Production & Manufacturing

Fitter - Basic Fitting Related Theory for Exercise 1.2.38

Drilling processes - Drilling Machines, Types, Use and Care

Objectives: At the end of this lesson you shall be able to
• name the various types of drilling machines
• name the parts of the bench and pillar type drilling machines
• compare the features of the bench and pillar type drilling machines.

The principle types of drilling machines are

– the sensitive bench drilling machine
– the pillar drilling machine
– the column drilling machine
– the radial arm drilling machine (radial drilling machine).
(You are not likely to use the column and radial type of
drilling machines now. Therefore, only the sensitive and
pillar type machines are explained here)
The sensitive bench drilling machine (Fig 1)
The simplest type of the sensitive drilling machine is shown
in the figure with its various parts marked. This is used for
light duty work.
This machine is capable of drilling holes up to 12.5 mm
diameter. The drills are fitted in the chuck or directly in
the tapered hole of the machine spindle.
For normal drilling, the work-surface is kept horizontal. If
the holes are to be drilled at an angle, the table can be
tilted. (Tilting arrangemented is shown in Fig.1) The pillar drilling machine (Fig 3): This is an enlarged
version of the sensitive bench drilling machine. These
drilling machines are mounted on the floor and driven by
more powerful electric motors.

Different spindle speeds are achieved by changing the belt

position in the stepped pulleys. (Fig 2) They are also used for light duty work. Pillar drilling
machines are available in different sizes. The larger
machines are provided with a rack and pinion mechanism
to raise the table for setting the work.

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Drill - Holding devices
Objectives : At the end of this lesson you shall be able to
• name the types of drill-holding devices
• state the features of drill chucks
• state the functions of drill sleeves
• state the function of drift.

For drilling holes on materials, the drills are to be held Sleeves and sockets are made with the same taper so that
accurately and rigidly on the on the machines. the taper shank of the drill, when engaged, will give a good
wedding action. Due to this reason morse tapers are called
The common drill-holding devices are drill chucks and self-holding tapers.
sleeves and sockets.
Drills are provided with five different sizes of morse tapers,
Drill Chuck and are numbered from MT1 to MT5.
Straight shank drills are held in drill chucks. For fixing and In order to make up the difference in sizes between the
removing drills, the chucks are provided either with a pinion shanks of the drills and the type of machine spindies,
and key or a knureld ring. sleeves of different sizes are used. When the drill taper
The drill chucks are held on the machine spindle by means shank is bigger than machine spindle, taper sockets are
of an arbor fitted on the drill chuck. (Fig 1) used. (Fig 1)
Taper Sleeves and Sockets (Fig 1)
Taper shank drills have a morse taper.

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While fixing the drill in a socket or sleeve, the tang portion
While removing the drill from the sockets/
should align in the slot. (Fig 2) This will facilitate the removal
sleeves, don't allow it to fall on the table or
of drill or sleeve from the machine spindle.
jobs. (Fig 4)

Use a drift to remove drills and sockets from the machine

spindle. (Fig 3)

Work-holding devices
Objectives : At the end of this lesson you shall be able to
• state the purpose of work-holding devices
• name the devices used for holding work
• state the precautions to be observed while using work-holding devices.

Workpieces to be drilled should be properly held or Workpieces which are not accurate may be supported by
clamped to prevent from roating along with the drill. wooden pieces. (Fig 2)
Improperly secured work is not only a danger to the
operator but can also cause inaccurate work, and breakage
to the drill. Various are used to ensure proper holding.
The machine vice
Most of the drilling work can be held in a machine vice.
Ensure that the drill does not drill through the vice after it
has passed through the work. For this purpose, the work
can be lifted up and secured on paralle blocks providing a
gap between the work and the bottom of the vice. (Fig 1)

Clamps and bolts

Driling machine tables are provided with T-slots for fitting
bolt heads. Using clamps and bolts, the workpieces can
be held very rigidly. (Fig 3) While using this method, the

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 There are many types of clamps and it is necessary to
determine the clamping method according to the work.
(Fig 5& 6)

packing should be, as far as possible, of the same height

as the work, and the bolt nearer to the work. (Fig 4)

Cutting speed and RPM

Objectives : At the end of this lesson you shall be able to
• define cutting speed.
• state the factors for determining the cutting speed
• differentiate between cutting speed and RPM
• determine RPM/spindle speed
• select RPM for drill sizes from tables.

For a drill to give a satisfactory performance, it must Tool manufacturers usually provide a table of cutting
operate at the correct cutting speed and feed. speeds required for different materials.
Cutting speed is the speed at which the cutting edge The recommended cutting speeds for different materials
passes over the material while cutting, and is expressed are given in the table. Based on the cutting speed
in metres per minute. recommended, the RPM, at which a drill has to be driven,
is determined.
Cutting speed is also sometimes stated as surface speed
or peripheral speed.
The selection of the recommended cutting speed for
drilling depends on the materials to be drilled, and the tool
material.

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 n - RPM
Materials Cutting
being drilled speed (m/min) v - cutting speed in m/min.
for HSS
d - diameter of the drill in mm
Aluminium 70 - 100
π = 3.14
Brass 35 - 50
Examples: Calculate the RPM for a high speed steel drill
Bronze(phosphor) 20 - 35
∅ 24 to cut mild steel.
Cast iron (grey) 25 - 40
Copper 35 - 45 The cutting speed for MS is taken as 30 m/min. from the
table.
Steel (medium 20 - 30
carbon/mild steel)
1000x30
Steel (alloy,high n= = 398 RPM
tensile) 5-8 3.14x24
Thermosetting
It is always preferable to set the spindle speed to the
plastic (low speed
nearest available lower range. The selected spindle speed
due to abrasive
is300 RPM.
properties) 20 - 30
The RPM will differ according to the diameter of the drills.
The cutting speed being the same, larger diameter drills will
Calculating RPM have lesser RPM and smaller diameter drills will have
higher RPM.
nxdxπ
v= m/min The recommended cutting speeds are achieved only by
1000 actual experiments.

vx1000
n= RPM
dxπ

Feed in drilling
Objectives : At the end of this lesson you shall be able to
• state what is meant by feed
• state the factors that contribute to an efficient feed rate.

Feed is the distance (X) a drill advances into the work in one
Finish required
complete rotation. (Fig 1)
Type of drill (drill material)
Material to be drilled
Factors like rigidity of the machine, holding of the workpiece
and the drill, will also have to be considered while determining
the feed rate. If these are not to the required standard, the
feed rate will have to be decreased.
It is not possible to suggest a particular feed rate taking all
the factors into account.
The table for the feed rate given here is based on the
average feed values suggested by the different
manufacturers of drills. (Table 1)
Feed is expressed in hundredths of a millimeter.
Example - 0.040mm
The rate of feed is dependent upon a number of factors.

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 TABLE 1 Too coarse a feed may result in damage to the cutting
edges or breakage of the drill.
Drill diameter Rate of feed (mm/rev)
(mm) HSS Too slow a rate of feed will not bring improvement in surface
finish but may cause excessive wear of the tool point, and
1.0 - 2.5 0.040 - 0.060
lead to chattering of the drill.
2.6 - 4.5 0.050 - 0.100
For optimum results in the feed rate while
4.6 - 6.0 0.075 - 0.150 drilling, it is necessary to ensure the drill cutting
6.1 - 9.0 0.100 - 0.200 edges are sharp. Use the correct type of cutting
fluid.
9.1 -12.0 0.150 - 0.250
12.1 - 15.0 0.200 - 0.300
15.1 - 18.0 0.230 - 0.330
18.1 - 21.0 0.260 - 0.360
21.1 - 25.0 0.280 - 0.380

Radial drilling machines

Objectives : At the end of this lesson you shall be able to
• state the uses of a radial drilling machine
• state the features of radial drilling machine.
Radial drilling machines are used to drill The arm is supported by a pillar (column). It can be rotated
- large diameter holes about with the pillar as centre. Therefore, the drill spindle
can cover the entire working surface of the table. The arm
- multiple holes in one setting of the work
can be lifted or lowered.
- heavy and large workpieces.
The motor mounted on the spindle head rotates the
Features (Fig 1) spindle.
The variable-speed gear box provides a large range of
R.P.M.
The spindle can be roated in both clockwise and
anticlockwise directions.
Angular holes can be drilled on machines having tilting
tables.
A coolant tank is mounted on the base.
Precautions
Ensure that the spindle-head and the arms are
locked properly to avoid vibration.
The workpiece and the drill should be rigidly
held.
Bring back the spindle head nearer to the pillar
after use.
Switch off power when not in use.
Use the drill drift for removing the drills, chucks
or sockets.
Use a minimum number of sockets and sleeves
to make for the spindle bore size.
Clean and oil the machine after use.
The radial drilling machine has a radial arm on which the Stop the machine to remove the swarf.
spindle head is mounted Use a brush to clean the chips and swarf.
The spindle head can be moved along the radial arm and
can be locked in any position

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Gang drilling machine and multiple spindle head drilling machine
Objectives: At the end of this lesson you shall be able to
• state the uses of a gang drilling machine
• state the construction of a gang drilling machine
• state the uses and construction of a multiple spindle head drilling machine.

Gang drilling machine (Fig 1)

It consists of a large base supporting a long table. The top

of the table is designed in such a way that several units The multiple spindle head drilling machine is specially
may be mounted on it. Each spindle is driven by its designed for mass production operations such as drilling,
individual directly connected motor. reaming or tapping many holes at one time in a specific unit
of work such as an automobile engine block.
The table has a groove around the outside for the return of
the cutting lubricant, and may have ‘T’-slots on its surface There may be two or more drill heads on one machine, each
for ease in clamping the work to the table. with many spindles. This is necessary when holes are
drilled from more than one direction - for example, on the
This type of machine is generally preferred when the work top side, and the end of a piece of work. Production units
is to be moved from spindle to spindle for successive of this type are seldom used in a tool room that usually
operations. does highly skilled work.
Multiple spindle head drilling machine (Fig 2)
The multiple spindle head drilling machine may have any
number of spindles - from 4 to 48 or more, all driven from the
one-spindle drive gear in one head.

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Production & Manufacturing
Fitter - Basic Fitting Related Theory for Exercise 1.2.39

Hand taps and wrenches

Objectives: At the end of this lesson you shall be able to
• state the uses of threading hand taps
• state the features of hand taps
• distinguish between different taps in a set
• name the different types of tap wrenches
• state the uses of diffrerent types of wrenches.

Use of hand taps

Hand taps are used for internal threading of components.
Features (Fig 1)
They are made from high carbon steel or high speed steel,
hardened and ground.
Threads are cut on the surface, and are accurately finished.

These are
first tap or taper tap
second tap or intermediate tap
plug or bottoming tap.
These taps are identical in all features except in the taper
lead.
The taper tap is to start the thread. It is possible to form
full threads by the taper tap in through holes which are not
deep.
To form the cutting edges, the flutes are cut across the
thread. The bottoming tap (plug) is used to finish the threads of
a blind hole to the correct depth.
For holding and turning the taps while cutting threads, the
ends of the shanks are squared. For identifying the type of taps quickly - the taps are either
numbered as 1, 2 and 3 or rings are marked on the shank.
The ends of the taps are chamfered (taper lead) for
assisting, aligning and starting of the thread. The taper tap has one ring, the intermediate tap has two
rings and the bottoming tap has three rings. (Fig 2)
The size of the taps and the type of the thread are usually
marked on the shank. Tap Wrenches

In certain cases, the pitch of the thread will also be Tap wrenches are used to align and drive the hand taps
marked. correctly into the hole to be threaded.

Markings are also made to indicate the type of tap i.e. first, Tap wrenches are of different types.
second or plug. Double ended adjustable wrench, T-handle tap wrench,
Types of Taps in a set solid type tap wrench.

Hand taps for a particular thread are available as a set Double-ended Adjustable Tap Wrench or Bar Type
consisting of three pieces. (Fig 2) Tap Wrench (Fig 3)

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This is the most commonly used type of tap wrench. It is These are small adjustable chucks with two jaws and a
available in various sizes. These tap wrenches are more handle to turn the wrench.
suitable for large diameter taps, and can be used in open This tap wrench is useful to work in restricted places, and
places where there is no obstruction to turn the tap. It is is turned with one hand only.
important to select the correct size of wrench.
This wrench is not available for holding large diameter taps.
T-Handle tap wrench (Fig 4)
Solid type tap wrench (Fig 5)
These wrenches are not adjustable.
They can take only certain sizes of taps. This eliminates
the use of wrong length of the tap wrenches, and thus
prevents damage to the taps.

Tap drill size

Objectives: At the end of this lesson you shall be able to
• state what is tap drill size
• choose the tap drill sizes of different threads from tables
• calculate the tap drill sizes for ISO metrice and ISO inch.
What is a tap drill size? Further it also requires a greater force for turning the tap if
a higher percentage formation of thread is required.
Before a tap is used for cutting internal threads, a hole is
to be drilled. The diameter of the hole should be such that Considering this aspect, a more practical approach for
it should have sufficient material in the hole for the tap to cut determining the tap drill sizes is
the thread.
Tap drill size = Major diameter – pitch
Tap drill sizes for different threads
= 10 mm - 1.5 mm
ISO Metric Thread
= 8.5 mm.
Tapping drill size
Compare this with the table of tap drill sizes for ISO
for M10 x 1.5 thread metric threads.
Minor diameter = Major diameter – 2 x depth ISO Inch (Unified) threads Formula
depth of thread = 0.6134 x pitch of a screw Tap Drill size =
2 depth of thread = 0.6134 x 2 x pitch
1
=1.226 x 1.5 mm = 1.839 mm Major diameter −
Number of threads per inch
Minor dia (D1)=10 mm – 1.839 mm
For calculating the tap drill size for 5/8" UNC thread
=8.161mm or 8.2 mm
Tap drill size = 5/8" – 1/11"
This tap drill will produce 100% thread because this is
equal to the minor diameter of the thread. For most = 0.625" – 0.091"
fastening purposes a 100% formed thread is not required. = 0.534"
A standard nut with 60% thread is strong enough to be
tightened until the bolt breaks without stripping the thread.

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The next drill size is 17/32" (0.531 inches)
Refer to chart for determining the pitches of
Compare this with the table of drill sizes for unified inch the thread.
threads.
What will be the tapping size for the following threads?
(a) M 20
(b) UNC 3/8
COMMERCIAL DRILL SIZES ISO INCH (UNIFIED) THREAD

NC National Coarse NF National Fine

Tap size Tharads Tap dirll size Tap size Therads Tap drill size
per inch per inch

5 40 38 5 44 37
6 32 36 6 40 33
8 32 29 8 36 29
10 24 25 10 32 21
12 24 16 12 28 14
1/4 " 20 7 1/4 " 28 3
5/16 " 18 F 5/16 " 24 1
3/8 " 16 5/16 " 3/8 " 24 0
7/16 " 14 U 7/16 " 20 25/64 "
1/2 " 13 27/64 " 1/2 " 20 29/64 "
9/16 " 12 31/64 " 9/16 " 18 33/64 "
5/8 " 11 17/32 " 5/8 " 18 37/64 "
3/4 " 10 21/32 " 3/4 " 16 11/16 "
7/8 " 9 49/64 " 7/8 " 14 13/16 "
1" 8 7/8 " 1" 14 15/16 "
1 1/8 " 7 63/64 " 1 1/8 " 12 1 3/6 "
1 1/4 " 7 17/64 " 1 1/4 " 12 1 11/6 "
1 3/8 " 6 17/32 " 1 3/8 " 12 1 19/64
"
1 3/4 " 5 1 9/16 "
2" 4 1/2 1 25/32 "
NPT National pipe thread

1/8 " 27 11/32 " 1" 11 1/2 1 5/32 "

1/4 ' 18 7/16 " 1 1/4 " 11 1/4 1 1/2 "

3/8 " 18 19/32 " 1 1/2 " 11 1/2 1 23/32 "

1/2 " 14 23/32 " 2" 11 1/2 2 23/16 "

3/4 " 14 15/16 " 2 1/2 " 8 2 5/8 "

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 TABLE FOR TAP DRILL SIZES- ISO METRIC THREADS

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Production & Manufacturing
Fitter - Basic Fitting Related Theory for Exercise 1.2.40-41

Letter punch and number punch

Objective: At the end of this lesson you shall be able to
• state the uses of letter Punch and Number Punch

Metal stamps are used to mark or identify work pieces. Numbers (Number punch). They can not be used on
They are available for stamping letters (Letter Punch) and hardened metal surfaces (Fig.1)

The letter punch set consists of A, B, C, D, E, F, G, H, N, or number (Fig.3) or space (Fig.4) a centre line should be
I, J, K, L, M, N, O, P,Q, R, S, T, U, V, W, X, Y, Z, and '&' scribed on the base line (Fig.2) Letters or numbers before
(Symbol) of 27 Letter punches in a set. The Number punch stamping should be placed on either side of the line from
set consists of 0,1,2,3,4,5,6,7,8, the number punch 6 will center line, so that middle letter is stamped over the
the used for punching number both 6 and 9 . centreline large size letter number punchs are used for
better impression by applying more than one stroke. While
The letters and numbers are formed in the reverse order. So
Punching on cast iron or hot rolled steel, the hard outer
that while punching letters and numbers will be in correct
layer of the metal should the removed by grinding or filing
position. A base line should be scribed on the metal
or machining for better impression are visibility.
surface, before stamping the letter or number using these
punches. Also to locate the position of middle letter (Fig.2)

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