5.

2 DRILLING MACHINE

Course Contents
Introduction
Types of Drilling Machine
Size of Drilling Machine
Work Holding Devices
Drill Tool Nomenclature
Drilling Machine Operations
5.2. Drilling Manufacturing Processes
Machine

Introduction
 The drilling machine is one of the most important machine tools in a workshop. As
regards its important is second only to the lathe.

 It was primarily designed to originate a hole; it can perform a number of similar

operations.

 In drilling machine, holes may be drilled quickly and at a low cost. The hole is
generated by rotating edge of a cutting tool known as ‘drill’, which exerts large force
on the work clamped to the table.

Types of Drilling Machine

 Drilling machines are made in many different types and sizes, each designed to
handle a class of work or specific jobs to the best advantages.
 The different types of drilling machines are:
1. Portable drilling machine 5. Gang drilling machine
2. Sensitive drilling machine 6. Multiple spindle drilling machine
A. Bench mounting 7. Automatic drilling machine
B. Floor mounting 8. Deep hole drilling machine
3. Upright drilling machine A. Vertical
A. Round column section B. Horizontal
B. Box column section
4. Radial drilling machine
A. Plain
B. Semi universal
C. Universal

Portable drilling machine

 As the name implies this type of drilling machine can be operated with ease
anywhere in the workshop and is used for drilling holes in workshop in any position
which cannot be drilled in a standard drilling machine.

 Some of portable machine are operated by hand power but some of the machine are
driven by individual motor.

 The maximum size of hole it can accommodate is not more than 12 to 18 mm.
Sensitive drilling machine

 Sensitive drilling machine is a small machine designed for drilling small holes at a
high speed in light jobs.
Manufacturing Processes 5.2. Drilling
Machine

 The base of machine may be mounted on a bench or on a floor.

1 – Table, 2 – Vertical drill spindle, 3 – Sleeve, 4 – Cone pulley, 5 – V Belt, 6 – Head, 7–

Driving motor, 8 – Vertical column, 9 – Base
Fig 3.1 Sensitive Drilling Machine
 It consists of a vertical column, horizontal table, a head supporting motor and driving
mechanism for driving and rotating the drill.

 There is no automatic feed of drill spindle.

 Drill is fed to the work by purely hand control.

 Hand feed permits the operator to feel or sense the progress of the drill into work,
so that if the drill becomes worn out or jams on any account, the pressure on the
drill may be released immediately to prevent it from breaking.

 Sensitive drilling machine are capable of rotating drills of diameter from 1.5 to 15.5
mm.

 Supersensitive drillimg machine designed to drill holes as small as 0.35 mm in

diameter and rotates at a high speed of 20000 rpm or above.
Upright drilling machine

 The upright drilling machine is designed for handling medium sized workpiece.
 Its construction is very similar to a sensitive drilling machine for having a vertical
column mounted upon the base.

 But this is larger and heavier than sensitive drilling machine and is supplied with
power feed arrangement.
5.2 Drilling Manufacturing Processes
Machine

 In an upright drilling machine a large number of spindle speeds and feeds may be
available for drilling different types of work.

 There are two types of upright drilling machines.

1. Round column section or pillar drilling machine
2. Box column section

1 – Bevel gear drive to spindle, 2 – Spindle, 3 – Over head shaft, 4 – Back stay,
5 – Cointer shaft cone pulley, 6 – Fast and loose pulley, 7 – Table elevating
handle, 8 – Foot padel, 9 – Base, 10 – Rack on column, 11 – Table elevating
clamp handle, 12 – Table clamp, 13 – Table, 14 – Column, 15 – Hand wheel for
quick hand feed, 16 – Hand wheel for sensitive hand feed
Fig 3.2 Upright Pillar Drilling Machine
 Round column section or pillar drilling machine consists of a round column that
rises from the base which rests on the floor, an arm and a round table assembly and
a drill head assembly.
 The arm and the table have three adjustments for locating workpiece under spindle.
1. Arm and table may be moved up and down on the column.
2. Arm and table may be moved in arc up to 180o around the column.
3. The table may be rotated 360o about its own center.
 The construction of machine being not very rigid so useful for lighter work.
 The maximum size of holes that the machine can drill is not more than 50 mm.
Manufacturing Processes 5.2. Drilling
Machine

 Upright drilling machine with box column section has the square table fitted on the
slides at the front face of the machine column.

 Heavy box column gives the machine strength and rigidity.

 The table is raised or lowered by an elevating screw that gives additional support to
the table.

 This special feature permits machine to work with heavier workpiece and holes more
than 50 mm diameter can be drilled by it.
Radial drilling machine
 The radial drilling machine is intended for drilling medium to large and heavy
workpieces.

 The machine consists of a heavy, round, vertical column mounted on large base.
 The column supports a radial arm which can be raised and lowered and may be
swing around to any position over the work bed.
 The drill head containing mechanism for rotating and feeding the drill is mounted on
a radial arm and can be moved horizontally on the guide ways.

1 – Base, 2 – Column, 3 – Radial arm, 4 – Motor for elevating the arm,

5 – Elevating screw, 6 – Guide ways,7 – Motor for driving the drill spindle,
8 – Drill head, 9 – Drill spindle, 10 – Table
Fig 3.3 Radial Drilling Machine
5.2 Drilling Manufacturing Processes
Machine

 These movements are useful to locate drill at any desired position.

 When several holes are drilled on a large workpiece the position of arm and the drill
may be moved from one position to other after drilling first hole without altering the
setting of the workpiece.

 In a Plain radial drilling machine, provisions are made for vertical adjustment of the
arm, horizontal movement of the drill head along with the arm and circular
movement of the arm in horizontal plane about the vertical column.
 In a Semi universal drilling machine, in addition to the above three movement, the
drill head can be swung about a horizontal axis perpendicular to the arm. This fourth
movement of the drill head permits drilling hole at an angle to the horizontal plane
other than the normal position.
 In a Universal drilling machine, in addition to the above four movements, the arm
holding the drill head may be rotated on a horizontal axis. All these five movements
in a universal drilling machine enable it to drill on a workpiece at any angle.
Gang drilling machine

 When a number of single spindle drilling machine columns are placed side by side on
a common worktable, machine is known as the gang drilling machine.

 The speed and feed of the spindle may be controlled individually.

 This type of machine is specially adapted for production work.
 A series of operations may be performed on the work by simply shifting the work
from on to other position on the work table.
Multiple spindle drilling machine
 The function of a multiple spindle drilling machine is to drill a number of holes in a
piece of work simultaneously and to produce the same pattern of holes in a number
of identical pieces in a mass production work.
 The spindles are so constructed that their center distance may be adjusted in any
position as per requirement of various jobs.
Automatic drilling machine
 Automatic machine can perform a series of machining operations at successive units
and transfer the work from one unit to the other automatically.

 Once the work is loaded at first machine then this will move from one machine to
the other where different operations may be performed and finished product comes
out at last without any manual handling.
Manufacturing Processes 5.2. Drilling
Machine

Deep hole drilling machine

 Special machined and drills are required for drilling deep holes in rifle barrels, crank
shaft, long shafts etc.

 The machine is operated at high speed and low feed.

 For that work is usually rotated while drill is fed into work and sometimes both work
and drill are rotated.
 The machine may be horizontal and vertical type.

Size of Drilling Machine

 The size of a drilling machine varies with the type of machine being considered.
 A portable drilling machine is specified by maximum diameter of the drill that it can
hold.

 The sensitive and upright drilling machines are specified by the diameter of the
largest piece that can be centered under the spindle.

 To specify a drilling machine fully further particulars such as the maximum size of
drill that the machine can operate, table diameter, the maximum spindle travel,
numbers of spindle speed and feeds available, Morse taper number of the drill
spindle, power input, floor space required, net weight of the machine, etc. are all
needed.

 The size of the radial drilling machine is specified by the diameter of the column and
length of the arm. Other particulars such as maximum drilling radius, minimum
drilling radius, spindle speeds and feeds, etc. should also be stated to specify the
machine fully.

Work Holding Devices

 Before performing any operation in a drilling machine it is absolutely necessary to
secure the work firmly on the drilling machine table.

 The devices commonly used for holding the work in a drilling machine are:
1. T - Bolts and Clamps 4. V - Block
2. Drill Press Vice 5. Angle Plate
3. Step Block 6. Drill Jigs
T - Bolts and Clamps
 One of the most common methods of holding the work directly on the drilling
machine table is by means of T - bolt and clamp.
 The diameter of T - bolts usually ranges from 15 to 20 mm.
5.2. Drilling Manufacturing Processes
Machine

 The clamps are made of mild steel flats 12 to 20 mm thick and 45 to 70 mm wide.
 The clamp is made to rest horizontally on the work surface and a clamping block and
the nut is then tightened.

1 – T -Bolt
Fig 3.4 Different views of T - Bolts

 The T - bolt must remain as close to the work as possible. Some of the common
types of clamps are:
 Plain slot clamp: The clamps are made of mild steel flat having a central slot
through which a T - bolt is made to pass. This is general purpose clamp.

 Goose neck clamp: The clamp is used for holding work of sufficient height. The
smaller size of T - bolts and packing can clamp the work securely due to the typical
shape of the clamp. The clamps are sufficiently strong and manufactured by forging.

1 – Goose neck clamp, 2 – Work Fig 3.6 U clamp

Fig 3.5 Use of Goose neck clamp
 U clamp: U - clamps are very useful for quick adjustment of the work. The clamps
can be removed without removing of the nut.

 Finger clamp: The finger clamps have a round or flat extension which may be fitted
in a hole of the workpiece for clamping.

 Adjustable step clamp: The adjustable step clamp has screw at its one end which is
used to level the clamp when its other end rests against the work. The work may be
quickly set up without any packing pieces.
Manufacturing Processes 5.2. Drilling
Machine

1 – Finger clamp, 2 – Work 1 – Adjusting screw, 2 – Clamp

Fig 3.7 Use of Finger clamp Fig 3.8 Use of adjustable step clamp
Drill Press Vise

 The drill press vise is one of the most common methods of holding small and regular
shaped workpieces.

 The work is clamped in a vise between a fixed jaw and a movable jaw. The extra slip
jaws are supplied for holding cylindrical or hexagonal bars.

1 – Work, 2 – Slotted arm

Fig 3.9 Universal Vise

 The screw of vise rotates in a fixed nut in the moveable jaw. The screw of vise may
be square or acme threaded.

 While clamping the work in a vise, parallel blocks are placed below the work so that
the drill may completely pass through the work without damaging the vise table.

 The drill press vise may be plain or universal type.

 In universal vise the base may be swiveled at any angle about the vertical axis and it
may be tilted in a vertical plane to drill hole in a work at different angles.

 Two lugs are provided at the base of the vise for clamping it securely on the work
table.
5.2. Drilling Manufacturing Processes
Machine

Step Block

 The step blocks are used in conjunction with T - bolts and clamps for holding the
work directly on the table.

1 – Step block, 2 – Plain slot clamp, 3 – T - bolt, 4 – Work

Fig 3.10 Use of step block

 The step block provides support for the other end of the clamp.

 The different steps of step blocks are used for leveling the clamp while handling
workpieces of different heights.

 The step blocks are made of mild steel.

V - Block

 The V - blocks are used for holding round workpieces.

1 – Clamp, 2 – V - block
Fig 3.11 Use of V- block

 The work may be supported on two or three blocks and clamped against them by
straps and bolts.

 V - Blocks are accurately machined cast iron or steel blocks.

Angle Plate
 The angle plates are usually made of cast iron having two faces right angles to each
other.
Manufacturing Processes 5.2. Drilling
Machine

 The faces are accurately finished and are provided with holes and slots for clamping
the work on one of its face while the other face rest upon the table and is bolted to
it.

Fig 3.12 Use of an angle plate

 The angle plates are used when it is necessary to drill a hole parallel to another
surface.
Drill Jigs
 The drill jigs are used for holding the work in a mass production process. A jig can
hold the work securely, locate the work, and guide the tool at any desired position.

1 – Drill, 2 – Clamping nut, 3 – T - bolt, 4 – Drill bush, 5 – Work

Fig 3.13 Use of drill jig
 The work may be clamped and unclamped quickly. Jigs are specially designed for
each type of work where quantity production is desired.

 Holes may be drilled at the same relative positions on each of identical workpieces
without marking the work individually.

 As shown in fig 3.13, the work is clamped below the jig and holes are located. The
drill is guided by bushing, and when the work is completed the second work is
clamped below the jig and process is repeated.
5.2. Drilling Manufacturing Processes
Machine

Drill Tool Nomenclature

Fig 3.14 Twist drill nomenclature

 The following are the nomenclature, definitions and functions of the different parts of
drill illustrated in fig 3.14.
Manufacturing Processes 3. Drilling Machine

 The following are the twist drill elements:

 Axis : The longitudinal centre line of the drill.

 Body: The portion of the drill extending from its extreme point to the
commencement of the neck, if present, other wise extending to the commencement
of the shank.

 Body clearance: That portion of the body surface which is reduced in diameter to
provide diametral clearance.

 Chisel edge: The edge formed by the intersection of the flanks. The chisel edge is
also sometimes called dead centre. The dead centre or the chisel edge acts as a flat
drill and cuts its own hole in the workpiece.
 Chisel edge corner: The corner formed by the intersection of alip and the chisel
edge.

 Face: The portion of the flute surface adjacent to the lip on which the chip impinges
as it is cut from the work.

 Flank: That surface on a drill point which extends behind the lip tp the following
flute.

 Flutes: The groove in the body of the drill which provides lip. The functions of the
flutes are: 1. To form the cutting edges on the point 2. To allow the chips to escape
3. To cause the chips to curl 4. To permit the cutting fluid to reach the cutting edges.

 Heel: The edge formed by the intersection of the flute surface and the body
clearance.

 Lands: The cylindrically ground surface on the leading edges of the drill flutes. The
width of the land is measured at right angles to the flute helix. The drill is full size
only across the lands at the point end. Land keeps the drill aligned.
 Lip (cutting edge): The edge formed by the intersection of the flank and face. The
requirements of the drill lips are: 1. Both lips should be at same angle of inclination
with the drill axis, 59o for general work 2. Both lips should be of equal length 3. Both
lips should be provided with the correct clearance.

 Neck: The diametically undercut portion between the body and the shank of the
drill. Diameter and other particularsa of the drill are engraved at the neck.

 Outer corner: The corner formed by the intersection of the flank and face.

 Point: The sharpened end of the drill, consisting of all that part of the drill which is
shaped to produce lips, faces, flanks and chisel edge.
 Right hand cutting drill: A drill which cuts when rotating in counter - clockwise
direction viewed on the point end of the drill.
5.2. Drilling Manufacturing Processes
Machine

 Shank: that part of the drill by which it is held and driven. The most common types
of shank are the taper shank and the straight shank. The taper shank provides means
of centering and holding the drill by friction in the tapered end of the spindle.
 Tang: The flattened end of the taper shank intended to fit into a drift slot in the
spindle, socket or drill holder. The tang ensures positive drives of the drill from the
drill spindle.

 Web: The central portion of the drill situated between the roots of the flutes and
extending from the point toward the shank, the point end of the web or core forms
the chisel edge.
 The following are the linear dimensions of the drill.
 Back taper: It is the reduction in diameter of the drill from the point towards the
shank.
 Body clearance diameter: The diameter over the surface of the drill body which is
situated behind the lands.
 Depth of body clearance: The amount of radial reduction on each side to provide
body clearance.

 Diameter: The measurement across the cylindrical lands at the outer corners of the
drill.

 Flute length: The axial length from the extreme end of the point to the termination
of the flute at the shank end of the body.

 Lead of helix: The distance measured parallel to the drill axis between the
corresponding point on the leading edge of the flute in one complete turn of the
flute.

 Lip length: The minumum distance between the outer corner and the chisel edge
corner of the lip.

 Overall length: The length over the extreme ends of the point and the shank of the
drill.

 Web (core) taper: The increase in the web or core thickness from the point of the
drill to the shank end of the flute.

 Web thickness: The minimum dimension of the web or core measured at the point
end of the drill.
Manufacturing Processes 5.2. Drilling
Machine

Drilling Machine Operations

 The different operations that can be performed in a drilling machine are:
1. Drilling 6. Spot facing
2. Reaming 7. Tapping
3. Boring 8. Lapping
4. Counter boring 9. Grinding
5. Countersinking 10. Trepanning
Drilling

 Drilling is the operation of producing a cylindrical hole by removing of metal by the

rotating edge of cutting tool called the drill.
 The drilling is the simplest method of producing a hole.

 Before drilling, the centre of hole is located on the workpiece by drawing two lines at
right angles to each other and then center punch is used to produce an indentation
at the centre.

 Drill point is pressed at this centre point to produce 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 always slightly oversize than drill used due
to vibration of the spindle and drill.
 A 12 mm drill may produce a hole as much as 0.125 mm oversize and 22 mm drill
may produce 0.5 mm oversize.

Fig 3.15 Drilling operation Fig 3.16 Reaming operation

5.2. Drilling Manufacturing Processes
Machine

Reaming

 Reaming is an accurate way of sizing and finishing a hole which has been previously
drilled.
 To finish a hole and to boring it to the accurate size, the hole is drilled slightly
undersize.

 The speed of spindle is made half of drilling and automatic feed may be produced.
 Reamer tool is used which has multipoint cutting edges.

 It can not originate hole, it simply follow the path which has been previ usly drilled.

 The material removed by this process is around 0.375 mm and for accurate work it
should not exceed 0.125 mm.
Boring
 Boring is performed in a drilling machine for reasons stated as under.
1. To enlarge a hole by means of an adjustable cutting tool with only one cutting
edge.
2. To finish a hole accurately and to bring it to the required size.
3. To machine internal surface of a hole already produced in casting.
4. To correct out of roundness of the hole.
5. To correct the location of the hole as the boring tool follows an independent
path with respect to the hole.

 In precision machine the accuracy is as high as ± 0.00125 mm.

Fig 3.17 Boring operation Fig 3.18 Counter boring operation

Counter boring
 Counter boring is the operation of enlarging the end of hole cylindrically.

 The enlarged hole forms a square shoulder with original hole.

Manufacturing Processes 5.2. Drilling
Machine

 This is necessary in some cases to accommodate the heads of bolts, studs and pins.
 Counter boring can give accuracy of about ± 0.050 mm.

 The cutting speed for counter boring is 25% less than that of drilling operation.
Counter sinking

 Counter sinking is the operation of making a cone shaped enlargement of the end of
a hole to provide a recess for a flat head screw or countersunk rivet fitted into the
hole.

 Standard countersinks have 60o, 82o or 90o inclined angle.

 Cutting speed is 25% less than that of drilling.

Fig 3.19 Countersinking operation Fig 3.20 Spot facing operation

Spot facing

 Spot facing is the operation of smoothing and squaring the surface ar around a hole for
the seat for a nut or the head of a screw.
 Counter bore or a special facing tool may be employed for this purpose.
Tapping
 Tapping is the operation of cutting internal threads by means of a cutting tool called
a tap.

 Tap may be considered as a bolt with accurate threads cut on it.

 The threads act as cutting edges which are hardened and ground.
 When tap is screwed into the hole it removes metal and cuts internal threads which
will fit into external threads of the same size.
Lapping
 Lapping is the operation of sizing and finishing a small diameter hole already
hardened by removing a very small amount of material by using a tap.
5.2. Drilling Manufacturing Processes
Machine

Grinding

 Grinding operation may be performed in a drilling machine to finish a hardened hole.

 Grinding wheel is made to revolve with the spindle and is fed up and down.
 Accuracy in grinding operation is ± 0.0025 mm.

Fig 3.21 Tapping operation Fig 3.22 Trepanning operation

Trepanning
 Trepanning is the operation of producing a hole by removing metal along the
circumference of a hollow cutting tool.
 Trepanning operation is performed for producing large holes.

 Fewer chips are removed but tool may be operated at higher speeds as the variation
in diameter of tool is limited by narrow cutting edge.