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Drilling Machines

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Drilling Machines 38-1 Drilling Machines • Probably first mechanical device developed • Principle of rotating tool to make hole • One of most common and useful machines in industry • Come in several types and sizes – From hand-fed to computer-controlled 38-2 Drilling Press • Drilling machine – Spindle • Turns drill to advance into work (hand or automatically) – Work table • Holds workpiece rigidly in place as hole drilled – Used primarily to produce holes in metal – Other operations: tapping, reaming, boring, counterboring, countersinking, spot-facing 38-3 Standard Operations • Drilling – Operation of producing hole by removing metal from solid mass using twist drill • Countersinking – Operation of producing tapered or cone-shaped enlargement to end of hole Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 38-4 Standard Operations • Reaming – Operation of sizing and producing smooth, round hole from previously drilled or bored hole • Boring • Truing and enlarging hole by means of single-point cutting tool Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 38-5 Standard Operations • Tapping – Cutting internal threads in hole with cutting tool called tap • Counterboring – Enlarging top of previously drilled hole to given depth to provide square shoulder for head of bolt or capscrew Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 38-6 Standard Operations • Spot Facing • Smoothing and squaring surface around hole to provide seat for head of cap screw or nut – Boring bar fitted with double-edged cutting tool • Pilot section on end to fit into existing hole Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 38-7 Principal Types of Drilling Machines • Wide variety of drill presses • Size of drill press may be designated in different ways by different companies – Some state size as distance from center of spindle to column of machine – Others state size by diameter of largest circular piece that can be drilled in center 38-8 Sensitive Drill Press Parts • Only hand feed mechanism – Control downfeed pressure • Manufactured in bench and floor model • Four main parts – Base, column, table and drilling head Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 38-9 Radial Drilling Machine Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-10 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 cuttings to escape during drilling process 40-11 Twist Drill Parts • Most made of high-speed steel – Replaced carbon-steel drills for two reasons • Can be operated at double the cutting speed • Cutting edge lasts longer – Stamped with letters H.S or H.S.S. • Carbide-tipped drills – Speeds for production have increased up to 300% over high-speed drills 40-12 Three Main Parts of a Drill Point Body Shank Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-13 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 Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-14 Body • Portion of drill between shank and point • Consists of number of parts for cutting • Flutes – Two or more 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 Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-15 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 Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-16 Point Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-17 Lip Clearance • Is the relief ground on point of drill extending from cutting lips back to the heel Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-18 Four Systems of Drill Sizes • 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) 40-19 Types of Drills • Wide variety manufactured to suit specific drilling operations and materials • Design of drills vary – Number and width of flutes – Amount of helix or rake angle of flutes – Shape of land or margin – Shape of flute: straight or helical – Whether helix is right-hand or left-hand 40-20 1.Twist Drills • Manufactured from three main materials – Carbon-steel drills • Used in hobby shops not for machine shop work • Cutting edges wear down quickly – High-speed steel drills • Used in machine shop work • Cutting edges withstand more heat and wear – Cemented-carbide drills • Operated at high speeds, withstand higher heat, and can drill hard materials 40-21 2.General-Purpose Drill • Has two Helical flutes • Designed to perform well on wide variety of materials, equipment and job conditions • Can be made to suit different conditions and materials by varying point angle, speeds and feeds • Straight-shank drills called general-purpose jobbers length drills Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-22 3.Oil Hole Drills • Have one or two oil holes running from shank to cutting point – Compressed air, oil, or cutting fluid can be forced through when deep holes being drilled • Used on turret lathes and screw machines • Cutting fluid cools drill's cutting edges and flushes chips out of hole Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-23 4.Step Drills • Used to drill and countersink or drill and counter bore different sizes of holes in one operation • May have two or more diameters ground • Each size or step separated by square or angular shoulder Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-24 5.Saw-Type Hole Cutter • Cylindrical-diameter cutter with twist drill in center to provide guide for cutting teeth on hole cutter • Made in various diameters • Used for drilling holes in thin materials • Little burr produced Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-25 Drilling Facts and Problems • Excessive speed • Excessive clearance Examples of each • Excessive feed on following slides • Insufficient clearance • Cutting lips with unequal angles • Cutting lips with unequal in length • Loading and galling 40-26 Excessive speed will cause wear at outer corners of drill. This permits fewer regrinds of drill due to amount of stock to be removed in reconditioning. Discoloration is warning sign of excess speed. Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-27 Excessive clearance results in lack of support behind cutting edge with quick dulling and poor tool life. Despite initial free cutting action. Clearance angle behind cutting lip for general purposes is 8º to 12º. Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-28 Excessive feed sets up abnormal end thrust, which causes breakdown of chisel point and cutting lips. Failure induced by this cause will be broken or split drill. Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-29 Insufficient clearance causes the drill to rub behind the cutting edge. It will make the drill work hard, generate heat, and increase end thrust. This results in poor holes and drill breakage. Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-30 The web is the tapered central portion of the body that joins the lands. Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-31 Cutting lips with unequal angles will cause one cutting edge to work harder than the other. This causes torsion strain, bellmouth holes, rapid dulling, and poor tool life. Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-32 Cutting lips unequal in length cause chisel point to be off center axis and will drill holes oversize by approximately twice the amount of eccentricity. Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 40-33 Loading and galling is caused by poor chip removal with insufficient dissipation of heat so that material anneals itself to the cutting edge and flute. This condition frequently results from using wrong drills for the job or inadequate cutting fluid application. Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 41-34 Cutting Speeds and Feeds • Two important factors – Diameter and material of cutting tool – Type
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