Manufacturing Processes 1

(MDP 114)
First Year,
Mechanical Engineering Dept.,
Faculty of Engineering,
Fayoum University

Dr. Ahmed Salah Abou Taleb

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Machining Operations & Machine Tools
Turning

Planner Milling

Gears Drilling

Machine

Screw
Shaper
Thread

Saw Broacher

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Drilling Machine

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 Definition
 Drilling is the operation of producing circular hole in the
workpiece by using a rotating cutter called DRILL.

 The machine used for drilling is called drilling machine.

 The drilling operation can also be accomplished in lathe,

in which the drill is held in tailstock and the work is held
by the chuck.

 The most common drill used is the twist drill.

 It is the simplest and accurate machine used in

production shop.
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 Drilling Machine Types
Drilling Machine

Construction Feed

Portable, Hand driven,

Sensitive, Power driven
Radial,
up-right,
Gang,
Multi-spindle
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 Drilling Machine Types
Drill

Twist Drill Step Drill Core Drill

Holes with different Holes with different Enlarge diameters of

diameters. diameters. exiting holes.

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 Drilling Machine
Sensitive Drilling Machine

 Drill holes from

1.5 to 15mm

 Operator senses
the cutting action
so sensitive
drilling machine

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 Drilling Machine
Up Right Drilling Machine

 Drill holes up
to 50mm

 Table can move

vertically and
radially

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 Drilling Machine
Radial Drilling Machine

 It the largest and

most versatile
used for drilling
medium to large
and heavy work
pieces.

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 Drill Material
The two most common types are:
1. HSS drill
- Low cost
2. Carbide- tipped drills
- high production and in CNC machines

Other types are:

Solid Carbide drill, TiN coated drills, carbide coated
masonry drills, parabolic drills, split point drill

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 Twist Drills
• End-cutting tools.
• Used to produce holes in most types of materials.
• Two helical grooves, or flutes, are cut lengthwise
around body of drill.
– Provide cutting edges and space for chip to escape during
drilling process.
• Most made of high-speed steel (H.S. or H.S.S.)
– Replaced carbon-steel drills due to
• It can be operated at double the cutting speed
• Carbide-tipped drills
– Speeds for production have increased up to 300%
over high-speed drills
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Tool Nomenclature

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Drill Main Parts
Point

Body

Shank

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 Shank
• Straight-shank drills
– Held in drill chuck
– Up to ½ in. in diameter

• Tapered-shank drills
– Fit into internal taper of drill press spindle
– Tang provided on end to prevent drill from slipping

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 Body
• Portion of drill between shank and point
• Consists of number of parts for cutting

• Flutes
– Two helical grooves cut around body of drill
– Form cutting edges, admit cutting fluid, allow chips
to escape hole

• Body Clearance
– Undercut portion of body between margin and
flutes

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 Body, cont.
• Margin
– Narrow, raised section on body of drill
– Next to flutes and extends entire length of flutes
– Provides full size to drill body and cutting edges

• Web
– Thin partition in center of drill, extends full length of
flutes
– Forms chisel edge at cutting end of drill

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Point

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 Lip Clearance

• Is the relief ground on point of drill extending from

cutting lips back to the heel 18
 Drill Point Characteristics
The use of various point angles and lip clearances, in
conjunction with thinning of the drill web, will allow:
1. Control size, quality and straightness of drilled hole
2. Control size, shape and formation of chip
3. Control chip flow up flutes
4. Increase strength of drill's cutting edges
5. Reduce rate of wear at cutting edges
6. Reduce amount of drilling pressure required
7. Control amount of burr produced
8. Reduce amount of heat generated
9. Permit use of various speeds and feeds for more efficient
drilling 19
 Conventional Point (118º)
• Most commonly used drill point
• Gives satisfactory results for most general-
purpose drilling
• Lip clearance of 8º to 12º for best results
– Too much weakens cutting edge and causes drill to
chip
– Too little results in use of heavy drilling pressure

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 Long Angle Point (60º to 90º)
• Used on low helix drills for drilling of nonferrous
metals, soft cast irons, plastics, fibers, and wood
• Lip clearance generally from 12º to 15º
• Flat may be ground on face of lips to prevent drill
from drawing itself into the soft material

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 Flat Angle Point (135º to 150º)
• Used to drill hard and tough materials
• Lip clearance on flat angle point drills 6º to 8º to
provide as much support as possible for cutting
edges
• Shorter cutting edge tends to reduce friction and
heat during drilling

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 Drill Sizes Systems
• Fractional
– Range from 1/64 to 4 in. (steps of 1/64th )
• Number
– Range from #1 (.228 in.) to #97 (.0059 in.)
• Letter
– Range from A to Z (A = .234 in., Z = .413 in.)
• Millimeter (Metric)
– Miniature (0.04 to 0.09 mm, steps of 0.01 mm)
– Straight-shank standard (0.5 to 20 mm)
– Taper-shank (8 up to 80 mm)
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 Tool Holding devices
• The different methods used for holding drill in a drill
spindle are:
• By directly fitting in the spindle hole.
• By using drill sleeve
• By using drill socket
• By using drill chuck

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 Drilling Operations
• Operations that can be performed in a drilling
machine are:
 Drilling
 Reaming
 Boring
 Counter boring
 Countersinking
 Tapping

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Drilling Operations

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Drilling Operations

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 Types of cutters
Reamers :-
Multi tooth cutting tool.
Accurate way of sizing and finishing the preexisting hole.
Accuracy of 0.005 mm can be achieved.

Boring Tool:-
Single point cutting tool.
Boring tool is held in the boring bar which has the shank.
Accuracy of 0.005 mm can be achieved.

Counter Bore Tool:-

Special cutters uses a pilot to guide the cutting action .
Accommodates the heads of bolts.
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 Types of cutters
Countersinks :-
Special angled cone shaped enlargement at the end of
the hole
Cutting edges at the end of conical surface.

Combined Countersinks and central drill :-

Special drilling tool to start the hole accurately.
At the end it makes countersinks in the work piece.

Gun drill :-
Machining of lengthy holes with less feed rates.
To overcome the heating and short life of the normal drill
tool 29
 Types of cutters

Tapping:-
For cutting internal thread
Multi cutting edge tool.

Tapping is performed
either by hand or by
machine.

Minor diameter of the

thread is drilled and then
tapping is done.
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 Through Hole vs. Blind Hole
Through holes - drill exits the opposite side of work
Blind holes – drill does not exit work on opposite side

Two hole types: (a) through hole, and (b) blind hole
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 Work Holding Devices
Machine Table Vice

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 Machining Calculations
• Cutting Speed (v):-
It’s the peripheral speed of the drill (m/min)
v  D N
D = diameter of the drill in (m), N = Speed of rotation in (rpm)

• Material Removal Rate (MRR):-

It’s the volume of material removed by the drill per
unit time (mm3/min)

MRR  2
D f N
4 33
 Machining Calculations
• Feed Rate (fr) mm/min:-
fr  f N

• Machining Time (T) :-

It depends upon L = the length of the hole to be drilled , N =
speed, f = feed, A= allowance account for drill point angle, D =
tool diameter, and θ = drill point angle.

L A  
T A  0.5 D tan 90  
f N  2

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 Precautions for Drilling machine
• Lubrication is important to remove heat and friction.
• Machines should be cleaned after use
• Chips should be removed using brush.
• T-slots, grooves, spindles sleeves, belts, pulley should
be cleaned.
• Machines should be lightly oiled to prevent from
rusting

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 Safety Precautions
• Do not support the work piece by hand – use work
holding device.
• Use brush to clean the chip
• No adjustments while the machine is operating
• Ensure for the cutting tools running straight before
starting the operation.
• Never place tools on the drilling table
• Avoid loose clothing and protect the eyes.
• Ease the feed if drill breaks inside the work piece.

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 ?????

How can you perform a hole in large heavy

workpiece?

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 Boring

Figure 22.12 - A vertical boring mill –for large, heavy workparts

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