Unit IV: LATHE & DRILLING MACHINE 5.

. Knurling It is an operation performed on the lathe to generate serrated surface on work piece using a knurling tool which impresses its pattern on the workpiece. Knurling tool consists of one upper roller and one lower roller which has desired impression pattern The rollers are made up of hardened steel The impression pattern can be straight or diamond pattern. The tool is set in the tool post in such a way that the upper & lower roller of the knurling head touches the surface of the workpiece. The tool is pressed against revolving work piece till the desired depth of embossing is obtained. The axis of the knurling head will be parallel to the workpiece axis A speed of 60 to 80 rpm with a feed of 0.38 to 0.76 mm/rev is used.

6. Drilling Drilling is a metal cutting process carried out by a rotating tool called twist drill' or 'drill bit' to make circular holes in solid materials.

One end of the workpiece is held in a chuck, while the other end is left free as shown in Figure. The drill bit is held in the tapered hole of the tailstock sleeve and is fed into the rotating workpiece with the help of the rotating hand wheel of tailstock.

 The hole is generated by the sharp edges of the rotating drill bit that is forced to move against the rigidly clamped workpiece. The chip gets curled and escapes through the helical grooves provided in the drill bit. Note: drilling can be only done through the axis of rotation of the workpiece.

Figure: Drill Attachment

Figure: drilling

Fig: Drill bit

DRILLING MACHINE A power operated machine tool which holds the drill in its spindle rotating at high speeds & when manually moved linearly against the workpiece produces a hole is called Drilling machine. Size of the holes produced varies from thousandth of a cm up to 7.5 cm diameter.

Classification of drilling machine Drilling machines are manufactured in different sizes for different classes of work and classified as follows: 1. Portable Drilling Machine 2. Pillar Drilling Machine 3. Gang Drilling machine 4. Multiple Drilling Machine 5. Bench Drilling Machine 6. Radial Drilling Machine 1. Portable Drilling Machine: A portable drilling machine is used for drilling holes in light work such as, structural fabrications, fitting work in assemblies, and also in cases where high accuracy is not required" 2. Pillar Drilling Machine Pillar drilling machines are generally employed for both medium and heavy duty jobs. It consists of a robust pillar erected over a sturdy base which is fixed on the floor. 3. Gang Drilling Machine A gang drill is made up of many drilling heads; placed side by side and the workpieces is mounted on a long common work table. Each drill head can have different tools like reamer, countersinking tool etc to perform different operation successively.

4. Multiple Spindles Drilling Machine The multiple spindle drilling machines drills several holes of different diameters simultaneously. 5. Bench Drilling Machine Bench drilling machines are light duty drilling machines usually placed on workbenches hence the name bench drilling machine. This type of drilling machines is also called sensitive drilling machines because of its accurate and well balanced spindle. It is used in small workshops. Parts of a Bench Drilling Machine A sketch of bench drilling machine is as shown in the figure. It consists of a base over which vertical main column made of a hollow steel pipe is mounted. The upper side of the vertical column carries a moving head which consists of a driving motor, a V- belt drive unit of a stepped cone pulley. The power is transmitted to the main spindle through the stepped cone pulley drives and gearing systems. The spindle speed can be varied by altering the belt position on the stepped cone pulley. A drill chuck is used to fit small size drills in the spindle. For bigger sizes the drill itself will be fitted directly in the spindle. The workpiece is mounted on table called work table which is provided with T-slots to clamp workpiece rigidly on the table. Work table can also be raised or lowered over the arm as well as radially about the column axis locked at suitable position. The hole location on the job is made with a centre punch. The tip of the drill has to be aligned with center of the hole to be drilled which is marked with center punch mark. The machine is started and with the help of drill Feed handle, the drill bit is slowly fed so that the 'point' of the drill bit touches the indentation mark. Gradual feed is given so as to produce the hole.

 When the hole is completed, the drill bit is withdrawn carefully by rotating the hand wheel in the reverse direction. Note: 1. only small size holes can be drilled. 2. The drill bit is fed into the workpiece by drill Feed handle, which enables the operator to sense or feel the movement of the cutting tool into the workpiece. Hence, these machines are also called 'Sensitive drilling machine'. 6. Radial Drilling Machine A radial drilling machine is as shown in figure. This is used for drilling operations on heavy and large workpiece in any position without moving them on the work table. It consists of a large heavy base with a stationary working table, a heavy cylindrical column with a heavy large radial arm extending from it Radial arm can be raised, lowered and rotated in a complete circle around the column to any desired location. The combined motion of the radial arm and drilling head enables in moving the drill to any position. Drilling head can move to and fro along the arm. Radial arm receives power from a motor which is mounted over it and can slide vertically over the elevating screw. A drill head contains the sleeve, spindle unit and gear box to obtain required feed and speed. The drill head can be moved horizontally over the arm on the guide ways and clamped at any desired position. A hand wheel helps in giving a manual or automatic down feed for the drill. The hole location on the job is made with a centre punch.

 The tip of the drill has to be aligned with center of the hole to be drilled which is marked with center punch mark. Feed wheel is used to lower the rotating spindle to perform the drilling operation. The drill is withdrawn carefully by rotating the hand wheel in the reverse direction. Advantages (i) The tool head (arm) permit the drill to be located at any desired position over the stationary work piece. (ii) Possible to work on odd shaped jobs and to drill larger diameter holes. (iii) Accurate precision drilling is possible. Specifications of Drilling Machines The general specifications of various drilling machines are as follows: (i) The maximum diameter of drill that can be used. (ii) The maximum size of work piece that can be worked. (iii) Size of working table (iv) Power (motor) capacity of the machine (v) For Radial drilling machines, diameter of column and the length of the arm have to be specified. (vi) For gang drilling machines and multi drill head drilling machines number of spindles with sizes have to be specified OPERATIONS ON DRILLING MACHINE The common operations that can be performed using a drilling machine are as follows (i) Reaming (ii) Boring (iii) Tapping (iv) Counter sinking (v) Counter boring (vi) Spot facing. (i) Reaming: It is the process of smoothening the surface of the predrilled hole using a tool called 'reamer' A reamer is similar to the drill bit but has multi-longitudinal straight flutes as shown in the Figure. To obtain a smoothly finished accurate size hole, a slightly undersize hole will be drilled first using twist drill. Then twist drill is replaced by reamer and the speed is reduced to half of that used in drilling The amount of material to be removed by reamer should not exceed 0.125mm. Note: Reaming removes only a small amount of material & produces a smooth finish on the drilled surface. (ii) Boring It is an enlarging operation of a predrilled hole, using an adjustable 'boring tool' which has a single cutting point.

 When a desired size drill is not available or a non-standard size hole has to be drilled then the nearest size hole is drilled first using the standard drill. Then twist drill is replaced by a boring tool. While the tool is rotating, it is lowered there by the size of the hole is increased to its entire depth as shown in figure. (iii) Tapping It is an internal thread generating operation in a predrilled hole, using a set of 3 taps used one after the other in succession. To generate a specific size thread, the nearest drill size is calculated and drilled first. Then using standard size taps, slowly and gradually the threads are generated as shown in the Figure

(iv) Counter Sinking It is an operation to produce a conical surface at the end of a predrilled hole, using a counter sink- a conical shaped cutting tool as shown in the Figure. The angle size of the hole depends on the angle size of the screw head or rivet head, whichever is to be seated in it. Generally the included angles of countersink tool are 60, 82 or 90. Cutting speed must be half of that used for similar size drill. Countersink head fastener in a countersink hole avoids unwanted projection over the top surface of the work piece E.g. Furniture, joints in doors, windows etc. (v) Counter Boring

 it is an operation to enlarge one end of the pre drilled hole concentrically to the required depth, using a counter bore' tool, to form a square shoulder as shown in the Figure. The counter bore is used to drive in the socket head, screws, bolts, pins etc. The cutting tool will have a small cylindrical projection called pilot to guide the tool to maintain concentricity with the original hole. The diameter of the pilot should be equal to the diameter of predrilled hole. (vi) Spot Facing It is an operation to produce a smooth flat surface around a drilled hole to give a good bearing surface for proper seating of a bolt heads, washers, nuts etc. It may be done using counter bores or special spot facing tools.