MACHINING PROCESS –I

Lecture 7
Drilling and Related Operations

Engr. Muhammad Mahboob

 Drilling
Machining operation used to create a round hole in a work
part.
Contrasts with boring which can only enlarge an existing
hole.
Cutting tool called a drill or drill bit-a rotating cylindrical tool
which has two cutting edges on its working end.
The rotating drill feeds into the stationary work part to form
a hole whose diameter is equal to the drill diameter.
Drill Bit
 Operations Related to Drilling
Most of these operations follow drilling; a hole must be made
first by drilling, and then the hole is modified by one or the
other operations
Reaming
Tapping
Counter boring
Countersinking
Centering
Spot facing
 Reaming
Used to slightly enlarge a hole, provide better tolerance on
diameter, and improve surface finish.
The tool called reamer has straight flutes.
 Tapping
Used to provide internal screw threads on an existing hole.
Tool called a tap.
 Counter boring
Provides a stepped hole, in which a larger diameter follows a
smaller diameter partially into the hole.
Used to seat bolt heads into a hole.
 Countersinking
This is similar to counter boring, except that the step in the hole is
cone-shaped for flat head screws and bolts.
 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.
 Spot facing
Spot facing is similar to milling.
It is used to provide a flat machined
surface on the work part in a localized area.
Countersinking Centre drilling Spot facing
 Cutting Conditions in Drilling
To determine the rotational speed of the drill. Letting N
represent the spindle rev/min,

where
v = cutting speed, mm/min (in/min);
D= the drill diameter, mm (in).
In some drilling operations, the work piece is rotated about a
stationary tool, but the same formula applies.
 Cutting Conditions in Drilling
Feed f in drilling is specified in mm/rev (in/rev).
Recommended feeds are roughly proportional to drill
diameter; higher feeds are used with larger diameter drills.
Feed can be converted to feed rate using the same equation
as for turning.

where
fr = feed rate, mm/min (in/min).
 Cutting Conditions in Drilling
The machining time required to drill a through hole can be determined by
the following formula

where
Tm = machining (drilling) time, min;
t = work thickness, mm (in);
fr =feed rate, mm/min (in/min);
A = an approach allowance that accounts for the drill point angle
 Cutting Conditions in Drilling
Thus, for a blind hole, machining time is given by

where
A = the approach allowance
θ= drill point angle.
 Through Holes vs. Blind Holes
Through-holes - drill exits the opposite side of work
Blind-holes – drill does not exit work on opposite side

Two hole types: (a) through-hole, and (b) blind hole

 Cutting Conditions in Drilling
The rate of metal removal in drilling is determined as the product of
the drill cross sectional area and the feed rate.
 Problem 1
A drilling operation is to be performed with a 12.7 mm diameter twist
drill in a steel workpart. The
hole is a blind hole at a depth of 60 mm and the point angle is 118°.
The cutting speed is 25 m/min
and the feed is 0.30 mm/rev. Determine (a) the cutting time to
complete the drilling operation, and
(b) metal removal rate during the operation, after the drill bit reaches
full diameter.
 Solution
(A)
N = v/πD = 25(103) / (12.7π) = 626.6 rev/min
fr = Nf = 626.6(0.30) = 188 mm/min
A = 0.5D tan (90 – θ/2)
= 0.5(12.7)tan(90 – 118/2) = 3.82 mm
Tm = (d + A)/fr
= (60 + 3.82)/188 = 0.339 min
(B)
RMR = 0.25πD2fr = 0.25π(12.7)2(188) = 23,800 mm3/min
 Problem 2
A gun drilling operation is used to drill a 9/64-in diameter hole
to a certain depth. It takes 4.5 minutes to perform the drilling
operation using high pressure fluid delivery of coolant to the
drill point. The current spindle speed = 4000 rev/min, and
feed = 0.0017 in/rev. In order to improve the surface finish in
the hole, it has been decided to increase the speed by 20%
and decrease the feed by 25%. How long will it take to
perform the operation at the new cutting conditions?
 Drill Presses: The Machine Tools
for Drilling
The standard machine tool for drilling is the drill press.
There are various types of drill press.
1. Upright drill
2. Bench drill
3. Radial drill
4. Multi spindle drill
5. Gang drill
6. Cnc drill presses
 Upright drill
The upright drill stands on the floor and consists of a table for
holding the work part, a drilling head with powered spindle
for the drill bit, and a base and column for support.
 Bench drill
Similar drill press, but smaller, is the bench drill, which is
mounted on a table or bench rather than the floor.
 Radial drill
The radial drill, is a large drill press designed to cut holes 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.
 Gang drill
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 work part along the worktable from one spindle to the
next.
GANG DRILL
 MULTIPLE SPINDLES
A related machine to gang drilling is the multiple-spindle
drill, in which several drill spindles are connected together to
drill multiple holes simultaneously into the work part.
MULTIPLE SPINDLES
 CNC drill presses
CNC drill presses are available to control the positioning of
the holes in the work parts.
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.
 CNC Turret Drilling Machine

Figure A three-axis computer numerical control drilling

machine. The turret holds as much as eight different
tools, such as drills, taps, and reamers.
 Work Holding for Drill Presses
Work part can be clamped in a vise, fixture, or jig
Vise
general purpose work holder with two jaws
Fixture
work holding device that is usually custom-designed for the particular work
part.
The fixture can be designed to achieve higher accuracy in positioning the
part, faster production rates, and greater operator convenience in use
Drill jig
similar to fixture but also provides a means of guiding the tool during drilling
Drill Jig