DRILLING

Many types of drilling machines are used in engineering manufacture and the choice of a
particular drilling machine will depend on the diameter of the hole to be drilled and whether
the drilling operation is part of a mass production process. If holes are to be drilled in single
components, a considerable degree of skill is required and generally three types of drilling
machines are used;
1. Sensitive drilling machine
2. Pillar drilling machine
3. Radial drilling machine

a. Sensitive Drilling machine

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Sensitive drilling machine
In this machine, changes in spindle speeds are affected by changing the position of the
driving belt on the conned pulley while a self-centering chuck allows rapid drill changing.
The feeding of the drill is motivated by hand permitting a nice sense of feel which is very
necessary when drilling small diameter holes hence the name sensitive driller.
The drill is unsuitable for drilling large holes or operations such as counter boring, spot
facing or countersinking.

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 b. Pillar Driller

Pillar Drilling Machine

This can be considered to be a stronger and more robust type of sensitive driller. Although
provision is made for hand feed of the drill, its usually possible to feed the drill automatically
(feeds of 0.076mm/rev-0.38mm/rev). The spindle speeds are usually lower (50rpm-1200rpm)
than those of a sensitive driller thus permitting the use of larger diameter drill bits (6mm-
25mm) and operations such as spot facing. The pillar driller also offers greater work holding
capabilities

Worktable Movements of a Pillar Drilling Machine

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The arm holding the table can move up and down. The table can be rotated 360o on the arm
supporting it. The arm in turn can be rotated 180o around the main column and locked in any
position.
Gang drilling: A gang-drilling machine consists of several individual columns, drilling
heads, and spindles mounted on a single base and utilizing a common table. These machines
are designed for machining parts requiring several hole-machining operations, such as
drilling, countersinking, counterboring, or tapping. The workpiece is moved from one drilling
spindle to the next, where sequential machining operations are performed by one or more
operators.

Multi spindle drilling: It is used to drill two or more holes in a work piece simultaneously.
The holes are drilled on number of work pieces with the same accuracy, so as to make them
interchangeable.

Types of Drills
The most common drills are twist drills
Twist drills
The modern twist drill is made from a cylindrical blank by machining two helical groves into
it to form flutes. The flutes run the full length of the body and have several functions
a. Provide the rake angle
b. Form the cutting age
c. Provide passage for the coolant
d. Facilitate swarf removal

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The flutes are slightly tapered relative to the axis of the drill and become shallower towards
the shank as shown

Sharpening of drills:
Sharp drill bits are fun to use, they work so well. Dull bits are dangerous and easily break.

There are many features on a drill bit that can be defined with the three most basic features
being: the lip, land, and chisel.
The "lip" is what does the actual cutting. The two lips on the twist drill should be symmetric
if an equal cutting is to be done while drilling. If one lip is favored while sharpening, it will
become bigger than the other and most of the cutting will be performed on one side of the bit.
This is bad as it makes non-straight holes and breaks the drill bit in no time.

The "land" or "landing" is what follows the lip and will support the sharp edge while the bit is
cutting. The landing must be angled in such a way that it leaves clearance between the part
you are trying to drill and the lip. However, too much angle subtracts support from the lip,
and will cause the bit to chip more often, especially on the corners.
The "chisel" is the line which is created when the landing from both sides of the twist drill
intersect. In truth, this area does no cutting. Don't think of it as a true chisel. In fact, while the

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drill is turning and being forced down into your work-piece, the chisel smears the wood or
metal you are drilling into the lips. For this reason, it is especially important to create a very
small chisel.

Speeds and Feeds of drills

In drilling, the speed of the drill is one of the most important factors to be considered. The
speed could be referred to as the cutting speed, the surface speed or peripheral speed. It is the
cutting speed of a point on the circumference of the drill in meters per minute, that is, a drill
with a cutting speed of 100 m/min if rolled on a flat surface would travel 100 meters in one
minute
If
CS= Cutting speed recommended (m/min)
D= Diameter of the drill bit (mm)
N= Revolutions per minute of the drilling machine.
T= time required to machine a hole (min)
L= length of travel (mm)

Then it follows that

𝜋𝐷𝑁
1) 𝐶𝑆 = 1000 𝑚/𝑚𝑖𝑛

2) L = Metal thickness + Length of approach + over travel

𝜋𝐷 2
3) Material removal rate = × 𝑓 × 𝑁 𝑚𝑚3 /𝑚𝑖𝑛
4
𝐿
4) 𝑡 = 𝑓𝑁 𝑚𝑖𝑛

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Example.

You are required to drill a 30 mm diameter hole in a workpiece having a thickness of 60mm
to the complete depth. The cutting speed is 20 m/min. and the feed is 0.25 mm/rev. Assume
the length of approach to be 10mm and over travel to be 2 mm. Determine

i) The drill rotation speed(rpm)

𝜋𝐷𝑁
𝑠𝑝𝑒𝑒𝑑 = 𝑚/𝑚𝑖𝑛
1000
𝑠𝑝𝑒𝑒𝑑
𝑁 = 1000 ×
𝜋𝐷
20
= 1000 × = 𝟐𝟏𝟐. 𝟐𝟏𝒓𝒑𝒎
𝜋 × 30
ii) The length of travel of the drill
L = Metal thickness + Length of approach + over travel
= 60mm + 10mm + 2mm = 𝟕𝟐𝐦𝐦

iii) The material removal rate(MRR)

𝜋𝐷2
Material removal rate = × 𝑓 × 𝑁 𝑚𝑚3 /𝑚𝑖𝑛
4
𝜋 × 302 𝑚𝑚3
= × 0.25 × 212.21 = 𝟑𝟕𝟓𝟎𝟎. 𝟔𝟎 𝑚𝑚3 /𝑚𝑖𝑛
4 𝑚𝑖𝑛

iv) The time required to just drill the hole

𝐿
𝑡= 𝑚𝑖𝑛
𝑓𝑁
72
𝑡= 𝑚𝑖𝑛 = 𝟏. 𝟑𝟓𝟕𝑚𝑖𝑛
0.25 × 212.21

NB
Feed is the distance the drill advances into the work for each revolution

Work handling methods on a drilling machine

It’s very important that the work should be held securely by clamping it to the table to avoid
inaccurate wok and to avoid accidents. All work should always be bolted unless it’s so large
and heavy that it could not possibly give any trouble. Fixtures used to achieve these include
machine vices, vee blocks, angle plate and clumps.

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 Machine Vice
Angle plate

Drilling jigs and fixtures.

Jigs and fixtures are production tools used to accurately manufacture duplicate and
interchangeable parts. Jigs and fixtures are specially designed so that large numbers of
components can be machined or assembled identically, and to ensure interchangeability of
components.
A jig in particular is a work holding device that holds, supports and locates the workpiece
and additionally guides the cutting tool for a specific operation. Jigs are usually fitted with
hardened steel bushings for guiding or other cutting tools. a jig is a type of tool used to
control the location and/or motion of another tool. An example of a jig is when a key is
duplicated, the original is used as a jig so the new key can have the same path as the old one.
A fixture on the other hand is a work holding device that holds, supports and locates the
workpiece for a specific operation but does not guide the cutting tool. It provides only a
reference surface or a device. What makes a fixture unique is that each one is built to fit a
particular part or shape. The main purpose of a fixture is to locate and in some cases hold a
workpiece during either a machining operation or some other industrial process.

A jig differs from a fixture in that it guides the tool to its correct position in addition to
locating and supporting the workpiece.

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A drill bushing, also known as a jig bushing, is a tool used in metalworking jigs to guide
cutting tools, most commonly drill bits. They are designed to guide, position, and support the
cutting tool.

Lathe Machine Operations.

Turning – a machining process in which a single-point tool remove material from the surface
of a rotating work piece. It’s done to decrease the diameter of the work.
Facing: It’s a machining process in which material is cut from the end in order to generate a
flat surface.
Boring – This is the process of enlarging a hole that has already been drilled/cast using a
single point cutting tool. Cutting is done inside diameter of the work material.
Drilling: This is a cutting process that uses a drill bit to cut a hole of circular cross section in
a material.
Threading: This is the process of cutting screws on a circular blank.

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