Drilling Process

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MANUFACTURING AND MATERIALS DEPARTMENT

MME1103 Workshop Technology Manual Drilling

4.3

BASIC FORMULA FOR DRILLING OPERATION

Cutting speeds and RPM calculations are those operations that are strictly drilling operations, but the drilling operation is also used to perform other operations such as reaming, tapping, countersinking and counterboring. The following are the basic formula that are commonly used in the drilling operation.

Cutting speed is the peripheral speed of the cutting edge = D N; where D is the drill diameter and N is the rotational speed (rpm)

The cutting speed selection depends on both the workpiece and cutter materials; N = V x 1000 rpm, where D V is cutting speed N is rotational speed (rpm)

and

* Note that V is in m/min and D in mm

Feed (f) is the distance the drill penetrate per revolution (mm/rev), the share of each cutting edge is = f/2

Depth of cut is taken as half the diameter for drilling = D/2

Drilling time (T) can be given by the equation;

T = L / f N; where f is the feed (mm/rev) N is the rotational speed (rpm) L is the sum of hole depth, approach and over travel distances
*The approach is usually considered as 0.4D while over travel ranges from 1 to 3mm.

Material removal rate (MRR) in drilling is the volume of material removed by the drill per unit time.

MRR = ( D / 4).(f).(N)

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MANUFACTURING AND MATERIALS DEPARTMENT

MME1103 Workshop Technology Manual Drilling

4.3.1 Sample Questions

1) 20 mm diameter drill is on a drilling machine with cutting speed 25. If the feed is 0.25 mm/rev, what is the MRR? What is the MRR is the drill diameter is tripled? 2) The hole of a diameter of 44.7 mm is to be drilled to a depth of 60 mm and reamed to a diameter of 45 mm. The feed is 0.56 mm/rev for drilling. The cutting speed is 70.6 m/min. The reaming approach is 0.55 mm and over travel is 2 mm. Determine :a) b) c) d) The feed and spindle speed for reaming operation. The drilling time The reaming time The MRR for the drilling operation.

4.4 DRILLING TECHNIQUES

In a standard drilling operation, the following steps are taken (Gupta, 1996): a) Firstly, the workpiece is marked with a centre punch at the centre of the hole to be drilled. b) It is then held firmly in a vice or other suitable clamping device and place on the table of the drilling machine.

c) The socket containing the drill is fitted in the machine spindle. d) The spindle is lowered by the hand lever and it is ensured that the point of the drill is in exact alignment with the previously marked centre of the hole. e) The motor is now started and the rotating drill is gradually pressed into the workpiece to produce the desired hole. f) The pressure should be frequently relived during the drilling operations, otherwise the cutting edges of the drill will be strained and the drill is damaged. g) In order to avoid spoiling the cutting edge of the drill, coolant such as oil or soap water should be used constantly during the drilling operation.

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MANUFACTURING AND MATERIALS DEPARTMENT

MME1103 Workshop Technology Manual Drilling

4.4.1 Cutting Fluids

A large number of coolant and cutting oils are used in drilling operations. A good cutting fluid will cool the workpiece and tool and will also act as a lubricant between the chip and the tool to reduce friction and heat buildup. Table 4.2 lists some of the cutting fluids for different materials.

Materials Dry

Aluminum Brass Bronze Cast iron Steels Low carbon Alloy Stainless Others
Emulsifying or soluble oils mixed in water Animal or mineral oils with added sulfur or chlorine

x x x

Type of cutting fluid Soluble Oil Kerosene Sulfurised Oil x x x x

Mineral oil

x x x

x x x

: :

For main requirement to use inexpensive cooling medium For operations that tend to create more friction and for reaming, counterboring, countersinking and tapping operations

Table 4.2 List of cutting fluids for different materials

4.5

GUIDELINES IN DESIGN

The general design guidelines recommended by Kalpakjian at. (2001) for drilling, reaming and tapping operations are as follows: a) Design should allow holes to be drilled on flat surfaces and perpendicular to the drill motion. Exit surfaces for the drill should also be flat. b) Interrupted hole surfaces should be avoided or minimized for improved dimensional accuracy. c) Hole bottom should if possible match standard drill point angles (Section 4.1.1). Flat bottoms or odd shapes should be avoided.

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MANUFACTURING AND MATERIALS DEPARTMENT

MME1103 Workshop Technology Manual Drilling

d) Through holes are preferred over blind holes. If holes with large diameters are required, the parts should have a pre-existing hole. e) Part should be designed so that all drilling can be done with a minimum of fixturing and without repositioning the workpiece. f) It may be difficult to ream blind or intersecting holes because of the possibility of tool breakage. Extra hole depth should be provided. g) Blind holes must be drilled deeper than subsequent reaming or tapping operations that may be performed.

4.6

TROUBLESHOOTING

A general guideline to the probable causes of problems in drilling operations is listed below Kalpakjian & Schmid, 2001:
Problem Drill breakage
Possible Causes Dull drill; seizing in hole because of chips clogging flutes; feed too high; lip relief angle too small Cutting speed too high; ineffective cutting fluid; rake angle too high; drill burned and strength lost when sharpened Drill misaligned or bend; lips not equal; web not central Same as above; machine spindle loose; chisel edge not central; side pressure on workpiece Dull drill; ineffective cutting fluid; welding of workpiece material on drill margin; improperly ground drill; improper alignment

: :

Excessive drill wear

Tapered hole Oversized hole Poor hole surface finish

: : :

Table 4.3: List of problems and possible causes in drilling operation

Figure 4.4: Causes of oversize drilling: (a) drill lips ground to unequal lengths, (b) drill lips ground to unequal angles, and (c) unequal angles and lengths

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MANUFACTURING AND MATERIALS DEPARTMENT

MME1103 Workshop Technology Manual Drilling

4.7 SAFETY RULES

Poor work habits will lead to injuries. Chip flying into unprotected eyes, dropping heavy tools, getting hair or clothing caught in a rotating drill are among many hazards that can be avoided through safe work habits. The list below denotes a safety rules that student/ machinist need to be follow when doing the drilling operation: a) Workpieces should always be secured with bolts and strap clams, C-clamps or fixtures. A drill press vise should be used when drilling small parts. If a clamp should come loose and a merry go round result, do not try to stop it from turning with your hands. Turn of the machine quickly. b) Ensure all parts are properly secured and safe to run before starting the machine. c) Never clean the taper in the spindle when the drill is running, since this could result in broken fingers or worse injuries. d) Always remove the chuck key immediately after using it. A key left in the chuck will be thrown out at high velocity when the machine is turned on. e) Never stop the drill press spindle with your hand after you have turned off the machine, sharp chips often collect around the chuck or spindle. Do not reach around, near or behind a revolving drill. f) Do not leave the machine running unattended. g) Remove and clear all metal chips in between machine parts before and after usage. h) Do not change gear when the machine is running. i) Use a brush instead of your hands to clean chips off the machine. Never use an air jet for removing chips as this will cause the chips to fly at a high velocity and may lead to cuts and eye injuries. Do not clean chips or wipe oil while the machine is running. j) When moving the head or table on sensitive drill presses, make sure a safety clamps is set just below the table or head on the column; this will prevent the table from suddenly dropping if the column clamp is prematurely released.

4.8 PROJECT DRILLING

To be supplied by Sis Tuti

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MANUFACTURING AND MATERIALS DEPARTMENT

MME1103 Workshop Technology Manual Drilling

REFERENCES

Groover M.P., (1996), Fundamentals of Modern Manufacturing, Materials, Processes and Systems, International Editions, Prentice Hall. Gupta J.K. (1996), Basic Workshop Practice, S. Chand & Company Ltd. Kalpakian, S & Schmid, S.R. (2001), Manufacturing Engineering and th Technology - 4 International Edition, Prentice Hall International. Kibble R.R, Neely J.E, Meyer R.O & White W.T. (2002). Machine Tool Practiceth 7 Edition, Prentice Hall.

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