Module 3 Drilling, Boring and Broaching

1
 Drilling
Working principle: The rotating edge of the drill exerts a
large force on the workpiece and the hole is generated.
The removal of metal in a drilling operation is by
shearing and extrusion.

Portable drilling machine: It is a small light weight,

compact and self contained unit that can drill holes upto
12.5 mm diameter. The machine is driven by a small
electric motor operating at high speed. The machine is
capable of drilling holes in the workpieces in any
position. 2
 Drilling operation

Spot facing: Spot facing is the

operation of smoothing and squaring Boring: Boring is the operation of truing
the surface around and at the end of a Tapping: Tapping is the and enlarging a previously drilled hole by
hole so as to provide a smooth seat operation for making internal means of a single point cutting tool.
for a nut or for the head of a cap threads in a hole by means of a Boring is done on drilling machine to
screw. Spot facing is generally done tool called tap. The tap is perform the following tasks on a hole
on castings and forgings. essentially a bolt with threads already drilled:
cut on it.

3
 Drilling operation

Counter boring: Counter boring is the

Counter sinking is the operation of Reaming: The holes that are produced by
operation of enlarging one end of an
making a cone shaped enlargement drilling are rarely straight and cylindrical in
existing hole concentric with the original
at the end of a hole to provide recess form. To produce accurate and smooth holes,
hole with square bottom. It is done to
for a flat head screw or a the drilled holes are reamed by a tool called
accommodate the heads of bolts, studs
countersunk rivet. reamer. The reamer is a cutting tool having
and pins
several cutting edges in straight or helix
4 shape.
Twist drill Geometry
• 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.

5
 Body: The portion between the shank and the
drill bit tip is called ‘Body. The body is mostly
fluted and relieved.
Shank: The part of the drill bit that holds into the
holding is called the ‘shank’.
Point: The sharpened end of the drill, consisting
of all that part the drill which is shaped to produce
lips, faces, flanks and chisel edge.
Web : The central portion of the drill situated
between the roots of the flutes and extending
from the point toward the shank; the point end of
the web or core forms the chisel edge.
Lips: The main cutting edges of the drill are
formed by the intersection of the flank and the
flute surfaces. For a good cutting, it should be
straight, symmetrical with the axis of the shaft
and equal in length.

Body clearance: To provide diameter clearance the body surface diameter is reduced.
Chisel edge: The chisel edge is the point. Here two cutting lips meet at extreme tip.
Chisel edge Angle: The chisel edge angle is the angle between the chisel edge and cutting lip measured
plane normal to the axis.(120°to 135 °)
6
 Helix angle or rake angle : The helix or rake
angle is the angle formed by the leading edge
of the land with a plane having the axis of the
Drill. The usual value of rake angle is 30°

Point angle : This is the angle included

between the two lips projected upon a plane
parallel to the drill axis and parallel to the two
cutting lips. The usual point angle is 118°

Face: The flute surface portion adjacent to the lip, when it is cut from the work the chip impinges.
Flank: Drill surface which extends behind the lip to flute.
Flutes: The Twist Drill body has grooves and it is known as flutes.
Heel: The Heel is the intersection of the flute surface and the body clearance.
Neck: Neck is the portion of the body with reduced diameter between body and shank.
Tang: The tang is flattened end of the taper shank. 7
8
Types of drilling machine
The different types of drilling machine which are most
commonly used are:
1. Portable drilling machine.
2. Sensitive drilling machine (Bench mounting or table top
and Floor mounting).
3. Upright drilling machine (Pillar or Round column section
and Box column section).
4. Radial drilling machine (Plain, Semi-universal and
Universal).
5. Gang drilling machine.
6. Multiple spindle drilling machine.
7. Deep hole drilling machine. (Vertical and Horizontal)
8. Automatic drilling machine

1. Portable drilling machine.

9
2.Table top sensitive drilling 2.Floor mounting sensitive drilling machine
machine
10
 1. Base: 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 workpiece to be fastened to the base.
2. Column: 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.
3. Table: The table, either rectangular or round. Drill machine/press in
shape supports the workpiece 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 workpiece. Slots are provided in most tables to allow
the jigs, fixtures or large workpieces to be securely fixed directly to the
table.
4. Drilling Head: The drilling head, mounted close to the top of the
Sensitive drill machine/press: This is a column, houses the driving arrangement and variable speed pulleys.
light weight, high speed machine designed These units transmit rotary motion at different speeds to the drill
for drilling small holes in light jobs. spindle. The hand feed lever is used to control the vertical movement
Generally the machine has the capacity to of the spindle sleeve and the cutting tool.
rotate drills of 1.5 to 15.5 mm at high speed
of 20,000 rev/min. 11
3.Box column section upright drilling machine 4.Radial drilling machine
can drill of maximum 50 mm size 12
 When a number of single spindle drilling machine columns are
placed side
by side on a common base and have a common worktable, the
machine is
known as the gang drilling machine. In a gang drilling machine four
to six
spindles may be mounted side by side.

A series of operations may be performed on the work by simply

shifting the work from one position to the other on the work table.

5.Gang drilling machine

13
14
 Tool Holders
The revolving spindle of a drilling machine can hold different cutting tools for different operations.
The different methods used for holding tool- in a drill spindle are

1. By directly fitting in the spindle.

2. By a sleeve.

3. By a socket.

4. By chucks.

5. By special attachments.

a. Tapping attachment
b. Floating Holder

15
1. By directly fitting in the spindle.
All general purpose drilling machines have the spindle bored out to a
standard taper to receive the taper shank of the tool.
The taper used in a drill spindle is usually Morse standard taper which is
approximately 1 :20.
While fitting the tool the shank is forced into the tapered hole and the tool
is gripped by friction. The tool may be rotated with the spindle by friction
between the tapered surface and the spindle ;

but to ensure a positive drive the tang or tongue of the tool fits into a slot at
the end of the taper hole. The tool may be removed by pressing a tapered
wedge known as the drift into the slotted hole of the spindle.
Fig.5.17 illustrates a drill fitted directly into the spindle through a sleeve.
Fig.5 .18 shows a drift or key.

It can be noted that sleeve used in drill spindle should not be affected
while the drift is pushed to take out the drill bit. Usually a mallet should be
used instead of a hammer.

16
2. By a sleeve.
Sleeve :
The drill spindle is suitable for holding only one size of shank. If the taper
shank of the tool is smaller than the taper in the spindle hole, a taper sleeve is
used:

The outside taper of the sleeve conforms to the drill spindle taper and the
inside taper holds the shanks of smaller size tools or smaller sleeves. The
sleeve fits into the taper hole of the spindle and holds tool shanks of smaller
sizes in the tapered hole.

The sleeve has a flattened end or tang which fits into the slot of the spindle.
The tang of the tool fits into a slot provided at the end of the taper hole of the
sleeve. The sleeve with the tool may be removed by forcing a drift within the
slot of the spindle and the tool may be separated from the sleeve by the similar
process.

Different sizes of tool shanks may be held in the spindle by using different
sizes of sleeve. The taper on the outer surface does not change but that on
the inner surface varies with the different sizes of the tool shanks

17
3. By Socket
Socket :
When the tapered tool shank is larger than the spindle taper drill sockets are used to
hold the tool. Drill sockets are much longer in size than the drill sleeves.

A socket consists of a solid shank attached to the end of a cylindrical body. The taper
shank of the socket conforms to the taper of the drill spindle and fits into it. The body
of the socket has a tapered hole larger than the drill spindle taper into which the taper
shank of any tool may be fitted.

The tang of the socket fits into the slot of the spindle and the tang of the tool fits into
the slot of the socket.

18
Drill chucks : The chucks arc especially intended for holding smaller size drills or any other
tools.
Drill chucks have tapered shanks which are fitted into the drilling machine spindle. Different types
of drill chucks are manufactured for different purposes. The most common types of chucks are
1. Quick change chuck.
2. Three-jaw self-centering chuck

Quick change chuck. :

The chuck is used for locating a series of tools one after another for machining a hole without
stopping the spindle. This reduces much of machining time.

It consists essentially of a body 1 having taper shank which is fitted into the spindle. A sliding
collar 4 is fitted loosely on the rotating body. The collar 4 may be raised or lowered by hand
without stopping the
spindle. The sleeve 2 has a taper hole which holds the tool shank. The sectional view of the
sleeve is shown in Fig.5.22.
There are several sleeves which are used for holding different tools required for different
machining operations. The sleeve 2 holding the tool may be fitted into the body I. Holes are
provided on the body I of the chuck in which balls 3 are placed and recesses are cut on the
corresponding surface of the sleeve where the balls are placed when it is fitted into the chuck.
When the collar 4 is raised with one hand the sleeve with its tool may be fitted in the chuck body
with the other hand. The sleeve causes the balls to come out from the recess. When the collar 4
is lowered it forces the balls into the recesses and the sleeve 2 is locked by the balls 3 with
19
the
body of the chuck I.
Three-jaw self-centering chuck :
A self-centering drill chuck is illustrated in Fig.5.23. This type of chuck is
particularly adapted for holding tools having straight shanks.

Three slots are cut 120° apart in the chuck body which houses three jaws
having threads cut at the back that meshes with a ring nut. The ring nut is
attached to the sleeve. Bevel teeth are cut all round the sleeve body. The
sleeve may be rotated by rotating a key having bevel teeth cut on its face
which meshes with the bevel teeth on the sleeve.

The rotation of the sleeve causes the ring nut to rotate in a fixed position and
all the three jaws close or open by the same amount from the centre holding
or releasing the shank of a tool.

20
DRILLING MACHINE TOOLS
Drill : A drill is a fluted cutting tool used to originate or enlarge a hole in a
solid material. Drills are manufactured in a wide variety of types and sizes.
The types of the drill commonly used are
1. Flat or spade drill
2. Straight fluted drill
3. Two-lip twist drill
a. Parallel shank (short series or "Jobbers" twist drill)
b. Parallel shank (stub series) twist drill
c. Parallel shank (long series) twist drill
d. Taper shank twist drill
4. Taper shank core drill (Three or four fluted)
5. Oil tube drill
6. Centre drill

21
Flat or spade drill :
A flat drill is sometimes used when a same sized twist drill is not
available.
It is usually made from a piece of round tool steel which is forged to
shape and ground to size, then hardened and tempered.
The cutting angle varies from 90 ° to 120 ° and the relief or clearance at
the cutting edge is 3 ° to 8 °.
The disadvantage of this type of drill is that each time the drill is ground
the diameter is reduced. Further, it cannot be relied upon to drill a true
straight hole, since the point of the drill as a tendency to run out of
centre.

other difficulty of using this type of drill is that the chips do not come out
from the hole automatically

22
Straight fluted drill:
A straight fluted drill has grooves or flutes running parallel to the drill axis. A
straight fluted drill may be considered as a cutting tool having zero rake.
This type of drill is inconvenient in standard practice as the chips do not
come out from the hole automatically. It is mainly used in drilling brass,
copper or other softer materials.
In drilling brass, the twist drill tends to advance faster than the rate of feed
and the drill digs into the metal.
No such difficulty occurs in the use of a straight fluted drill when drilling sheet
metal. The straight fluted drill does not tend to lift the sheet as does the twist
drill.

23
Twist drills : The most common type of drill in use today is the twist drill. It was originally manufactured by
twisting a flat piece of tool steel longitudinally for several revolutions, then grinding the diameter and the point.
The present day twist drills are made by machining two spiral flutes or grooves that run lengthwise around the
body of the drill.

Parallel shank (short series or 'Jobbers’) twist drill:

The drill has two helical flutes with a parallel shank of approximately the
same diameter as the cutting end. The diameter of the drill range from 0.2
to 16 mm increasing by 0.02 to 0.03 mm in lower series to 0.25 mm in
higher series

Parallel shank (stub series) twist drill :

The drill is a shortened form of the parallel shank twist drill; the
shortening being on the flute length. The diameter of the drill ranges
from 0.5 to 40 mm Figure 5.37 Parallel shank (stub series) increasing
by 0.3 mm in twist drill lower series to 0.25 to 0.5 mm in higher
series.
24
Parallel shank (long series) twist drill:
The drill have two helical flutes with a parallel shank of approximately the shank
diameter as the cutting end, which however does not exceed the diameter at the
drill point.
The overall length of this drill is the same as that of a taper shank twist drill of
corresponding diameter.

The diameter varies from Figure 5.38 Parallel shank (long series) 1.5 to 26 mm
increasing by twist drill 0.3 mm in lower series to 0.25 mm in higher series

Taper shank twist drill :

The drill have two helical flutes with a taper shank for
holding and driving the drill. The diameter ranges from 3
to 100 mm.

25
Oil tube drill :
The oil tube drills are used for drilling deep holes. Oil tubes run lengthwise
spirally through the body to carry oil directly to the cutting edges.

Cutting fluid or compressed air is forced through the holes to the cutting point of
the drill to remove the chips, cool the cutting edge and lubricate the machined
surface

Centre drills :
The centre drills are straight shank, two fluted twist drills used
when centre holes drilled on the ends of a shaft. They are made
in finer sizes.

26
27
Horizontal boring machine:
•The work is supported on a table which is stationary and tool revolves in a horizontal axis.
•Can perform boring, reaming, turning, threading, facing, milling , grooving and many other operations with
suitable tools.
•Work piece which are heavier and asymmetrical can be easily held and machined.
•Different types has been designed to suit the different purpose.

28
Horizontal boring machine

29
 (2) Column
(1) Head Stock •Column supports head stock and tail stock.
•It is the most important part of a boring machine.
•It contains spindles. It guides up and down movement by means of ways.
•It supports, drives and feeds the boring tool. •It is hollow and heavily constructed.
•The spindle rotation is reversible for backing out tools. •To balance head stock and make it easy to move.
•Boring tool is held in boring head which will be held in head •Columns are keyed, dowelled and bolted to the base of the
stock. machine.

(3) Runways (4) End Support Column

•Definition: •Definition:
An out-board bearing is required to support the other end of the
When ever the column is traversing the base used is known as bar is known as end END SUPPORT COLUMN.
runway. •End support column is necessary in case of long boring and
•Main function of runways are to carry the main column, end heavy tools are used.
support column and rotary table if any. •There is an opened and closed type of end support.

30
(5) Table (6) Saddle
•Main function of the table is to support for holding the •The main function of saddle is to provide a compound
workpiece rigidly during the operation. movement of the table.
•Table is equipped with suitable ranges of feeds as well as quick •This helps the table to move axially as well as transversely
reverse mechanism. to the spindle.
•Table moves perpendicular to the axis of the spindle

Applications Of HBM
1.Horizontal boring machine can be used to drill, bore ream
holes.
2.These are widely used in batch production where work piece
is less.
3.These machine can also be used for machining type parts like
gear boxes and engine blocks.

31
Vertical Boring Machine:
•The work rotates on a horizontal table about a vertical axis and
the tool is stationary except for feed.
•Machine may look like a vertical lathe.
•Larger diameter and heavy work pieces, can be set up more
quickly than in lathe.
•Multiple tooling may be adapted with its turret type tool post,
increasing the rate of production.

32
Vertical Boring Operation

33
34
 Broaching
Broaching is a machining process for removal of a layer of material of desired width and depth usually in one
stroke by a slender rod or bar type cutter having a series of cutting edges with gradually increased protrusion.

A broach is a multiple-edges cutting tool that has successively higher cutting edges along the length
of the tool.

Types of Broaches according to Broaches may be classified in various ways,

1 . Type of operation : internal or external.
2. Method of operation : push or pull.
3. Type of construction: solid, built-up, inserted tooth, progressive cut, rotor cut, double jump, or
overlapping tooth.
4. Function : surface, keyway, round hole, splint, spiral, burnishing, etc.

Broaching of inside surfaces is called internal or hole broaching and of outside surfaces,
external or surface broaching. Internal broaching tools are designed to enlarge and cut various
contours in holes already made by drilling, punching etc. External surface broaching competes with
milling, planing, shaping, shaping, and similar operations.

35
Typical examples of shapes produced by internal broaching

36
 A push broach is one that is designed to be pushed through the workpiece by
special press or a push broaching maching. Because of the tendency to bend
under compressive loads, the push broach must be short and stocky, which
means fewer teeth
are in the broach and, less material can be removed for each pass of the tool.
In a pull broach , the tool is entirely in tension and long slender broaches are
possible, having a large number of teeth, consequently more stock can be
removed for each
pass.

Internal pull broach elements

Push broach 37
Pull end : This is designed to permit engagement of the broach with the broaching machine through the use of a
puller head.
Front pilot : This centres the broach in the hole before the teeth begin to cut.
Roughing and semifinish teeth They remove most of the stock in the hole.
Finishing teeth : They are for sizing the hole and must have the shape required of the finished hole.
Rear pilot and follower rest : They support the broach after the last tooth leaves the hole.

38
 Land : The top portion of a tooth is called the land and in most
cases ground to give a slight clearance.

Back off or clearance angle : This corresponds to the relief angle

of a single point tool. This is 1.5° to 2° for both cast iron and steel.
Finish teeth have a smaller angle ranging from 0 to 1.5 °.

Rake or hook angle or face angle : This corresponds to the rake

angle on a lathe tool. The rake angle varies according to the
material being cut, and in general, increases as the ductility
increases. Values of this angle for most steels range from 12 to 15°
Enlarged tooth form on Pitch.: The linear distance from the cutting edge of one tooth to the
broach corresponding edge on the next tooth is called the pitch t and differs
for
cutting (roughing and semi finish) and finishing teeth.
39
Broaching, according to the method of operation, may be classified
as
follows:
1 . Pull broaching : The work is held stationary and the broach is pulled
through the work. Broaches are usually long and are held in a special
head. Pull broaching is used mostly for internal broaching but it can do
some surface broaching.
2. Push broaching : The work is held stationary and the broach is
pushed through the work. Hand and hydraulic arbor presses arc popular
for push broaching, This method is used mostly for sizing holes and
cutting keyways.
3. Surface broaching : Either the work or the broaching tool moves
across the other. This method has rapidly become an important means of
surface finishing. Many irregular or intricate shapes can be broached by
surface broaching, but the tools must be specially designed for each job.
4. Continuous broaching : The work is moved continuously and the
broach is held stationary. The path of movement may be either straight
horizontal or circular. This method is very suitable for broaching a number
of similar works at a time

40
 Broaching machines are probably the simplest of all machine tools. They consist of a work
holding fixture, a broaching tool, a drive mechanism, and a suitable supporting frame.
Although the component parts are few, several variations in design are possible.
There are two principal types of machines
: horizontal and vertical. In addition to these standard types, there are special and
continuously operating machines. Both horizontal and vertical types have one or more
rams depending on production requirement.

Horizontal broaching machines : Nearly

all horizontal machines are of the pull type.
They may be, used for either internal or
external broaching, although internal work is
the most common. A horizontal broaching
machine shown in Fig. consists of a bed or a
base a little more than twice the length of the
broaching stroke, a broach pilot and the
drive mechanism for pulling the broach.
Horizontal broaching machines are used
primarily for broaching keyways, splines,
slots, round holes, and other internal shapes
or contours. They have the disadvantage of
Horizontal surface broaching machine taking
more floor space than do the vertical 41
machines
Vertical broaching machines : The vertical types may be
obtained in either push or pull type. The push type is the
most popular. A vertical broaching machine is shown in Fig.
Vertical
machines are employed in multiple operations, since they
are convenient to pass work from one machine to another,
and they are more likely to be found doing surface
operations.

Vertical machines require an operator platform or a pit and

are
economical of floor space than the horizontal type. Modern
vertical broaches are offered with both hydraulic and
electromechanical drives. But hydraulic drives are the most
common because they cost less.

Push down type vertical surface broaching machine

42
Broaching has been used in mass production because of following outstanding features and
advantages
1. Rate of production is very high. With properly applied broaches, fixtures, and machines, more
pieces can be turned out per hour by broaching than by any other means,
2. Little skill is required to perform a broaching operation. In most cases the operator merely
loads and unloads the workpiece.
3. High accuracy and a high class of surface finish is possible. A tolerance of ± 0.0075 mm and a
surface finish of about 0.8 microns (1 micron = 0.001 mm) can be easily obtained in broaching.
4. Both roughing and finishing cuts are completed in one pass of the tool.
5. The process can be used for either internal or external surface finishing.
6. Any form that can be reproduced on a broaching can be machined.
7. Cutting fluid may be readily applied where it is most effective because a broach tends to draw
the fluid into the cut.

Certain reasons, however, limit the application of the broaching

process. They are
1. High tool cost. A broach usually does only one job and is expensive to make and sharpen.
2. Very large workpieces cannot be broached.
3. The surfaces to be broached cannot have an obstruction.
4. Broaching cannot be used for the removal of a large amount of stock.
5. Parts to be broached must be capable of being rigidly supported and must be able to withstand
the forces that set up during cutting.
43
44