ABSTRACT
Any industrys has its own desire to maintain their ability to provide
challenges is an important task and the efficient delivery of their cargo, play
multiple spindle system. The drilling machine drills not only in particular
single machine.
NEED OF THE PROJECT
To reduce power
1.INTRODUCTION
selective removal of metal. The term machine tool is usually reserved for
tools that used a power source other than human movement, but they can be
consider that the true machine tools were born when direct human
different kinds of tools. The earliest lathe with direct mechanical control of
the cutting tool was a screw-cutting lathe dating to about 1483. This lathe
"produced screw threads out of wood and employed a true compound slide
rest".
2. LITERATURE SURVEY
existed for millennia (for example, lathes and bow drills existed in ancient
Egypt), but it was not until the later Middle Ages and the Age of
Clock makers of the middle ages and renaissance men such as Leonardo da
for industrial machine tools. During the 18th and 19th centuries, and even in
many cases in the 20th, the builders of machine tools tended to be the same
people who would then use them to produce the end products (manufactured
goods). However, from these roots also evolved an industry of machine tool
machine tools for sale to others. The first machine tools offered for sale (i.e.,
around 1800. Others, such as Henry Maudslay, James Nasmyth, and Joseph
manufactured end products and millwright work into the realm of building
machines used flywheels to stabilize their motion and had complex systems
of gears and levers to control the machine and the piece being worked on.
Soon after World War II, the numerical control (NC) machine was
punched cards to control their motion. In the 1960s, computers were added
to give even more flexibility to the process. Such machines became known
could precisely repeat sequences over and over, and could produce much
more complex pieces than even the most skilled tool operators.
Before long, the machines could automatically change the specific cutting
and shaping tools that were being used. For example, a drill machine might
contain a magazine with a variety of drill bits for producing holes of various
different operations. The next logical step was to combine several different
machine tools together, all under computer control. These are known as
machining centers, and have dramatically changed the way parts are made.
From the simplest to the most complex, most machine tools are capable of at
function. A drilling system and method are provided. The drilling system
comprising a tool body, a drill bit, a mechanism for applying weight to the
drill bit (WOB), and a control system for controlling the rate of rotation of
the drill bit (RPM) and the weight applied to the bit during drilling. The
control system is configurable to a first mode in which RPM and WOB are
and a second mode in which RPM and WOB are controlled to maintain a
switch between the first and second modes depending on drilling conditions.
Botek Type 43A drill head. This is a BTA solid drill head with indexable
Youre probably accustomed to drilling holes with depths up to, say, five
times their diameter, or maybe, with the latest special drills, up to 15 or even
20 times diameter. But what if you have a customer who gives you a print
for a foot-long part with a quarter-inch hole all the way through 48
in diameter and 2 deep, or a 6 hole thats 35 feet deep. One hundred times
metal cutting. But it poses unique challenges. It requires special tools and in
For a smaller diameter hole like a quarter-inch hole a foot deep, you should
flute. The cutting oil or fluid is fed through the tool to the cutting edge and
exits through the V-groove, carrying the chips with it. Gun drilling is
commonly used for holes in the range of 0.5 mm (about 0.020) to two
inches diameter. To help keep the drill straight, you would use a drill
Gun drilling was invented more than a hundred years ago to provide straight,
precise gun barrels. It is suitable for holes from about half a millimeter
and chip evacuation. Typically the cutting fluid passes through one or two
holes in the shaft of the drill. It exits through the V-groove, which is usually
drilling machines. You might need 1 horsepower (hp) for cutting, but
perhaps 5 hp to pump the fluid at pressures in the range of 300 psi to 2000
psi.
Dedicated gun drilling machines are available, but gun drills can also be
flow rate are sufficient. For example, Swiss type automatic screw machines
system components and medical devices, such as bone screws, said George
Bursac, general manager, Star CNC Machine Tool Corp., Roslyn Heights,
Gun drilling is perfect for some applications, but to handle larger diameter
holes and provide faster cutting speeds, youll need a different type of
drilling system.
Star 12-axis Swiss type automatic lathe, with three turrets, allowing three
drilling to handle larger sized holes, called a single tube system (STS) or
trepanning, below).
The BTA drill consists of a drill head, a drill tube, a fluid induction unit and
associated fittings and supports. The drill head has cutting edges (often
indexable inserts) and passages for the cutting fluid to flow through. In
addition, the head has guide pads, which ride on the newly cut ID of the hole
and help keep the drill going straight. The drill head is mounted to a drill
tube, which acts as both the shaft of the drill and a return conduit for the
oval-shaped holes, fi rst one hole is drilled, then it is filled with a piece of
bar stock and the second hole is drilled. This allows an uninterrupted cut on
In a BTA system, cutting fluid comes in through a fluid induction unit that
seals against the face of the part. This unit also functions as a drill bushing to
support and align the drill. The fluid flows in through the space between drill
tube and the ID of the hole. In the cutting area the fluid picks up the chips
and then flows back out through openings in the face of the drill, exiting
BTA systems are typically used to drill deep holes from about 5/8 to about
20 in diameter,.This type of system will drill five to six times faster than
gun drilling, said Mark Sollich, president, BTA Heller Inc., Troy, Mich., a
tool manufacturer.
Numerical control (NC) is the automation of machine tools that are operated
processor, and then loaded into the CNC machines for production. Since any
with an external controller and human or robotic operators that move the
needed to produce any part is highly automated and produces a part that
The first NC machines were built in the 1940s and 1950s, based on existing
tools that were modified with motors that moved the controls to follow
points fed into the system on punched tape. These early servomechanisms
were rapidly augmented with analog and digital computers, creating the
processes.
Description
Modern CNC mills differ little in concept from the original model built at
MIT in 1952. Mills typically consist of a table that moves in the X and Y
axes, and a tool spindle that moves in the Z (depth). The position of the tool
small enough and speeds are not too great. On commercial metalworking
machines closed loop controls are standard and required in order to provide
As the controller hardware evolved, the mills themselves also evolved. One
change has been to enclose the entire mechanism in a large box as a safety
measure, often with additional safety interlocks to ensure the operator is far
enough from the working piece for safe operation. Most new CNC systems
CNC-like systems are now used for any process that can be described as a
friction stir welding, ultrasonic welding, flame and plasma cutting, bending,
Mills
CNC mills use computer controls to cut different materials. They are able to
proprietary languages while often simpler than G-code are not transferable
to other machines.
Lathes
Lathes are machines that cut spinning pieces of metal. CNC lathes are able
to make fast, precision cuts using indexable tools and drills with complicated
programs for parts that normally cannot be cut on manual lathes. These
machines often include 12 tool holders and coolant pumps to cut down on
tool wear. CNC lathes have similar control specifications to CNC mills and
programming language.
Plasma cutters
commonly used to cut steel and other metals, but can be used on a variety of
speed out of a nozzle; at the same time an electrical arc is formed through
that gas from the nozzle to the surface being cut, turning some of that gas to
plasma. The plasma is sufficiently hot to melt the material being cut and
moves sufficiently fast to blow molten metal away from the cut.
When the distance between the two electrodes is reduced, the intensity of the
electric field in the space between the electrodes becomes greater than the
strength of the dielectric (at least in some point(s)), which breaks, allowing
current to flow between the two electrodes. This phenomenon is the same as
electrodes. Once the current flow stops (or it is stopped depending on the
type of generator), new liquid dielectric is usually conveyed into the inter-
electrode volume enabling the solid particles (debris) to be carried away and
Wire EDM
Also known as wire cutting EDM, wire burning EDM, or traveling wire
EDM, this process uses spark erosion to machine or remove material with a
traveling wire electrode from any electrically conductive material. The wire
Sinker EDM
Sinker EDM, also called cavity type EDM or volume EDM, consists of an
between the two parts. As the electrode approaches the workpiece, dielectric
breakdown occurs in the fluid forming a plasma channel) and a small spark
jumps.
Water jet cutters
A water jet cutter, also known as a waterjet, is a tool capable of slicing into
machinery and other devices. Waterjet is the preferred method when the
materials being cut are sensitive to the high temperatures generated by other
Drills
EDMs
Embroidery machines
Lathes
Milling machines
Wood routers
Sheet metal works (Turret punch)
Plasma cutters
Laser cutting
Oxy-fuel
Surface grinders
Cylindrical grinders
3D Printing
submerged welding
knife cutting
glass cutting
In CNC, a "crash" occurs when the machine moves in such a way that is
Many CNC tools have no inherent sense of the absolute position of the table
have any reference to work from, and these limits are just for figuring out
the location of the part to work with it, and aren't really any sort of hard
the operator.
Many CNC tools also don't know anything about their working environment.
Machines may have load sensing systems on spindle and axis drives, but
some do not. They blindly follow the machining code provided and it is up
for the operator to manually abort the cutting process. Machines equipped
overload condition, but this does not prevent a crash from occurring. It may
only limit the damage resulting from the crash. Some crashes may not ever
If the drive system is weaker than the machine structural integrity, then the
drive system simply pushes against the obstruction and the drive motors
"slip in place". The machine tool may not detect the collision or the slipping,
so for example the tool should now be at 210mm on the X axis but is in fact
at 32mm where it hit the obstruction and kept slipping. All of the next tool
motions will be off by 178mm on the X axis, and all future motions are
now invalid, which may result in further collisions with clamps, vises, or the
machine itself. This is common in open loop stepper systems, but is not
motor and drive mechanism has occurred. Instead, in a closed loop system,
the machine will continue to attempt to move against the load until either the
alarm is generated.
cutting, but these are not a common component of most hobby CNC tools.
Instead, most hobby CNC tools simply rely on the assumed accuracy of
the number of pulses sent to the stepper over time. An alternate means of
for axis movement. In a closed loop system, the control is aware of the
actual position of the axis at all times. With proper control programming,
this will reduce the possibility of a crash, but it is still up to the operator and
manner. However, during the 2000s and 2010s, the software for machining
simulation has been maturing rapidly, and it is no longer uncommon for the
entire machine tool envelope (including all axes, spindles, chucks, turrets,
with 3D solid models, which allows the simulation software to predict fairly
accurately whether a cycle will involve a crash. Although such simulation is
not new, its accuracy and market penetration are changing considerably
movement directions. This is not always a true condition of CNC tools. CNC
tools with a large amount of mechanical backlash can still be highly precise
from one direction, and all driving systems are pressed tight together in that
one cutting direction. However a CNC device with high backlash and a dull
cutting tool can lead to cutter chatter and possible workpiece gouging.
reversals during cutting, such as the milling of a circle, where axis motion is
repeatedly precise for the cutting process, but some other reference object or
precision surface may be used to zero the mechanism, by tightly applying
pressure against the reference and setting that as the zero reference for all
Broaching machine
Drill press
Gear shaper
Hobbing machine
Hone
Lathe
Screw machines
Milling machine
Shaper
Saws
Planer
Grinding machines
energy beams takes place at the interface of the material and the
point of contact between the cutting tool and the uncut material,
defined with hard cutting tools than with energy beams, but can
later. All other functions and structure of the machine tool serve the
cutting tool edge(s), the tool holder, the slides and stages used to
move the tool and/or the work piece, the spindle holding the work
piece or the tool, the chuck, and fixtures, and internal vibration,
structural loop, which still influence the loop and cause errors,
example.
the time and/or resources to identify and quantify all errors, but the
cases. This is not to say that statistical analysis is not good, but the
roughness which does not exceed some allowable limit set by the
keep in mind how thermal growth can also influence these error
sources.
5. MACHINING OPERATIONS
tool can peel metal off, creating a smooth, round surface. A drill or
Other tools that may be used for various types of metal removal are
shape.
business.
on the surface.
6.DRILLING
the drill is held in tailstock and the work is held by the chuck.
The most common drill used is the twist drill.
Drilling Machine
The work piece is held stationary ie. Clamped in position and the drill
Types
1) Based on construction:
Portable,
Sensitive,
Radial,
up-right,
Gang,
Multi-spindle
2) Based on Feed:
Hand driven
Power driven
7.COMPONENTS OF DRILLING MACHINE
Spindle
The spindle holds the drill or cutting tools and revolves in a fixed
position in a sleeve.
Sleeve
The sleeve or quill assembly does not revolve but may slide in its
bearing in a direction parallel to its axis. When the sleeve carrying the
spindle with a cutting tool is lowered, the cutting tool is fed into the work:
and when its moved upward, the cutting tool is withdrawn from the work.
Feed pressure applied to the sleeve by hand or power causes the revolving
drill to cut its way into the work a fraction of an mm per revolution.
Column
The column is cylindrical in shape and built rugged and solid. The
Head
an electric motor and feed mechanism. The head is bolted to the column.
Worktable
Base
The base of the drilling machine supports the entire machine and
when bolted to the floor, provides for vibration-free operation and best
machining accuracy. The top of the base is similar to the worktable and may
be equipped with t- slot for mounting work too larger for the table.
Hand Feed
The hand- feed drilling machines are the simplest and most common
type of drilling machines in use today. These are light duty machine that are
operated by the operator, using a feed handled, so that the operator is able to
feel the action of the cutting tool as it cuts through the work piece. These
Power feed
The power feed drilling machine are usually larger and heavier than
the hand feed ones they are equipped with the ability to feed the cutting tool
spindle these machines are used in maintenance for medium duty work or
the work that uses large drills that require power feed larger work pieces are
usually clamped directly to the table or base using t bolts and clamps by a
small work places are held in a vise. A depth stop mechanism is located on
may seem overly simple, but is most often overlooked or is not possible.
machining interface, the point of contact between the tool and the workpiece
normally not possible. At the other end of the spectrum, a feedback device
the motor. Simply put, this feedback strategy will only provide information
about the angular change in the lead-screw drive mechanism and not about
the lead-screw or the linear position of the stage. The motor could be
will not be constant. The pitch may be larger in some regions of the lead-
screw and less in other regions. This will give an error in the linear location
of the ball-nut and the stage and workpiece attached to it. One bright side to
lead-screw non-linearity is that it is built into the mechanism and all other
to a feedback error. Because the tool edge is not where it is thought to be due
to wear, and its location can not be readily measured in use, this results in
the same type error as not measuring the location of interest. If the tool edge
some other known point on the tool holder, typically the tool slide at the
base of the tool holder sensed by a linear encoder, then any change in that
information will result in an error. As the tool edge wears, it is shortened and
is assumed the right angles are present and are maintained throughout all
as opposed to physically coupled, errors will result if the axes are not
"perfectly" orthogonal. A motion of only the x-axis, which carries the y-axis
stage, will result in some amount of y motion due to the axes not being at
called machine tool variables. The following variables are not all inclusive
volume, called the work volume or work envelope. The locations to move to
user commands. This implies that each move of the tool or workpiece is to a
location the machine has not previously visited (memorized or been taught)
of the machine tool to locate the desired point(s) for the machining operation
Accuracy will be affected by resolution, for example. All moves are integer
high resolution, fed by low resolution encoder feedback, can have high
resolution moves but low resolution of known position, and therefore low
accuracy. The machine can not interpolate between the least counts of the
resolution, and therefore will stop as soon as the commanded position is met.
This can cause repeatability errors depending from which direction the
The previous statements are not meant to imply that feedback sensors can
resolution and even detect rotation direction. The point is, the least count of
resolution will affect both accuracy and repeatability, but high resolution is
repeatability is also closely coupled with many of the other error sources
described
8.7 STIFFNESS
influence of machining forces and the static weight of the machine structure
work piece.
machines, with low internal or external damping, will transmit this vibration
the machine, can be amplified in the machined part. Therefore, a very stiff
deflection and compensate for it with the machine motions. This may require
possible to sense at high frequency, filter to low frequency, and perform the
required compensation.
material from which the machine and the structural loop are made also
impacts the performance of the machine. The damping characteristic of steel
is different from cast iron and from granite, for example. Additional
damping can be realized in granite, for example, by casting the shapes from
material may dampen the vibration very well during the first few
milliseconds but then "ring" for a relatively long time. Other materials may
lower the vibration more gradually at first but at a more constant rate so the
vibration dies out faster than the material that rings. One needs to investigate
spindle, vibration of the spindle has two primary effects. First, the spindle
vibration can permeate throughout the structural loop exciting the machine
structural loop is important to help reduce the amplitude level. The natural
approach zero for input frequencies well above the natural frequency. The
effect is more pronounced for larger values of damping between the natural
frequency and approximately 1.4 times the natural frequency and less at an
input frequency ratio greater than 1.4. This reiterates the fact that the
vibration signature of the basic machine requires some time, but is well
loop, particularly one at the tool tip and one at the workpiece will yield a
example, can give a good predictor for vibration induced errors. If the two
signals are in phase and of the same amplitude, there is essentially rigid
body motion and no relative motion between the tool tip and the workpiece.
are vast differences in the amplitude and/or phase of the motions, there will
vibration errors reside in the frequency domain of the machine and the
power spectral density, for example, will quickly reveal the dominant
those which are artifacts of the desired machining condition, and those
which are errors. By knowing the machining conditions, such as feed per
revolution, the desired effects (or at least those which would still be present
finished part. However, several factors associated with the work piece
material and how it is machined can also lead to uncertainty in the finished
results.
demanding, more care must be taken when constraining the work piece
against the cutting forces. By its nature, a part fixture induces stresses into
the work piece, and the stresses are particularly high where the fixture
structure contacts the work material. If the contact force is too small, the part
clamping force. A large force (ie large stress) also induces strain (surface and
internal displacement and stored strain energy) in the work piece. If the
unclamping the work piece the stored strain energy will be released and the
part will change shape. It will relax to a configuration with minimal internal
energy. This change of shape will cause the machined shape to change
machined and this can influence surface finish, precision, etc. About the only
machine differently with another tool material. One such material is 6061-T6
the tool leaving a built-up edge and relatively poor surface finish. This is
material made of a metallic binder with diamond particles imbedded into it.
Single crystal diamond however, will give relatively good surface finish
although over time aluminum can be seen adhering to the rake face of the
tool. This may take a low power microscope to observe this. Generally, the
precise machining results than softer materials. Reasons include fewer burrs
and shorter chips, which will interfere less with the cutting action. When
will form long continuous chips. The chips will break only due to high strain
the tool, or by wrapping around the tool and/or the rotating workpiece.
Except for the use of chip breakers, the methods for reducing continuous
continuous chips.
Other methods for increasing the machining precision
reduce the ductility of the material without significantly changing its in-use
properties. Brass may be needed instead of pure copper, for example. This is
materials will rapidly wear the diamond because these materials have a high
affinity for carbon. As machining takes place, the temperature at the cutting
interface will increase and the rate of diffusion of the diamond into the work
8.12 COOLANTS
friction between the tool and the work material (before and after the chip is
made), and to help reduce the temperature of the cutting action to increase
tool life and reduce material property changes which can come about by
the use of a lubricant will, in most cases, give a better surface finish with
as drilling, the use of a fluid is mandatory to help remove chips from the
drilled hole since microdrills do not have spiral flutes to assist with chip
removal.
in mind that the fluid (liquid particularly) has a relatively high thermal mass
(specific heat) and therefore if at a different temperature than the work and
tool, can cause thermal expansion/contraction errors. The ideal fluid would
be one which can remove all heat generated by cutting, yet remain at a
constant temperature. This would tend to suggest that phase change cooling
temperature process.
9. DRILL MATERIALS
- Low cost
Solid Carbide drill, TiN coated drills, carbide coated masonry drills,
parabolic drills, split point drill. Fig.4 shows various types of drills
The different methods used for holding drill in a drill spindle are
By directly fitting in the spindle hole.
Drilling
Reaming
Boring
Counter boring
Countersinking
Tapping
Drilling:
revolving tool called Drill. Fig. 9 shows the various operations on drilling
machine.
Reaming:
Boring:
tool. Boring operation is often preferred because we can correct hole size, or
alignment and can produce smooth finish. Boring tool is held in the boring
Counter Bore :-
Countersink:-
Special angled cone shaped enlargement at the end of the hole to
accommodate the screws. Cone angles of 60, 82, 90, 100, 110, 120
Tapping:-
Power supply
Motor Microcontroller
Spindle
program
Drill bit
Drilling operation
workpiece
WORKING PRINCIPLE
Various parts such as drill bit & rack pinion are attached to the
the pulley arrangement and the drilling tool also rotates. Numerical
by bearings.
14. CALCULATION
the properties of the material being drilled, drill material, drill diameter, rate
v = *D*N, where
d=D/2
difficult and the fresh cutting fluid is not able to cutting zone. Hence for
machining the lengthy hole special type of drill called gun drill is used.
Its the volume of material removed by the drill per unit time
MRR = ( D2 / 4) * f * N mm3 / min
It depends upon the length (l) of the hole to be drilled , to the Speed
t = L / f N min
cleaned.
Safety Precautions
Do not support the work piece by hand use work holding device.
Ensure for the cutting tools running straight before starting the
operation.
16.DESIGN CALCULATION
1. Calculate the speed of the drill bit to drill a hole of dia 20mm where the
N [rpm] = ( * D *N)/1000
= 397.8rpm
2. The dia of one end of a taper plug is 150mm and dia of the other end is
= (150-80)/ 300
= 0.233mm
3. The dia of one end of a taper plug is 150mm and dia of the other end is
= (150-80)/ 2*300
= 6.65
17.COST ESTIMATION
Higher productivity
Simple in construction
APPLICATIONS
Presence of every module has been reasoned out and placed carefully thus