Manufacturing Process I

Diploma in Mechanical Engineering

3 rd Semester
 CHAPTER-06
DRILLING
PREPARED BY – ANUP KUMAR GUCHAIT
LECTURER IN MECHANICAL ENGINEERING
PURULIA POLYTECHNIC, PURULIA
 Learning Outcomes

At the end of this lesson, the student would be able to:

1. Explain the working principle of drilling.
2. Classify the types of drilling machines.
3. Identify the basic parts and their function for Pillar drilling machine & Radial drilling
machine.
4. Explain different operations in drilling machine.
5. State Specifications of a drilling machine.
6. State types of drills and reamers.
Introduction
Drilling machine is one of the most important machine tools in a workshop. Drilling
machines are generally or mainly used to originate through or blind straight cylindrical holes in
solid rigid bodies and/or enlarge (coaxially) existing (pre-machined) holes on metal workpieces.
Though holes can be made by different machine tools in a shop, drilling machine is designed
specifically to perform the operation of drilling and similar operations. Drilling can be done
easily at a low cost in a shorter period of time in a drilling machine. The unit essentially consists
of:
 A spindle which turns the tool (called drill) which can be advanced in the workpiece
either automatically or by hand.
 A work table which holds the workpiece rigidly in position.

Working principle:
The rotating edge of the drill exerts a large force on the workpiece and the hole is generated. The
removal of metal in a drilling operation is by shearing and extrusion.

Fig. 6.1: Working principle of drilling.

6.1. CLASSIFICATION OF DRILLING MACHINE
The different types of drilling machine which are most commonly used are:
1. Portable drilling machine.
2. Sensitive drilling machine
a) Bench mounting or table top, b) Floor mounting
3. Upright drilling machine
a) Pillar or round column section, b) Box column section.,
4. Radial drilling machine
a) Plain, b) Semi-universal, c) Universal
5. Gang drilling machine.
6. Multiple spindle drilling machine.
7. Automatic drilling machine.
8. Deep hole drilling machine.
a) vertical, b) Horizontal
But in working principle all are more or less the same.
6.2. BASIC PARTS AND THEIR FUNCTIONS

PILLAR DRILLING MACHINE

A Pillar Drill is one that's secured by bolts to floor or work bench or stand. It has five parts,
including base, table, column, spindle and drill head. Fig. illustrates a pillar drilling machine.
Base: It is used to support and stabilize the vertical column of the pillar drill.
Table: It support the work piece and can be adjusted to accommodate the size of the work piece.
Some table are adjusted by rotating around the pillar
Column: It is the vertical member of the machine which supports the table and the head
containing all the driving mechanism. The column should be sufficiently rigid so that it can take
up the entire cutting pressure of the drill.
Spindle: Holds the drill and transmits rotation and axial translation to the tool for providing
cutting motion and feed motion both to the drill.
Drill head: It is mounted on the top of the column and houses the driving and feeding
mechanism for the spindle.

Fig. 6.2(a): Construction of Pillar Drill Machine

RADIAL DRILLING MACHINE

Fig. illustrates a radial drilling machine. The major parts are:
Base: It is used to support and stabilize the vertical column of the drill.
Column: The column is a cylindrical casting that is mounted vertically at one end of the base. It
supports the radial arm which may slide up or down on its face. An electric motor is mounted on
the top of the column which imparts vertical adjustment of the arm by rotating a screw passing
through a nut attached to the arm.
Radial arm: The radial arm that is mounted on the column extends horizontally over the base. It
is a massive casting with its front vertical face accurately machined to provide guide ways on
which the drill head may be made to slide. The arm may be swung round the column. In some
machines this movement is controlled by a separate motor.
Drill head: The drill head is mounted on the radial arm and drives the drill spindle. It encloses
all the mechanism for driving the drill at multiple speeds and at different feed. All the
mechanisms and controls are housed within a small drill head which may be made to slide on the
guide ways of the arm for adjusting the position of drill spindle with respect to the work.
Spindle: Holds the drill and transmits rotation and axial translation to the tool for providing
cutting motion and feed motion both to the drill.

Fig. 6.2(b): Construction of Radial Drilling Machine

6.3. DRILLING MACHINE OPERATIONS:

The different operation that can be performed in a drilling machine are:
Drilling: Drilling is the operation of producing a cylindrical hole by removing metal by the
rotating edge of the cutting tool called the drill. It is the one of the simplest methods of
producing a hole. Before drilling the centre of the hole is located on the workpiece by drawing
two lines at right angle to each other and then centre punch is used to produce an indentation at
the centre. The drill point is pressed at this centre point to produced the required hole. Drilling
does not produce an accurate hole in a workpiece and the hole is generated by drilling becomes
rough and the hole is slightly oversized than the drill used due to vibration of the spindle and the
drill.

Fig.6.3(a): Drilling operation Fig. 6.3(b): Reaming operation

Reaming: Reaming is an operation of finishing a previously drilled hole to give a good surface
finish and an accurate dimension. A reamer is a multi tooth cutter which rotates and moves
axially into the hole. The reamer removes relatively small amount of material. Generally the
reamer follows the already existing hole and therefore will not be able to correct the hole
misalignment.
Boring: Boring is an operation of enlarging a previously drilled hole to bring it to the required
size with a single point cutting tool. The machine used for this purpose is called boring machine.

Fig. 6.3(c): Boring operation Fig. 6.3(d): Counter boring operation

Counter boring: This process involves increasing the size of one end of an existing hole
concentric with the original hole. It is done to accommodate the heads of bolts, studs, and pins.
The Cutting edges of the counter bore may have straight or spiral teeth.

Counter sinking: It is the operation of making conical shaped enlargement at the end of the
hole. The included angle of the conical surface may be in the range of 60° to 90°. It is used to
provide recess for a flat headed screw or a counter sunk rivet fitted into the hole.
 Fig. 6.3(e): Counter sinking operation
Spot facing: It is a operation of smoothing and squaring the surface around and at the end of
hole for proper seating of bolt head or the head of a screw. It is done using a special spot facing
tool.

Fig. 6.3(f): Spot facing operation

Tapping: Process of cutting internal threads with a thread tool called as tap. Tap is a fluted
threaded tool used for cutting internal thread. Cutting speed is very slow.

Fig. 6.3(g): Tapping operation Fig. 6.3(h): Trepanning operation

Trepanning: Trepanning is a technique used for drilling larger hole diameters where machine
power is limited as it is not as power consuming as conventional drilling. In case of drilling the
entire hole is converted into chips. In this process a central hole is drilled. It receives the pilot of
the trepanning tool, thus, preventing the lateral displacement of the tool as it cuts the metal. The
trepanning tool does not machine the whole diameter, only a ring at the periphery. Instead of
removing all the material in the form of chips, a core is left at the centre of the hole.
Consequently, this method is for through hole applications.

Chamfering: Chamfering is the process of bevelling the extreme ends of a work piece. It is done
in order to remove the sharp edge of the workpiece surface, to protect the end of the work piece
from being damaged and to have a better look.

Fig. 6.3(i): Chamfering operation

6.4. SPECIFICATION OF A DRILLING MACHINE

Drilling machines are specified according to their types.
A portable drilling machine is specified by the maximum diameter of drill that can be held by it.
The size of the sensitive and upright drilling machine are specified by the size of the
largest workpiece that can be centered under the spindle.
The size of the radial drilling machine is specified by the diameter of the column and the
length of the arm in meter.
The multiple spindle drilling machine is specified by the drilling area, size of hole and
number of holes a machine can drill.
To specify a drilling machine completely, the following factors are also to be considered:
 Diameter of the table
 Maximum travel of the spindle
 Numbers and range of spindle speeds and feeds available
 Morse taper number of spindle
 Power input required
 Floor space required
 Weight of the machine etc.
6.5. TYPES OF DRILLS AND REAMERS

TYPES OF DRILL

Drill: A drill is a fluted cutting tool used to originate or enlarge a hole in a solid material. The
types o f drill commonly used are:
1. Flat or spade drill
2. Straight fluted drill
3. Two-lip twist drill
a) parallel shank (short series or 'jobbers') twist drill
b) parallel shank (stub series) twist drill
c) parallel shank (long series) twist drill
d) Taper shank twist drill
4. Taper shank core drill (Three or four fluted)
5. Oil tube drill
6. Centre drill

1. Flat or spade drill: In this type of drill cutting angle varies from 90°-120° and the relief or
clearance at the cutting edge is 3°-8°.

Fig. 6.5(a): Flat or spade drill

2. Straight fluted drill: A straight fluted drill has grooves or flutes running parallel to the drill
axis. It may be considered as a cutting tool having zero rake angle.

Fig. 6.5(b): Straight fluted drill

3. Two-lip twist drill: The most common type of drill in use today is the twist drill. The twist
drill are made by machining two spiral flutes or grooves that run lengthwise around the body of
the drill. Different types of twist drill are classified by Indian Standard Institute according to the
type of the shank, length of the flute and overall length of the drill. Two-lip twist drill are four
types:
a) parallel shank (short series or 'jobbers') twist drill
 b) parallel shank (stub series) twist drill
c) parallel shank (long series) twist drill
d) taper shank twist drill

Fig. 6.5(c): Parallel shank (short series or 'jobbers') twist drill

Fig. 6.5(d): Parallel shank (stub series) twist drill

Fig. 6.5(e): Parallel shank (long series) twist drill

Fig. 6.5(f): Taper shank twist drill

4. Taper shank core drill (Three or four fluted): These drills are intended for enlarging cored,
punched or drilled holes. These drills cannot originate a hole in solid material because the cutting
edges do not extend to the centre of the drill. The material is removed by a chamfered edge at the
end of flute.

Fig. 6.5(g): Taper shank core drill

5. Oil tube drill: These type of drill are used for drilling deep holes. Oil tubes run lengthwise
spirally through the body to carry oil directly to the cutting edges. Cutting fluid or compressed
air is forced through the holes to the cutting point of the drill to remove the chips, cool the
cutting edge and lubricate the machined surface.

Fig. 6.5(h): Oil tube drill

6. Centre drill: Centre drills are straight shank, two fluted twist drill used when centre holes are
drilled on the end of a shaft.

Fig. 6.5(i): Centre drill

TWIST DRILL NOMENCLATURE:

 Fig. 6.5(j): Twist drill nomenclature

Axis: It is the longitudinal centre line of the drill running through the centres of the tang and the
chisel edge.
Body: It is the part of the drill from its extreme point to the commencement of the neck, if
present. Otherwise, it is the part extending upto the commencement of the shank. Helical grooves
are cut on the body of the drill.
Shank: It is the part of the drill by which it is held and driven. It is found just above the body of
the drill. The shank may be straight or taper. The shank of the drill can be fitted directly into the
spindle or by a tool holding device.
Tang: The flattened end of the taper shank is known as tang. It is meant to fit into a slot in the
spindle or socket. It ensures a positive drive of the drill.
Neck: It is the part of the drill, which is diametrically undercut between the body and the shank
of the drill. The size of the drill is marked on the neck.
Diameter: Largest diameter measured across the top of the lands behind the point.
Back Taper: The diameter reduces slightly toward the shank end of the drill, this is known as
“back taper”. Back taper provides clearance between the drill and work-piece preventing friction
and heat.
Point: It is the sharpened end of the drill. It is shaped to produce lips, faces, flanks and chisel
edge.
Lip: It is the edge formed by the intersection of flank and face. There are two lips and both of
them should be of equal length. Both lips should be at the same angle of inclination with the axis
(59°).
Flank : Surface of drill which extends behind the lip to flute.
Land: It is the cylindrically ground surface on the leading edges of the drill flutes adjacent to the
body clearance surface. The alignment of the drill is maintained by the land. The hole is
maintained straight and to the right size.
Flutes: The grooves in the body of the drill are known as flutes. Flutes form the cutting edges on
the point. It allows the chips to escape and make them curl. It permits the cutting fluid to reach
the cutting edges.
Flute Length: The length of flute measured from the drill point to the end of the flute run out.
Flute length determines the maximum depth of drilling.
Margins: The cylindrical portion of the land that is not cut away to provide clearance.
Helix Angle: Angle formed between a line drawn parallel to the axis of the drill and the edge of
the land. (30° or 45°)
Point angle : This is the angle included between the two lips projected upon a plane parallel to
the drill axis and parallel to the two cutting lips. The optimum point angle of the twist drill for
the work material of mild steel is 118°.
Chisel Edge : It is the point where two cutting lips meets at extreme tip.
Chisel Edge Angle :Angle between chisel edge and cutting lip measured plane normal to axis.

TYPES OF REAMERS
A reamer is a tool used for enlarging or finishing a hole previously drilled, bored or cored to give
a good finish and an accurate dimension. A reamer is a multi-tooth cutter which removes
relatively small amount of material. There are various classification of reamers depending upon
the operation, purpose and shape. the commonly used reamers in I.S. specification are:
1. Chucking reamers with parallel or taper shank
a) Fluted reamer, b) Rose reamer
2. Machine bridge reamer
3. Machine jig reamer
4. Parallel hand reamer with parallel shank
5. Parallel or taper shank socket head reamer
6. Shell reamer
7. Taper pin hand or machine reamer
8. Expansion reamer

Reference Book
1. Choudhury S. K. H., Bose S. K., Choudhury A. K. H., Roy N., Bhattacharya S. C.,
Elements of Workshop Technology ( Vol. II: Machine Tools), Media Promoters &
Publishers Pvt. Ltd., 14th Edition, 2014.
2. Sarkar S. R., Manufacturing Process-I, Lakshmi Prakashani, 3rd Edition, 2016.
3. Jain, R. K., Production Technology, Khanna Publisher, 17th edition, 2009.
4. Raghuwanshi B. S., Workshop Technology ( Vol. II: Machine Tools), Dhanpat Rai & Co.
(Pvt.) Ltd., 10th Revised Edition, 2012.
Reference Website
1. https://www.nptel.ac.in/

Subjective Type Question

1. Classify drilling machines. How will you specify a drilling machine?
2. Explain principal parts of the pillar drilling machine with neat sketch.
3. Explain various types of operations performed on a drilling machine by neat sketches.
4. Illustrate different parts of a twist drill by neat sketches.
5. Write short notes on following:
(i) Drilling (ii) Boring, (iii) Reaming, (iv) Tapping, (v) Counter boring, (vi) Counter sinking.

Multiple Choice Questions

1. Which of the following operation, we can’t perform on drilling machine?

a) reaming
b) tapping
c) counter sinking
d) none of the mentioned

2. The drilling machine was primarily designed to originate a ____________.

a) flat surface
b) cylindrical surface
c) hole
d) taper surface

3. Which of the following operation is carried out to make the hole dimensionally more accurate?
a) reaming
b) tapping
c) boring
d) none of mentioned

4. Which of the following process is carried out to provide seating for head of screw?
a) counter boring
b) countersinking
c) tapping
d) none of the mentioned

5. Which of the following operation is used to enlarge the previously drilled hole?
a) reaming
b) tapping
c) boring
d) none of mentioned

6. Which of the following drilling machine is suitable for a job with multiple hole-
a) portable drilling machine
b) radial drilling machine
c) gang drilling machine
d) all of the above

7. Which of the following operation is carried out for cutting internal threads?
a) drilling
b) tapping
c) boring
d) none of the above

8. Trepanning operation is performed for-

a) finishing a drilled hole
b) producing large hole
c) sizing a small hole
d) none of the above

9. The metal is removed in drilling operation by-

a) compression
b) shearing
c) extrusion
d) shearing and extrusion

10. A portable drilling machine is specified by-

a) the size of the job, it can hold
b) maximum diameter of drill that it can hold
c) size of the table
d) maximum spindle travel

11. The optimum point angle of the twist drill for the work material of mild steel should be-
a) 135°
b) 118°
c) 90°
d)108°

12. _________ is provided in drill for the passage of chips and cutting fluid.
a) shank

b) flutes
c) tang
d) clearance
13. According to the shank type, drill can be classified as______
a) straight shank
b) taper shank
c) both taper shank and straight shank
d) none of the above

14. Twist fluted drills are preferred because-

a) it cuts hole efficiently
b) it is a light weight tool
c) chips moves out automatically
d) cutting lip is supported rigidly

15. Back taper is a-

a) slight decrease in diameter from front to back in the body of the drill
b) slight decrease in diameter from back to front in the body of the drill
c) slight decrease in diameter from front to back in the shank of the drill
d) slight decrease in diameter from back to front in the shank of the drill

Answers of MCQ
1. d), 2. c), 3. a), 4. b), 5. c), 6. c), 7. b), 8. b), 9. d), 10. b), 11. b), 12. b), 13. c), 14. c), 15. a)