Manufacturing Lecture

Manufacturing Technology I
ME 307
Chapter-22
2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
MACHINING OPERATIONS AND
MACHINE TOOLS
Turning and Related Operations
Drilling and Related Operations
Milling
Machining Centers and Turning Centers
Other Machining Operations
High Speed Machining
References:
Fundamentals of Modern Manufacturing:
materials, processes, and systems, 4
th
Ed., by
Mikell P. Groover, JOHN WILEY & SONS,
INC., 2010. (Chapter 22, pages 519-523)

After Manufacturing Technology. Metal Cutting & Machine Tools. By P N
RAO. 2002 by McGRAW-HILL.
Creates a round hole
in a workpart
Compare to boring
which can only
enlarge an existing
hole
Cutting tool called a
drill or drill bit (
cylindrical tool that
has two cutting edges)
Machine tool: drill
press
Figure 21.3 (b) drilling
Drilling
CUTTING CONDITIONS IN DRILLING
Cutting Speed
The cutting speed in a drilling operation is the
surface speed at the outside diameter of the
drill. (specified in this way for convenience)

Feed
Recommended feeds are roughly proportional
to drill diameter; higher feeds for larger
diameter drills.
Since 2 cutting edges -- the uncut chip
thickness (chip load) taken by each cutting
edge is half the feed.
Feed f in drilling is specified in mm/rev (in/rev).
It can be converted to feed rate using the
same equation as for turning:
f
r
= Nf (mm/min)
Through-holes - drill exits opposite side of work
Blind-holes does not exit work opposite side
Figure 22.13 Two hole types: (a) through-hole, and (b) blind hole.
Through Holes vs. Blind Holes
Machining Time
CUTTING CONDITIONS IN DRILLING
Approach Allowance (A mm)
represent the distance the drill must feed
into the work before reaching full diameter,
accounts for the drill point angle,

Rate of Metal Removal
The product of the drill cross-sectional area and
the feed rate:

Chisel-Point
Drill and
Crankshaft
Drill
Figure 23.19 Two common types of drills: (a) Chisel-point drill. The function of the pair of margins is to provide
a bearing surface for the drill against walls of the hole as it penetrates into the workpiece. Drills with four margins
(double-margin) are available for improved drill guidance and accuracy. Drills with chip-breaker features also are
available. (b) Crankshaft drills. These drills have good centering ability, and because chips tend to break up
easily, these drills are suitable for producing deep holes.
After Materials and
Processes in Manufacturing.
8th ed. By E. Paul DeGarmo,
J.T. Black, Ronald A.
Kohser. 1997 by Prentice-
Hall.
Point angles for various work materials
Work material Point angle,
degrees
Mild steel and other general
materials
Deep hole drilling
Hard materials
Soft non-ferrous materials
Hardened steel
Wood and non-metals
118

128
136
90
125
60
Cutting Process Parameters for Drilling
Work material Hardness BHN HSS
Speed, m/min Feed, mm/rev
Cast Iron
Cast Steel
AISI 1020
AISI 1040
Manganese Steel
Nickel Steel
Stainless Steel
Spring Steel
Tool Steel
Tool Steel
Tool Steel
Tool Steel
Tool Steel
Malleable Iron
Aluminum
Aluminum alloys
Copper
Brass
Bronze
Zinc alloys
Glass
200
280-300
110-160
170-200
185-215
200-240
150
400
150
200
215
300
400
110-130
95
170-190
80-85
190-200
180-200
110-125
25-35
12-15
35
25
5
18
15
6
23
18
15
12
5
26
275
18
21
70
54
70
4.5
0.13-0.30
0.06-0.19
0.20-0.50
0.13-0.30
0.06-0.19
0.06-0.19
0.13-0.30
0.06-0.19
0.20-0.50
0.13-0.30
0.13-0.30
0.06-0.19
0.06-0.19
0.20-0.50
0.13-0.90
0.13-0.30
0.06-0.19
0.20-0.50
0.20-0.50
0.20-0.50
0.06-0.19
Machining operations related to drilling
FIGURE 22.14
(a) reaming,
(b) tapping,
(c) counterboring,
(d) countersinking,
(e) center drilling,
(f) spot facing.
MACHINING OPERATIONS RELATED TO DRILLING
Reaming
used to slightly enlarge a hole,
to provide a better tolerance on its diameter,
and
to improve its surface finish.
the tool is called a reamer
Usually has straight flutes
Helical Reamer and Inserted-Blade Adjustable
Reamer
Figure 23.26 (a) Terminology for a helical reamer. (b)
Inserted-blade adjustable reamer.
Tapping
operation performed by a tap
used to provide internal screw threads on an
existing hole.
Tapping
Figure 23.27 (a) Terminology for a tap. (b) Tapping of steel nuts in production.
Counterboring
provides a stepped hole,
a larger diameter follows a smaller diameter
partially into the hole.
used to seat bolt heads into a hole so the
heads do not protrude above the surface.
Countersinking
similar to counterboring, except that the step
in the hole is cone-shaped
for flat head screws and bolts.
Centering
Also called center drilling,
drills a starting hole to accurately establish its
location for subsequent drilling.
The tool is called a center drill.
Spot Facing
similar to milling
used to provide a flat machined surface on the
workpart in a localized area.
Fig 8.49 Various types of drills and drilling operations
After Manufacturing Processes for Engineering Materials, Fourth ed., by Serope Kalpakjian,
Steven R. Schmid. 2003 by Prentice Hall.
Comparative characteristics of hole making operations
Hole Parameter Drilling Reaming Boring Counter boring
Smallest size, mm 1.6 1.6 9.5 6
Largest size, mm 50 100 250 75
Negative tol., mm 0.896 D
-0.5
0.010 0.008 0.512 D
-0.5
+ 0.064
Positive tol., mm 0.896 D
-0.5
+ 0.075 0.010 0.008 0.640 D
-0.5
+ 0.075
Straightness, mm 0.013 (l/D)
3
+ 0.050 2.5 0.013 0.250
Roundness, mm 0.100 0.013 0.075
Parallelism, mm 0.025 (l/D)
3
+ 0.075 0.25 0.025 0.250
Depth limit, mm 300 400 225 500
True position, mm
0.200 0.25 0.003 0.003
Surface finish, mm 2.54 0.41 0.20 1.25
After Materials and
Processes in
Manufacturing. 8th ed. By
E. Paul DeGarmo, J.T.
Black, Ronald A. Kohser.
1997 by Prentice-Hall.
Types of Drills
Figure 23.21 Various types of drills.
Gun Drill
Figure 23.22 (a) A gun drill showing various features. (b)
Schematic illustration of the gun-drilling operation.
Trepanning
Figure 23.23 (a) Trepanning tool. (b) Trepanning with a drill-mounted single cutter.
Upright drill press
stands on the floor

Bench drill similar
but smaller and
mounted on a
table or bench
Figure 22.15 Upright drill press
Drill Press
Large drill press
designed for
large parts
Figure 22.16 Radial drill press
(photo courtesy of Willis
Machinery and Tools).
Radial Drill
Vertical Drill Press and Radial Drilling
Machine
Figure 23.24 (a) Schematic illustration of the components of a vertical drill press. (b) A
radial drilling machine. Source: (b) Courtesy of Willis Machinery and Tools.
After Materials and Processes in
Manufacturing. 8th ed. By E.
Paul DeGarmo, J.T. Black,
Ronald A. Kohser. 1997 by
Prentice-Hall.
Three-Axis Computer Numerical-Control
Drilling Machine
Figure 23.25 A three-axis computer
numerical-control drilling machine. The turret
holds as many as eight different tools, such as
drills, taps, and reamers.
Work Holding for Drill Presses
Workpart in drilling can be clamped in any of
the following:
Vise - general purpose workholder with two
jaws
Fixture - workholding device that is usually
custom-designed for the particular workpart
Drill jig similar to fixture but also provides
a means of guiding the tool during drilling

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