MANUFACTURING PROCESS LAB I

Lab Report On:

DRILLING MACHINE

Name: Aaqib Zaman

Roll No: BSME-14-006
Instructor: Engineer Abdul Raheem

Department: Mechanical Department

University Of Lahore, Islamabad Campus.

Lab Session: 01
DRILLING MACHINE

INTRODUCTION

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.

WORKING PRINCIPLE

Drilling Machine is one of the most important machine tools in a workshop. It is designed to produce a
cylindrical hole of required diameter and depth in metal work pieces. 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.

DRIVE MECHANISM

It is a small machine used for drilling small holes in light jobs. In this drilling machine, the work piece is
mounted on the table and drill bit is fitted into a chuck which is fed into the work by purely hand control.
The power is supplied from the electric motor. The process of power transmission takes place with the help
of the v-bolt and the pair of pulley stacks opposite to each other. The speed of the spindle is fixed or
controlled with the help of the pulley stacks. A pinion engages a rack fixed onto the sleeve to provide
vertical up and down motion of the spindle and hence the drill so that the same can be fed into the work
piece or withdrawn from it while drilling. High rotating speed of the drill and hand feed are the major
features of drilling machine. Drills of diameter from 1.5 to 15.5 mm can be rotated in the spindle of drilling
machine.
PARTS OF DRILLING MACHINE

This machine consists of following parts:

Head: The head containing electric motor, V-pulleys and V-belt which transmit rotary motion to the drill
spindle at a number of speeds.

Sleeve: The sleeve or quill assembly does not revolve but may slide in its bearing in a direction parallel to
its axis.

Spindle: Spindle is made up of alloy steel. It rotates as well as moves up and down in a sleeve. A pinion
engages a rack fixed onto the sleeve to provide vertical up and down motion of the spindle and hence the
drill so that the same can be fed into the work piece or withdrawn from it while drilling. Spindle speed or
the drill speed is changed with the help of V-belt and V-step-pulleys. Larger drilling machines are having
gear boxes for the said purpose.

Chuck: Drill chuck is held at the end of the drill spindle and in turn it holds the drill bit.

Work Table: Adjustable work piece table is supported on the column of the drilling machine. It can be
moved both vertically and horizontally. Tables are generally having slots so that the vise or the work piece
can be securely held on it.

Base Table: Base table is a heavy casting and it supports the drill press structure. The base supports the
column, which in turn, supports the table, head etc.

Column: Column is a vertical round or box section which rests on the base and supports the head and the
table. The round column may have rack teeth cut on it so that the table can be raised or lowered depending
upon the work piece requirements.
TYPES OF DRILLING MACHINE

Drilling machines are manufactured in different types and sizes according to the type of operation, amount
of feed, depth of cut, spindle speeds, method of spindle movement and the required accuracy.
The different types of drilling machines are:
1. Portable drilling machine (or) Hand drilling machine
2. Sensitive drilling machine (or) Bench drilling machine
3. Upright drilling machine
4. Radial drilling machine
5. Gang drilling machine
6. Multiple spindle drilling machine
7. Deep hole drilling machine

Portable drilling machine

Portable drilling machine can be carried and used anywhere in the workshop. It is used for drilling holes on
work pieces in any position, which is not possible in a standard drilling machine. The entire drilling
mechanism is compact and small in size and so can be carried anywhere. This type of machine is widely
adapted for automobile built-up work. The motor is generally universal type. These machines can
accommodate drills from 12mm to 18 mm diameter. Portable drilling machines are operated at higher
speeds.

Sensitive drilling machine

It is designed for drilling small holes at high speeds in light jobs. High speed and hand feed are necessary
for drilling small holes. The base of the machine is mounted either on a bench or on the floor by means of
bolts and nuts. It can handle drills up to 15.5mm of diameter. The drill is fed into the work purely by hand.
The operator can sense the progress of the drill into the work because of hand feed. The machine is named
so because of this reason. A sensitive drilling machine consists of a base, column, table, spindle, drill head
and the driving mechanism.

Upright drilling machine

The upright drilling machine is designed for handling medium sized work pieces. Though it looks like a
sensitive drilling machine, it is larger and heavier than a sensitive drilling machine. Holes of diameter up
to 50mm can be made with this type of machine. Besides, it is supplied with power feed arrangement. For
drilling different types of work, the machine is provided with a number of spindle speeds and feed.

Radial drilling machine

The radial drilling machine is intended for drilling on medium to large and heavy work pieces. It has a
heavy round column mounted on a large base. The column supports a radial arm, which can be raised or
lowered to enable the table to accommodate work pieces of different heights. The arm, which has the drill
head on it, can be swung around to any position. The drill head can be made to slide on the radial arm. The
machine is named so because of this reason. It consists of parts like base, column, radial arm, drill head and
driving mechanism.
Gang drilling machine

Gang drilling machine has a long common table and a base. Four to six drill heads are placed side by side.
The drill heads have separate driving motors. This machine is used for production work. A series of
operations like drilling, reaming, counter boring and tapping may be performed on the work by simply
shifting the work from one position to the other on the work table. Each spindle is set with different tools
for different operations.

Multiple spindle drilling machine

This machine is used for drilling a number of holes in a work piece simultaneously and for reproducing the
same pattern of holes in a number of identical pieces. A multiple spindle drilling machine also has several
spindles. A single motor using a set of gears drives all the spindles. All the spindles holding the drills are
fed into the work at the same time. The distances between the spindles can be altered according to the
locations where holes are to be drilled. Drill jigs are used to guide the drills.

Deep hole drilling machine

A special machine and drills are required to drill deeper holes in barrels of gun, spindles and connecting
rods. The machine designed for this purpose is known as deep hole drilling machine. High cutting speeds
and less feed are necessary to drill deep holes. A non-rotating drill is fed slowly into the rotating work at
high speeds. Coolant should be used while drilling in this machine.

DRILL NOMENCLATURE

Drill geometry and its nomenclature are shown in figure. A twist drill has three principal parts:
1. Drill point or dead center
2. Body
3. Shank.

Drill axis: Drill axis is the longitudinal center line.

Drill point: Drill point is the sharpened end of the drill body consisting of all that part which is shaped to
produce lips, faces and chisel edge.

Lip or cutting edge: It is the edge formed by the intersection of the flank and face

Lip length: It is the minimum distance between the outer corner and the chisel-edge corner of the lip.

Face: Face is that portion of the flute surface adjacent to the lip on which the chip impinges as it is cut from
the work.

Chisel edge: It is the edge formed by the intersection of the flanks.

Flank: Flank is that surface on a drill point which extends behind the lip to the following flute.

Flutes: Flutes are the grooves in the body of the drill, which provide lips, allow the removal of chips, and
permit cutting fluid to reach the lips.
Flute length: It is the axial length from the extreme end of the point to the termination of the flutes at the
shank end of the body.

Body: Body is that portion of the drill nomenclature, which extends from the extreme cutting end to the
beginning of the shank.

Shank: Shank is that portion of the drill by which it is held and driven,

Heel: Heel is the edge formed by the intersection of the flute surface and the body clearance.

Body clearance: Body clearance is that portion of the body surface reduced in diameter to provide
diametric clearance.

Core or web: Core is the central portion of the drill situated between the roots of the flutes and extending
from the point end towards the shank; the point end of the core forms the chisel edge.

Lands: Lands are the cylindrically ground surfaces on the leading edges of the drill flutes. The width of
the land is measured at right angles to the flute.

Recess: Recess is the portion of the drill body between the flutes and the shank provided so as to facilitate
the grinding of the body. Parallel shank drills of small diameter are not usually provided with a recess.
Outer corner is the corner formed by the intersection of the lip and the leading edge of the land.

Chisel edge comer: It is the corner formed by the intersection of a lip and the chisel edge.

Drill diameter: It is the measurement across the cylindrical lands at the outer corners of the drill. .

Lead of helix: It is the distance measured parallel to the drill axis between corresponding points on the
leading edge of a flute in one complete turn of the flute.

Helix angle: It is the angle between the leading edge of the land and the drill axis.

Rake angle: It is the angle between the face and a line parallel to the drill axis. It is bigger at the face edges
and decreases towards the center of the drill to nearly 0. The result is that the formation of chips grows
more un-favorable towards the center.

Lip clearance angle: It is the angle formed by the flank and a plane at right angles to the drill axis; the
angle is normally measured at the periphery of the drill. To make sure that the main cutting edges can enter
into the material, the clearance faces slope backwards in a curve. The clearance angle is measured at the
face edge, must amount to 5 up to 8.

Point angle: It is the included angle of the cone formed by the lips.
PROCESS BEFORE PERFORMING DRILLING OPERATIONS

1. Cutting the Sheet Metal

Cut the sheet metal to a desired dimensions before performing the necessary drilling operations. Cut the
sheet metal by using hacksaw cutting blade, while mounted the sheet metal in a bench vice.

2. Punch Holes

After cutting the sheet metal, a mark of indentation is made at the required location with a center punch.

OPERATIONS PERFORMED ON DRILLING MACHINE

A drill machine is versatile machine tool. A number of operations can be performed on it. The operations
that are commonly performed on drilling machines are drilling, reaming, boring, and counter-boring,
counter-sinking. These operations are discussed as under.

1. Drilling

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 as shown in
figure. Drilling removes solid metal from the job to produce a circular
hole. 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 rotating drill is made to feed into the job.

2. Reaming

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 as shown
in figure. 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.

3. Boring

Figure 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. Boring operation is often
preferred because we can correct hole size, or alignment and can produce
smooth finish.
 4. Counter-Sinking

Counter-sinking operation is shown in figure. This is the

operation of making a cone shaped 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 with the main surface of the work.

5. Counter-Boring

Counter boring operation is shown in figure. 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.

REFERENCES

Singh, Rajender (2006), Introduction to basic manufacturing processes and workshop

technology, New Delhi: India.