Manufacturing Processes (2), IE-352

Ahmed M El-Sherbeeny, PhD

Spring 2016

Manufacturing Engineering Technology in SI Units, 6th Edition

Chapter 23:
Machining Processes: Hole Making – Part B (Drilling)
 Drilling, Drills, and Drilling Machines
2

 Most products have many holes in them

 e.g. for rivets on plane wings
 e.g. for bolts in engine blocks
 Holes used for:
 assembly with fasteners (e.g. screws, bolts, rivets)
 design purposes (e.g. weight reduction, ventilation)
 appearance
 Hole making:
 Among most important operations in manufacturing
 Drilling is major, common hole-making process
 Cost is among highest machining costs in car engine prodon
 Drilling, Drills, and Drilling Machines: Drills
3

 Drill properties:
 Have high length-to-diameter ratios (see next slide)
 Thus, capable of producing deep holes
 Caution: drills are flexible ⇒ should be used with care
 to drill holes accurately
 and to prevent breakage

 Drilling Marks:
 Drills leave burr* on bottom surface upon breakthrough
 ⇒ requires deburring operations
 Rotary motion of drilling
 ⇒ holes with “circumferential marks” on walls
 Drilling, Drills, and Drilling Machines: Drills
4
(AKA: standard-point twist drill)
2 common
types of
drills

a) margins:
provide bearing
surface for drill
b) have good centering against walls of
ability, chips break hole as it
easily ⇒ suitable for penetrates
deep holes workpiece
 Drilling, Drills, and Drilling Machines: Drills
5

Drill oversize:
 Oversize: fact that ∅ of hole > drill ∅ (slightly)
 This is visible: easy to remove drill after making hole
 Oversize depends on:
 Quality of drill
 Equipment
 Expansion of metallic/non-metallic material due to drilling heat
 In the end: possible that final hole ∅ < drill ∅
 To improve S.F. and dim. acc.:
 Perform reaming/honing* on drilled holes
 Capabilities of drilling/boring: shown on next slide
 Drilling, Drills, and Drilling Machines: Drills
6

 Note, depth/diameter is a ratio (i.e. unitless)

 e.g. for twist drill:
 typical depth @ 100 𝑚𝑚 ∅ = 8 ∗ 100 𝑚𝑚 = 800 𝑚𝑚
 Drilling, Drills, and Drilling Machines: Drills
7

Twist Drill
 Most common drill: conventional standard-point twist drill
 Geometry of drill point:
 normal rake angle and 𝑉 of cutting edge vary with distance
from center of drill
 Main features of twist drill (typical angles):
1. Point angle (118° 𝑡𝑡 135°)
2. Lip-relief angle (7° 𝑡𝑡 15°)
3. Chisel-edge angle (125° 𝑡𝑡 135°)
4. Helix angle (15° 𝑡𝑡 30°)
 Drilling, Drills, and Drilling Machines: Drills
8

Cont. Twist Drill

 Grooves in drills:
 Spiral grooves run along length of drill
 Chips: guided through grooves, upward
 Grooves: also allow cutting fluid to reach cutting edges
 Some drills have internal longitudinal holes for cutting fluids (a)
⇒ lubrication, cooling, flushing chips
 Drills have chip-breaker feature ground along cutting edges
 Drill angles (chosen carefully):
 Produce accurate holes
 Minimize drilling forces and torque
 Increase drill life
 Small change in angles ⇒ great change in performance*
 Drilling, Drills, and Drilling Machines: Drills
9

Other Types of Drills

 Step drill:
 Holes with ≥ 2 ∅’s
 Core drill:
 Enlarge existing hole
 Counter boring/countersinking:
 Make depressions on surfaces to accommodate heads of
screws, bolts below workpiece surface
 Center drill:
 Short; produce hole at end of piece of stock
 Spot drill:
 Spots (i.e. starts) hole at desired location on a surface
 Drilling, Drills, and Drilling Machines: Drills
10

Other Types of Drills

 Spade drills (a):

 Removable bits
 Large ∅ holes
(indexable)
 Deep holes
 Advantages: high stiffness, ease of grinding edges, low cost
 Straight-flute drill (b):
 Similar to spade drill
 Solid carbide (c), carbide-tipped drills* (d) for drilling:
 Hard materials (e.g. cast irons)
 High-temp. metals
 Abrasive (e.g. concrete) and composite materials (e.g. glass)
 Drilling, Drills, and Drilling Machines: Drills
11

Gun Drilling
 Name origin “gun”
Gun drill
 Drilling gun barrels
 Features: Gun drilling
 Drilling deep holes operation

 Requires a special drill

 Hole depth-to-∅ ratio: ≥ 300: 1
 𝐹𝑡 balanced by bearing pads on inside surface
 ⇒ gun drill: self-centering (important for drilling deep holes)
 Gun trepanning:
 Uses cutting tool similar to gun drill
 Tool has a central hole
 Drilling, Drills, and Drilling Machines: Drills
12

Cont. Gun Drilling

 Cutting fluid
 Forced under high pressure through passage in drill body (fig a)
 Cooling and lubrication effect
 Also: flushes out chips that could be trapped in deep holes
 ⇒ chips don’t interfere with drilling operation
 ⇒ no need to retract tool to clear chips (i.e. unlike twist drills)
 Drilling, Drills, and Drilling Machines: Drills
13

Trepanning
 Name origin:
 “Trypanon” (Greek) i.e. boring a hole
 Cutting tool produces a hole:
 By removing a disk-shaped piece (core) from flat plates
 Without changing all material to chips (i.e. unlike drilling)
 Can make disks:
 Up to 250 𝑚𝑚 in diameter
 From flat sheets, plates, structural members (e.g. I-beams)
 Carried out:
 On lathes, drill presses, or other machine tools
 Using single-point or multipoint tools (fig. b)
 Drilling, Drills, and Drilling Machines: Drills
14

Cont. Trepanning

a) Trepanning tool
b) Trepanning with drill-
mounted single cutter
 Drilling, Drills, and Drilling Machines:
Material-removal Rate in Drilling
15

 Material-removal rate (MRR) in drilling:

 Volume of material removed per unit time*
 Drill diameter: 𝐷
 C.S.A. of drilled hole: 𝜋𝐷2 /4 𝑚𝑚2
 Velocity of drill (⊥ to workpiece):
 𝑉 = 𝑓𝑓
 𝑓, feed: dist. drill penetrates/unit rev., i.e. 𝑓 = 𝜋𝐷 [𝑚𝑚/𝑟𝑟𝑟]
 𝑁: rotational speed [𝑟𝑟𝑟/min]
𝜋𝐷2
 ⇒ 𝑀𝑀𝑀 = 𝐶. 𝑆. 𝐴 ∗ 𝑉 = ∙ 𝑓𝑓
4
 Check dimensions: 𝑀𝑀𝑀 = 𝑚𝑚2 𝑚𝑚/𝑟𝑟𝑟 𝑟𝑟𝑟/𝑚𝑚𝑚
= 𝑚𝑚3 /𝑚𝑚𝑚 (which are units of volume / unit time)
 Drilling, Drills, and Drilling Machines:
Thrust Force and Torque
16

 Thrust force (𝐹𝑡 )

 Acts perpendicular to hole axis (i.e. radially or sideways)
 Excessive 𝐹𝑡 ⇒
 Drill: bends or breaks
 Workpiece: distorted (esp. if it does not have sufficient stiffness*)
 or Workpiece: slips into workholding fixture
 𝐹𝑡 depends on:
1. Strength of the workpiece material
2. Feed
3. Rotational speed
4. Drill diameter
5. Drill geometry
6. Cutting fluid
 Drilling, Drills, and Drilling Machines:
Thrust Force and Torque
17

 Finding 𝐹𝑡 :
 Accurate calculation is difficult
 Range:
 few 𝑁 for small drills
 to 100 𝑘𝑘 for high-strength materials with large drills
 Experimental data: helps in using drills
 Drilling, Drills, and Drilling Machines:
Thrust Force and Torque
18

Torque
 Knowledge of torque (𝑇) in drilling:
 Essential for estimating the power requirement
 But difficult to calculate (due to many factors involved)
 𝑇 𝑁 ∙ 𝑚 can be estimated from data tables:
 e.g. table showing sp. power for different materials (Table 21.2)
 Note, power dissipated in drilling = torque * rotational speed
 i.e. 𝑷𝑷𝑷𝑷𝑷 = 𝑻 ∗ 𝑵 𝑁. 𝑚 𝑟𝑟𝑟/𝑚𝑚𝑚
𝑷𝑷𝑷𝑷𝑷
 Remember, 𝑠𝑝. 𝑝𝑜𝑜𝑜𝑜: 𝒖𝒕 = 𝑊 ∙ 𝑠/𝑚𝑚3
𝑴𝑴𝑴
𝑷𝑷𝑷𝑷𝑷 𝒖𝒕 ∙𝑴𝑴𝑴
 ⇒𝑻= = 𝑁. 𝑚/𝑠 / 𝑟𝑟𝑟/𝑚𝑚𝑚
𝑵 𝑵
 Note, for proper units: 𝑁 must be expressed as:
 𝑁: rotational speed from [𝑟𝑟𝑟/min] to 2𝜋 𝑟𝑟𝑟./60𝑠 **
 Drilling, Drills, and Drilling Machines:
Thrust Force and Torque
19

EXAMPLE 23.4
Material-removal Rate and Torque in Drilling
A hole is being drilled in a block of magnesium alloy with a
10 − 𝑚𝑚 drill bit at a feed of 0.2 𝑚𝑚/𝑟𝑟𝑟 and with the
spindle running at 𝑁 = 800 𝑟𝑟𝑟. Calculate the material-
removal rate and the torque on the drill.
 Drilling, Drills, and Drilling Machines:
Thrust Force and Torque
20

Solution
Material-removal Rate and Torque in Drilling
The material-removal rate is

 π (10) 2 
MMR =  (0.2)(800) = 12,570 mm3 / min = 210 mm3 /s
 4 

The power required is Power = (210)(0.5) = 105 W

105
The torque is T = = 1.25 Nm
83.8

Copyright © 2010 Pearson Education South Asia Pte Ltd

 Drilling, Drills, and Drilling Machines:
Drill Materials and Sizes
21

 Drill materials:
 Usually made from 𝐻𝐻𝐻
 Also solid carbides or with carbide tips
 Drills commonly coated with:
 𝑇𝑇𝑇 or 𝑇𝑇𝑇𝑇* for increased wear resistance
 Polycrystalline-diamond-coated drills:
 Used to make fastener holes
 Used with fiber-reinforced plastics
 Have high wear resistance
 1000’s of holes can be drilled with little damage to drill material
 Drilling, Drills, and Drilling Machines:
Drill Materials and Sizes
22

 Standard twist-drill sizes consist of following series:

1. Numerical
 No. 97 (0.0059 𝑖𝑖. − 0.15 𝑚𝑚 ) to No. 1 (0.228 𝑖𝑖. − 5.79 𝑚𝑚)
2. Letter
 A (0.234 𝑖𝑖. − 5.94 𝑚𝑚 ) to Z (0.413 𝑖𝑖. − 10.49 𝑚𝑚)
3. Fractional
1 1 1
 Straight shank: from − 1 𝑖𝑖. (in − 𝑖𝑖. increments) to
64 4 64
1 1
1 𝑖𝑖. (in − 𝑖𝑖. increments)*
2 32
1 3 1 1
 Taper shank: − 1 𝑖𝑖. (in 𝑖𝑖. ∆′ 𝑠) to 3.5 𝑖𝑖. (in 𝑖𝑖. ∆′ 𝑠)
8 4 64 16
4. Millimeter
 From 0.05 𝑚𝑚 (0.002 𝑖𝑖.) in 0.01 𝑚𝑚 ∆′ 𝑠
 Drilling, Drills, and Drilling Machines:
Drilling Practice
23

 Drill chucks:
 Used to hold drills (and similar hole-making tools)
 Tightened with/without keys
 Special chucks
 Have quick change features
 Do not require stopping the spindle
 Available for use in production machinery
 Lateral deflection of drill:
 Drills do not have a centering action
 ⇒ tend to “walk” on workpiece surface at start of operation
 Problem severe with small-D long drills, may lead to failure
 Drilling, Drills, and Drilling Machines:
Drilling Practice
24

 Avoiding lateral deflection of drill (at start of drill):

1. Guide drill using fixtures
2. Use center drill to make small starting hole before drilling
 Usually @ 60° point angle
3. Grind drill point to an S shape (important with CNC machines)
 This has a self-centering characteristic
 ⇒ no need for center-drilling
 Produces accurate holes with improved drill life
4. Use centering punch ⇒ produces initial impression
5. Add dimples (or other features) in cast or forged blank

Copyright © 2010 Pearson Education South Asia Pte Ltd

 Drilling, Drills, and Drilling Machines:
Drilling Practice
25

Drilling Recommendations
 Speed:
 Recommended ranges for 𝑉 and 𝑓 shown in table (next slide)
 Speed here is surface speed, 𝑉, of drill at its periphery
 Example:
12.7 𝑚𝑚 drill, rotating at 300 𝑟𝑟𝑟*, has a surface speed of:
𝑉 = 𝑟𝑟𝑟𝑟𝑟𝑟 ∗ 𝑁
12.7 1
= 𝑚𝑚 300 𝑟𝑟𝑟/𝑚𝑚𝑚 (2𝜋 𝑟𝑟𝑟/𝑟𝑟𝑟)( 𝑚/𝑚𝑚)
2 1000
= 12 𝑚/𝑚𝑚𝑚
 Note how surface speed (𝑅𝑅) is different than drill velocity (𝑓𝑓)
 Drilling holes < 1 𝑚𝑚 (in diameter):
 𝑁 can be up to 30,000 𝑟𝑟𝑟 (depending on workpiece material)
 Drilling, Drills, and Drilling Machines:
Drilling Practice
26

Drilling Recommendations
 Drilling, Drills, and Drilling Machines:
Drilling Practice
27

Drilling Recommendations
 Feed:
 Feed in drilling: dist. drill travels into workpiece per revolution
 Recommendation: for most workpiece materials:
drills with 𝐷 = 1.5 𝑚𝑚 should have 𝑓 = 0.025 𝑚𝑚/𝑟𝑟𝑟
 Example:
A 1.5 𝑚𝑚 − 𝐷 drill rotating at 2000 𝑟𝑟𝑟, has linear speed of:
𝑉 =𝑓∗𝑁
= 0.025 𝑚𝑚/𝑟𝑟𝑟 2000 𝑟𝑟𝑟/𝑚𝑚𝑚
= 50 𝑚𝑚/𝑚𝑚𝑚
 Drilling, Drills, and Drilling Machines:
Drilling Practice
28

Drilling Recommendations
 Chip removal during drilling:
 Can be difficult
 Especially: deep holes in soft and ductile workpiece materials
 To avoid this:
 Retract drill periodically (“pecking”), then:
 Removing chips accumulated along drill flutes
 Otherwise: drill may break due to high 𝑇, or
“walk-off” location and produce mis-shaped hole
 Table: shows guide to general problems in drilling operations
 Drilling, Drills, and Drilling Machines:
Drilling Practice
29

Drilling Recommendations
 Drilling, Drills, and Drilling Machines:
Drilling Practice
30

Drill Reconditioning
 Drills reconditioned by grinding, either:
 Manually (i.e. by hand), or
 With special fixtures
 Reconditioning: especially important with CNC machines
 Hand grinding:
 Difficult
 Requires considerable skill to produce symmetric cutting edges
 Grinding on fixtures:
 Accurate
 Done on special computer controlled grinders
 Coated drills can be recoated
 Drilling, Drills, and Drilling Machines:
Drilling Practice
31

Measuring Drill Life

 Drill life measured by no. of holes drilled:
 Before they become dull, and
 Need to be re-worked or replaced
 Determining drill life experimentally:
 Clamping material on dynamometer/force transducer
 Drilling number of holes
 Recording 𝑇 or 𝐹𝑡 during each operation
 After certain no. of holes: 𝑇 & 𝐹𝑡 ↑ since tool becomes dull
 Drill life here is: no. of holes drilled until this transition begins
 Other techniques to measure drill life:
 Monitoring vibrations and acoustic emissions (Ch. 21: tool life)
 Drilling, Drills, and Drilling Machines:
Drilling Machines
32

 Drilling machines
 Used for drilling holes, tapping, reaming and small-diameter
boring operations
 Most common machine: drill press (fig. a)
 Drilling process:
 Workpiece is placed on adjustable table by:
 Clamping directly into slots and holes in the table, or using:
 Vise* (→: swivel vise), which’s then clamped to table
 Drill is lowered:
 Manually (requires skill in judging appropriate 𝑓), or:
 Using handwheel, or:
 By power feed at preset rates
 Drilling, Drills, and Drilling Machines:
Drilling Machines
33

Schematic: components Radial drilling

of vertical drill machine
 Drilling, Drills, and Drilling Machines:
Drilling Machines
34

 Drill presses:
 Designated by largest workpiece 𝐷 accommodated on table
 Typical range 𝐷 = 150 𝑡𝑡 1250 𝑚𝑚
 Adjusting spindle speed
 Necessary to maintain proper cutting speed at drill cutting edge
 Allows using different drill sizes
 Types of drilling machines (traditional machines)
1. Simple: bench type drills, used to drill small-𝐷 holes
2. Large: radial drills (fig. b), used for large workpieces
3. Universal drilling machines: drill head can be swiveled to drill
holes at an angle
 Drilling, Drills, and Drilling Machines:
Drilling Machines
35

 Cont. Types of drilling machines (developments):

4. Numerically controlled three-axis drilling machines (fig.):
 Operations performed automatically & in desired sequence using turret
 Turret holds different tooling tools
5. Gang drilling:
 Drilling machines with multiple spindles*
 Used for high-production-rate operations
 Capable of drilling 50 holes in 1 cycle (different sizes, depths, locations)
 Also used for reaming, counterboring operations
6. Numerical-control turret drilling machines
 Replacing machine tools and gang-drilling machines
7. Special drilling machines
 e.g. produce holes in continuous hinges (e.g. piano hinges)
 Horizontal and produce holes up to 3 − 𝑚 long segments per cycle
 Drilling, Drills, and Drilling Machines:
Drilling Machines
36

3-axis NC drilling machine;

turret holds as many as 8
different tools (e.g. drills,
taps, reamers)
 Drilling, Drills, and Drilling Machines:
Drilling Machines
37

 Workholding devices:
 Ensure workpiece is located properly
 Keep workpiece from slipping or rotating during drilling
 Available in various designs
 Important features:
 3-point locating (for accuracy)
 3-D workholding for secure fixtures
 Drilling, Drills, and Drilling Machines:
Design Considerations for Drilling
38

 Basic design guidelines for drilling:

1. Designs should allow holes to be drilled
 On flat surfaces and ⊥ to drill motion
 Otherwise: drills deflect and hole will not be located properly
2. Interrupted hole surfaces should be avoided
 This ensures: dim. acc., longer drill life, avoids vibrations
3. Hole bottoms should match standard drill-point angles
4. Through holes are preferred over blind holes
5. Dimples should be provided:
 When pre-existing holes not possible, to reduce drill “walk-off”
6. Parts should be designed to drill with minimum of fixturing
7. Blind holes: drill deeper than subsequent reaming/tapping