpenters to metal fabricator everyone need had
drilling machine. Hand drilling machines are normally small in size and are portable. Hand
drilling machines are equipped with a drill chuck where smaller sized drills can be held. The
hand drilling is mostly performed by holding the hand drilling machine normal to the plane
where you are making the hole and by forcing the rotating drill into the work piece.
See that you have held the hand drilling machine straight and perpendicular to the drilling face or
else you are at risk of either breakage of drill or work piece.

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& 
128

The machine has only a hand feed mechanism for feeding the tool into the work piece. This
enables the operator to feel how the drill is cutting and accordingly he can control the down feed
pressure. Sensitive drill presses are manufactured in bench or floor models,  |the base of
machine may be mounted on a bench or floor.
The main operating parts of a sensitive machine/drill press are Base, Column, Table, and Drill
Head.
´|  1 :
The base is a heavy casting that supports the machine structure; it provides rigid mounting for
the column and stability for the machine. The base is usually provided with holes and slots which
help to Bolt the base to a table or bench and allow the work-holding device or the work piece to
be fastened to the base.
´| 8/

The column is a vertical post that Column holds the worktable and the head containing the
driving mechanism. The column may be of round or box section.
´|  5
The table, either rectangular or round. Drill machine/press in shape supports the work piece and
is carried by the vertical column. The surface of the table is 90-degree to the column and it can
be raised, lowered and swiveled around it. The table can be clamp/hold the required the work
piece. Slots are provided in most tables to allow the jigs, fixtures or large work pieces to be
securely fixed directly to the table.
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The drilling head, mounted close to the top of the column, houses the driving arrangement and
variable speed pulleys. These units transmit rotary motion at different speeds to the drill spindle.
The hand feed lever is used to control the vertical movement of the spindle sleeve and the cutting
tool.
The system is called the sensitive drilling machine/press as the operator is able to sense the
progress of drill with hand-faced.

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A drill is a multi point cutting tool used to produce or enlarge a hole in the workpiece.
It usually consists of two cutting edges set an angle with the axis. Broadly there are three
types of drills:
´| Flat drill,
´| Straight-fluted drill, and
´| Twist drill
Flat drill is usually made from a piece of round steel which is forged to shape and ground
to size, then hardened and tempered. The cutting angle is usually 90 deg. and the relief or
clearance at the cutting edge is 3 to 8 deg. The disadvantage of this type of drill is that each
time the drill is ground the diameter is reduced. Twist drill is the most common type of drill
in use today. The various types of twist drills (parallel shank type and Morse taper shank
type) .

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The rotating edge of the drill exerts a large force on the work piece and the hole is
generated. The removal of metal in a drilling operation is by shearing and extrusion.

Working Principle of Drill machine Sensitive Drill Machine/Drill Press


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´| Drilling

´| Reaming

´| Boring

´| Counter boring

´| Countersinking

´| Spot facing

´| Tapping

´| apping

´| Grinding

´| Trepanning.

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This is the operation of making a circular hole by removing a volume of metal from the
job by a rotating cutting tool called drill. Drilling removes solid metal from the job to produce a
circularhole. Before drilling, the hole is located by drawing two lines at right angle and a center
punch is used to make an indentation for the drill point at the center to help the drill
in getting started. A suitable drill is held in the drill machine and the drill machine is adjusted to
operate at the correct cutting speed. The drill machine is started and the drill starts rotating.
Cutting fluid is made to flow liberally and the cut is started. The rotating drill is made to feed
into the job. The hole, depending upon its length, may be drilled in one or more steps. After the
drilling operation is complete, the drill is removed from the hole and the power
is turned off.

 /

This is the operation of sizing and finishing a hole already made by a drill. Reaming is
performed by means of a cutting tool called reamer. Reaming operation serves to make the hole
smooth, straight and accurate in diameter. Reaming operation is performed by means of a
multitooth tool called reamer. Reamer possesses several cutting edges on outer periphery and
may be classified as solid reamer and adjustable
reamer.

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Fig. shows the boring operation where enlarging a hole by means of adjustable cutting
tools with only one cutting edge is accomplished. A boring tool is employed for this purpose of
work

8
 292

Counter boring operation is shown in Fig... It is the operation of enlarging the end of a
hole cylindrically,as for the recess for a counter-sunk rivet. The tool used is known as counter-
bore.

8
 29
:

Counter-sinking operation is shown in Fig. 22.10. This is the operation of making a
coneshaped enlargement of the end of a hole, as for the recess for a flat head screw. This is done
for providing a seat for counter sunk heads of the screws so that the latter may flush withthe
main surface of the work.

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This is the operation of sizing and finishing a hole by removing very small amounts of
material by means of an abrasive. The abrasive material is kept in contact with the sides of a hole
that is to be lapped, by the use of a lapping tool.

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This is the operation of removing enough material to provide a flat surface around a hole
to accommodate the head of a bolt or a nut. A spot-facing tool is very nearly similar to the
counter-bore




It is the operation of cutting internal threads by using a tool called a tap. A tap is similar
to a bolt with accurate threads cut on it. To perform the tapping operation, a tap is screwed into
the hole by hand or by machine. The tap removes metal and cuts internal threads, which will fit
into external threads of the same size. For all materials except cast iron, a little lubricate oil is
applied to improve the action. The tap is not turned continuously, but after every half turn, it
should be reversed slightly to clear the threads. Tapping operation is shown in Fig.


2 42

Core drilling operation is shown in Fig.. It is a main operation, which is performed on
radial drilling machine for producing a circular hole, which is deep in the solid metal by means
of revolving tool called drill.

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Machine Table Vice: The machine vice is equipped with jaws which clamps the work piece.
The vice can be bolted to the drilling table or the tail can be swung around swung around. Fig. shows the
standard and swivel vice. The swivel vice is a machine wise that can be swivel through 360° on a
horizontal plane.

Machine Table vice.

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It¶s the peripheral speed of the drill. The cutting speed depends upon the properties of the
material being drilled, drill material, drill diameter, rate of speed, coolant used etc«

v = *D*N

where

D = dia of the drill in m

N = Speed of rotation in rpm

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It¶s the movement of drill along the axis (rpm)

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The distance from the machined surface to the drill axis.

d=D/2

As the depth of hole increases, the chip ejection becomes more difficult and the fresh cutting fluid
is not able to cutting zone. Hence for machining the lengthy hole special type of drill called µgun drill¶ is
used.

  2  /0   39
It¶s the volume of material removed by the drill per unit time

MRR = (D2 / 4) * f * N mm3 / min

 

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It depends upon the length (l) of the hole to be drilled , to the Speed (N) and feed (f) of the drill

t =  / f N min

 

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Drilling is done on heavy and larger objects manually but if holes are to be drilled at
certain angles it is impossible to achieve accuracy by hand drilling. Hence there is a need for
better and futuristic equipments in order to make human work easier which has been the sole
concern behind every inventions that we see today in our day to day life. A similar effort to give
rise to a new cost effective and simpler solution to the already present radial drilling machine is
the main objective of our project. Our project is made keeping in mind of the needs of present
day small scale industry and provide them the ease of working which was previously benefited
only by the large scale industries who had huge investment capital. Since it is a portable type of
design this machine also removes the difficulties of dismantling work pieces and then drilling it
instead it can be used to directly mount on the large work piece or near to it.

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´| In a radial arm drilling machine can only rotate upto 270o about its base

´| Work part should always be smaller than its work table form it perform the drilling
operation.

´| As machine being very heavy its less portable

´| Cost of machine is also high

´| Maintenance of machine is also high

´| Difficult for the small scale industries to afford the costlier machines

´| Angular drilling cannot be done on the work piece

´| More space is required

´| Reach of the machine is very limited to structure

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From time immemorial, there has been a lot of problem faced by people .They use to
drill manually, which is time consuming process and is a hectic job. The modern drilling
machine available in market is costly and small scale industries cannot afford it.

In order to overcome this problem we are coming out with a new idea of multi axis arm
type drilling machine.

Multi axis arm type drilling machine is something that was not available for small scale
industries but our design has brought down the cost of the machine in such a way that any small
scale industries can implement it.

Here the whole assembly need not be dismantled instead by modifying our base we can
fix our machine on to the assembly itself

It is simple to use and complicated drills can be achieved very easily.

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  1 
The base acts a support for the whole machine. The parts of the base are mentioned
below

Base Plate
Design of the lower base plate is made such so that it allows various ways of clamping on to
ground as well as on to any work bench. It¶s made of a cast iron .›ngraving are made on to it
measure the angle of rotation .ower base plate holds the complete structure on to it. Shock
absorbing pads can be placed at bottom to reduce vibration during machining operation. ocking
of base plate can be done using high tension bolts on ground. ocking of base plate on the work
bench can be done using the C- clamps and various other clamping devices.

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Base plate contains of the following parts:

X| Spigot
X| T slot
X| T bolt

SPIGOT

´| It has a diameter of 126mm and a height of 11mm. It has the main support for upper base
plate.
´| It helps upper base plate to revolve over bottom base plate achieving 360° angle of
rotation without missing the angle of axis of rotation.
´| It maintains the centre axis of two plates while rotation.
´| It helps the upper plate to rotate at greater accuracy.
´| It¶s has smoother finish to reduce friction at contact region of plates.


´| It has a diameter of 286mm and a height of 13mm. It is made of Cast iron material.
´| It is used to guide the bolt.
´| Its main purpose is to lock the upper base plate with help of the nuts.
´| The base consists of a hole to guide the bolts into it.

  
´| It has a diameter of 246 mm and a slot below of 126mm to a depth of 12mm for it to
accommodate on the base. It is made of ›N8 material.
´| It consist of spigot mechanism as well to give 180o rotation to the arm assembly
´| The rotation of the vertical plate is done using another mechanism i.e. Worm gear
mechanism. This mechanism is driven manually using hand held lever
´| The degree of rotation is measured using engravings provided on plate
´| A worm gear used is a 24 teeth 2.5 module a single start worm. Hence one full rotation of
the worm will rotate the arm assembly by 15 degrees.

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´| Since we have used a single start worm gear it prevents slippage and reverse motion due
to the load of the arm. Hence some amount of locking is done.
´| Spigot helps in maintaining the axis of rotation and does not allow the axis of rotation to
change hence maintaining the accuracy of rotation. Back lash is very less.


  
´| The dimensions of this plate is 225x120x16mm.
´| It has 4 holes in order to accommodate on the base assembly.
´|

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´| The pinion or worm has a smaller number of teeth, usually one to four, and since they
completely wrap around the pitch cylinder they are called threads. Its mating gear is
called a worm gear, which is not a true helical gear.
´| A worm and worm gear are used to provide a high angular velocity reduction between
non-intersecting shafts which are usually at right angles. The worm gear is not a helical
gear because its face is made concave to fit the curvature of the worm in order to provide
line contact instead of point contact. Because of the line contact, worm gear can transmit
high tooth loads. The disadvantage of worm gearing is the high sliding velocities across
the teeth.

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The arm is of a hollow rectangular tube. It has dimensions of 40*80*400. It is made up of M.S. medium
carbon steel. There are two arms:

´| Primary arm
´| Secondary arm.

The primary arm holds the secondary arm and it is with the help of this arm the 180° of rotation is
transferred from the t plate to the secondary arm in order to move the drill head at angles.


128
2/ 27 2/
It is made of M.S. rectangular tube.

Firstly a rectangular tube of 420mm is taken. Two holes are drilled on either face of the arm. The
side of the arm is engraved like a U section and cut with axe blade to ease the rotation of arms
over the spigot and the secondary arm.

Four rectangular blocks of ›N 8 material are used to place inside the end part of the
hollow rectangular bar so that it can withstand the self load of the machine and the bending
moment on the ends. The blocks are welded by tig welding operation.

Hand grinding is done to make circular shape at the end of the arms in order to accommodate
more angular motions and to provide good surface finish. High tension bolts are used to lock the
arms on the spigot of the T slot and 3 scrub screws are used around the bolt at each end of the
arm to increase the contact surface area and prevent the slippage of arm due to self weight. The
final dimensions of arm is 40*80*400.

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128
 
4 27 2/
It is made up of M.S. steel. This arm joins the primary arm and the drill head(cross slide).

Construction:

An arm of 420 mm is taken and cut. It is cut in such a way that a 16x75mm remains on the ends
of the rectangular plate.

Then two small ›N8 rectangular plates are welded at both the ends and grinded to a semi circular
shape so that easy rotation of arms can be achieved.

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It has the following parts:

Feed rod: which gives the feed for the drilling machine.

Clamp mechanism: It is used to hold the drilling machine intact with the cross slide.

ead screw: It is used to give the linear motion to the cross slide.

Hand wheel: To provide feed and the depth of the hole.

Guide ways: Guides the rectangular plate on which the hand drill is fixed.

There is a aluminium fixture that comes on the rectangular block in order to clamp the drilling
machine.

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The cross slide along with drilling machine.

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We have used a hand drilling machine to be fixed on the cross slide. The hand drilling
machine weighs around 1.8 kg and a maximum speed of 3000 rpm at no load condition. Power
required to run the drilling machine is around 450Watts. It is a variable speed drilling machine.
A maximum of 10mm drill can be achieved with variable speed control.

Our drilling machine can drill holes on concrete, wood and metal. The drill bit can be rotated
both clockwise and anticlockwise direction.

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The drilling machine can be changed depending on the customer requirements and hence the
drilling capacity need not be limited because specific drilling machine have their capacities.


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´| Complete automation can be achieved

´| ›asy locking technique can be derived.
´| 180o rotation of the upper base plate can be modified further more to achieve 360o
rotation
´| Mobility of machine can be increased.
´| Portability can be improvised.
´| Base bottom plate can be magnetized for an environment where no clamping is possible.
´| ocking in the base can be further accurate by the use of gears or any stepper motor.

,  #  #

´| The machine can be automated by fixing motors at joints so as to rotate the base, arms
and cross slide.

´| ocking mechanism can be improvised for greater accuracy by giving graduated scales.

´| The drilling head assembly with slide can be replaced by other equipments like tig
welding gun/ gas welding nozzle/ gas cutting equipment thus making it a multifunctional
machine.

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40
  1
´| Price comparative to other available in market will be much cheaper the presently
available smallest radial drilling machine will cost approximately 1.5 lakhs well this
machine costs only 40000 rupees.
´| High accuracy while drilling complex drills can be achieved.
´| It is a multifunctional portable machine.
´| The sixth degree of freedom is an added advantage of using the machine.
´| The machine design on further up gradation is a new step towards evolution of drilling
machine would outnumber the presently available model.
´| Helping the needy small scale industries had been our motto and we have succeeded in
giving a simpler solution which has a huge scope to be improvised in the near future.
´| The flexibility of machining is also one of the main feature of our machine.

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Our project is a sincere and combined effort from all the team members involved. The
team goal was to produce a cost effective drilling machine which would help the small scale
industry. It would help to drill holes easily at any desired angle accurately. So this project stands
in line to produce fully automated portable drilling machines in the upcoming years. There are
plans to develop the project in the near future. This is just the beginning.

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:12  22 4

wPRODUCTION T›CHNOOGY´ by TATA McGRAW-HI

wMACHIN› D›SIGN DATA HANDBOOK´ by Dr. K. INGAIAH

 1  22 4
www.google.com

www.wikipedia.org|

http://www.scribd.com/doc/29436115/Introduction-to-Drilling-Technology

http://www.radialdrillingmachine.net/

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