Drilling

1.0 Introduction
The drilling machine or the drill press is essential in any
metalworking shop. Although drill presses are manufactured in a
wide variety of types and sizes, all drilling machine contain certain
basic parts. A bench type sensitive drill press (pillar drill) is shown
in fig 1.

Fig. 1- Pillar drill

Its main parts are the:

Base- Usually made of cast iron, it provides stability to the
machine and also rigid mounting for the column.
Drilling head- Contains the mechanism used to revolve the
cutting tool and advance it into the workpiece.

 Column- Accurate cylindrical post that fits into the base. The
table is fitted to the column and may be adjusted to any point
between the base and the head.
Table- Either round or rectangular in shape, it is used to
support the workpiece to be machined.
Other types of drilling machines: Upright, radial and numerical
control drilling machines.

2.0 Tool holding devices

The most common tool holding devices found in a machine shop
are drill chucks.

2.1 Drill chuck

Drill chucks are the most common devices used on a drill press for
holding straight shank cutting tools. The most common types of
drill chucks are: key type and keyless type.
Key type drill chucks
Small drills have straight (parallel) shanks and they are usually
held in a self centering chuck. This can be observed in fig.2.

Fig. 2- Drill chuck and chuck key

Many different types of chuck keys are available, each adjustable

over a complete range to give good gripping power. To ensure
maximum grip, the chuck should be tightened using the correct
chuck key. This prevents the drill from spinning during use and
chewing up the drill shank.
Keyless drill chucks
They are used more in production work since the chuck may be
loosened or tightened by hand without a key.
Large drills have tapered shanks (Morse-taper shanks) which fit
directly into the spindle without the need for a chuck. They are
located and driven by a taper, as shown in fig. 3. To remove the
shank from the spindle a taper key, known as a drift is used.

Fig. 3- Morse taper shank and drift

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3.0 Precaution to be taken when using the chuck

key
A hazard in the use of chucks is the possibility of leaving a chuck
key in position. When machine is switched on the key can fly in
any direction and cause serious injury. Hence, after tightening a
chuck, the chuck key must always be removed.

4.0 Twist drill

4.1 Parts of a twist drill
Twist drills are used to produce holes in most types of material.
The different parts of a drill are shown in fig. 4:
Shank Generally drills up to 13 mm diameter have straight
shanks, while those over this diameter have tapered shanks.
Straight-shank drills are held in a drill chuck. Tapered-shank drills
fit into the internal taper of the press spindle.
Flutes
The flutes run full length of the body and have several functions:
1. They provide the rake angle
2. They form the cutting edges
3. They provide the passage of the coolants
4. They facilitate swarf removal.
Web
It is the thin partition in the centre of the drill that extends full
length of the flutes. This part forms the chisel edge at the cutting
end of the drill. The web gradually increases in thickness toward
the shank to give the drill strength.

Point
The point of a twist drill consists of the chisel edge, lips, lip
clearance and heel. The chisel edge is the chisel-shaped portion of
the drill point. The lips are the cutting edges and must be equal in
length and have the same angle so that the drill will run true and
does not cut a hole larger than the size of the drill. The clearance is
the relief ground to the point of the drill extending from the cutting
lip back to the heel. The average lip clearance is from 80 to 120,
depending on the hardness or softness of the material to be drilled.

Fig. 4- Parts of a twist drill

Web- Extends the full length of the flutes and forms the chisel edge
at the cutting end of the drill.

4.2 The cutting edge

Efficient drilling of a wide variety of materials used in the industry
requires a great variety of drill points. A drill is generally
considered a roughing tool capable of removing metals quickly. It
is not expected to finish a hole to the accuracy possible with a
reamer. However, a drill can often be made to cut more accurately
and efficiently by proper drill point grinding.
When regrinding the drill, it is essential that the point angles are
correct. The angles and lip length must be symmetrical. Otherwise
incorrect drilling will be performed as shown in fig. 5.

Fig. 5- Effects of incorrect angles

If the lip length is unequal, an oversized hole will result. If the
angles are unequal, then only one lip will cut and undue wear will
result. An unbalanced force will cause the drill to flex and
wander. The hole will become displaced as drilling proceeds. If
both faults are present at the same time, an inaccurate ragged hole
will result.
The use of various point angles and lip clearances will:
1. Control the size, quality, and straightness of the drilled hole.
2. Control the size, shape, and formation of the chip.
3. Control the chip flow up the flutes.
4. Increase the strength of the drills cutting edges.
5. Reduce the rate of wear at the cutting edges.
6. Reduce the amount of drilling pressure required.
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7. Control the amount of burr produced during drilling.

8. Reduce the amount of heat generated.
9. Permit the use of various speeds and feeds for more efficient
drilling.
4.3 Point angles
Conventional point (1180) The most commonly used drill points
and gives satisfactory results for most generally purpose drilling.
For best results the lip clearance should be 80 to 120.
Long angle points (600 to 900) Used for drilling nonferrous
metals, soft cast irons, plastics, fibres, and wood. Lip clearance is
generally 120 to 150.
Flat angle point (1350 to 1500) Generally used to drill hard and
tough materials. Lip clearance is generally 60to 80 to provide as
much support as possible for the cutting edges.

Fig. 6

4.4 Types of twist drill

A variety of twist drill styles are manufactured to suit specific
drilling operations, types and sizes of material, high production
rates, and special applications. The design may vary according to
width of flutes, the amount of helix, rake angle of the flutes, or the
shape of land or margin.
Twist drills are manufactured from:
(i) carbon tool steel- used in hobby shops;
(ii) high-speed steel- used in machine shops;
(iii) cemented carbides- used in industry to drill hard
materials.
Types of drill:
(i) General purpose drill consists of 2 helical flutes. It is a
general purpose drill.
(ii) Low-helix drill Used to drill brass and thin materials. It
can remove large volume of chips formed by high rates of
penetration.
(iii) High helix drills- Are designed to drill deep holes in
aluminium and other materials where the chips have
tendency to jam in the hole. They consist of wider flutes
which assist in clearing the chips.
(iv) Core drill- Designed with three or four flutes.- Used to
enlarge cored, drilled or punched holes. Produces a good
finish.
(v) Straight fluted drill Used to drill soft materials such as
brass, bronze, copper, etc. Does not draw itself into the
material while cutting.
(v) Spade drills- Has two cutting lips.
(vi) Step drill- 2 or more diameters ground on it. Can be used
to drill and countersink or drill and counterbore different
sizes of holes in one operation.
(vii) Saw-type hole cutter.

Fig. 7- Types of drill

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4.5 Drilling speed

Cutting speed is the distance that a point on the circumference of a
drill will travel in 1min. It is normally given in metres per minute
(m/min). It can also be given in terms of revolutions per minute
(r/min).
The drilling machine can be run at various speed. High speeds are
used for drills of small diameters and low speed for those of large
diameters. Higher speeds are also used on softer materials.
Different materials have different recommended speeds. This is
shown in Table 1.
Table 1- Cutting speeds for high speed steel twist drills:
Material
being
Cutting speed
drilled
(m/min)
Aluminium
70-100
Brass
35-50
Bronze
20-35
Cast iron
25-40
Copper
35-45
Mild steel
30-40
Medium carbon steel
20-30
Thermosets
20-30

The cutting speeds are based on:

The work is rigidly clamped.
The machine is in good condition.
A coolant is used if required.
The drill is correctly selected.
Twist drill cutting angles

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Converting m/min into r/min

To determine the correct number of r/min of a press spindle for a
given drill size, the following should be known:
1. The type of material to be drilled.
2. The recommended cutting speed of the material.
3. The type of material from which the drill is made.
Formula:
r/min = [Cutting speed (m/min)x1000]/D(mm)

5.0 Feed
Feed is the distance that a drill advances into the work for each
revolution. Since the feed rate is a determining factor in the rate of
production and the life of the drill, it should be carefully chosen for
each job. The rate of feed is generally governed by:
The diameter of the drill.
The material of the workpiece.
The condition of the drilling machine.
A general rule of thumb is that the feed rate as the drill size
increases. A drill size of 6mm, e.g., will have a feed of only 0.05 to
0.1mm, while a 25mm drill will have a feed of 0.25 to 0.63 per
revolution. Too coarse a feed may chip the cutting edges or break
the drill. Too light a feed causes chattering or scraping noise,
which quickly dulls the cutting edges of the drill.

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6.0 Drilling calculations

A. Drill Speed (Spindle speed), rpm

N=

k CS
D

D is Drill Diameter
V (or CS) is cutting speed (a Handbook Value)
N = machine speed in revolutions/minute (rpm)
k is a constant to correct speed (V) and part diameter (D i )
Units
V given in surface feet per minute, D1 in inches: k = 12
V given in meters per second, D1 in mm: k = 60000
V given in meters per minute, D1 in mm: k = 1000
If CS for a given rpm rate is desired, CS = ND/k

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B.

Cutting Time (min)

CT

(L + A )
fr* N

A is a llo w a n c e ; u s u a lly
f

D
2

is d rill fe e d ra te

L is le n g th o f H o le

C.

MRR is (again) Material Removal Rate

MRR =

Vol . Removed D 2 Lf r N D 2 f r N
=
=
CT
4L
4

And note, no material is removed while the Drill travels through

the Allowance Zone
Use caution with units!!

6.1 Example
Calculate the r/min required to drill a 15 mm hole in tool steel
using a high-speed steel drill. Assume the cutting speed = 18
m/min.
r/min= [18x320]/15
= 384

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7.0 Cutting fluids

Drilling work at the recommended cutting speeds and feeds causes
considerable heat to be generated at the drill point. This heat must
be dissipated as quickly as possible; otherwise it will cause the
drill to dull rapidly. Basically a good cutting fluid should:
1. Cool the workpiece and tool.
2. Reduce friction.
3. Improve the cutting action
4. Protect the work against rusting.
5. Wash away chips.
Soluble oil is a recommended cutting fluid for many materials such
as aluminium and steel alloys.

8.0 Work holding

It is dangerous to hold work being drilled by hand. There is always
a tendency for the drill to grab the work and spin around it.
Therefore, the work should be securely fastened to the machine
table.
Nevertheless, small holes in relatively large components are
sometimes drilled with work handheld. Small work can be held in
a machine vice. Larger work can be clamped directly to the
machine table. Vee blocks, angle plates and parallel plates can be
used for that purpose. This is shown in fig. 6.

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Fig. 8- Holding work for drilling

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9.0 Drilling operations

9.1 Use of twist drill
Whenever there is a need to drill a hole in a piece of metal, the
position of the hole on the workpiece is marked out. The centre of
the hole is indicated by a centre dot, using a centre punch. This
centre dot is used to line up the drill and as a means of starting the
drill in the correct position. The workpiece is set on the worktable,
carefully clamped in position or held in a vice as shown above.
Before the drilling operation is started, the size of the drill is
checked. If the diameter of the hole is too large, it should be drilled
with a smaller diameter drill first. Then the required drill size is
used.
Most trouble in drilling arises when the drill breaks through the far
surface. The drill is guided through the workpiece by the cutting
edge, keeping the hole straight. When the cutting edge breaks
through the other side of the workpiece, the cutting edge can no
longer guide the drill and keep it central, and the drill will then
wobble and bounce in its own hole, an occurrence known as
chatter.
When the complete drill point has almost broken through there is a
tendency for the drill to snatch or grab. This happens when the
metal still to be cut is so thin that it is pushed aside rather than cut
and the drill pulls itself through the helix angle, in the same way
that a screw thread advances. In the case an unclamped work, it
would be pulled up the drill, wrenching it out of the hand holding it
and causing injury or breakage, or both.
There is one more problem with drilling thin sheets; when the drill
is pushed with too much force into the metal, it tends to distort the
thin sheet initially, rather than cut it.

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To prevent all these problems, thin sheets can be supported on

waste metal plates while drilling.

9.2 Drilling work held in a vice

The most common method of holding small workpieces is by
means of a vice which may be held by hand or clamped to the table
[for holes larger than 13 mm diameter, the vice should be clamped
to the table as shown in fig. 9].

Fig. 9
1. Spot the hole location using a centre punch
The chisel edge at the end of the web on most drills is generally
wider than the centre punch mark on the work, and therefore it is
difficult to start a drill at the exact location. To prevent the drill
from wandering off centre, it is considered good practice to first
spot every centre punch mark and provide a guide for the larger
drill which will be used.
2. Mount the correct drill in the drill chuck.
3. Set the drill press to the proper speed for the size of drill and the
type of material to be drilled.

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4. Fasten a clamp.
5. Mount the work on parallels in a drill vice and tighten it
securely.
6. With the vice against the table top, locate the spotted hole under
the centre of the drill.
7. Start the drill press spindle and begin to drill the hole.
8. Raise the drill occasionally and apply cutting fluid during the
drilling operation.
9. Ease up the drilling pressure as the drill starts to break through
the workpiece.

9.3 Standard operations

A Drilling produces a straight hole

B Countersinking- A countersink bit is used to produce a
countersunk hole to receive countersunk head of rivets and screws.
For this reason the included angle is 900.
C Reaming- To finish a hole accurately to the required size.
D Boring Used to true and enlarge a hole.
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E Spot-facing Produces a square surface.

F Tapping Produces internal threads.
The most common taps used in a drill press are the hand taps.
Hand taps are available in sets containing the taper, plug and
bottoming taps.
G Counterboring - Used to enlarge an existing hole to provide a
flat and square seating for a screw, bolt, or nut under the workpiece
surface.
Homework
1. The fig. shows a door bolt made of mild steel. Describe how you
would fabricate part B of the door bolt in the workshop, paying
particular attention to the slot.

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