MECHANICAL ENGINEERING DEPARTMENT

DJJ10033
TECHNOLOGY 1
WORKSHOP
UNIT 2
drilling
LEARNING OUTCOME
After studying this topic student will be able to:

1. Sketch and name the parts of twist drill

2. Explain how drill sizes are stated and determined
3. Explain steps of marking out before drilling
4. Explain method of holding a drill bit.
5. Calculate the spindle speed revolution(rpm) and
the feed rate including factor that influence the
selection of the cutting speed.
6. State types of coolants, function and advantages.
7. Prepare Standard Operating Procedures for
drilling.
2
Introduction
 Drilling is a process for producing holes. The holes may
be cut from the solid or existing holes may be enlarged.

 The machine used for drilling is called drilling machine.

 The purpose of the drilling machine is to:

– Rotate the drill at a suitable speed for the material
being cut and the diameter of the drill.
– Feed the drill into the workpiece.
– Support the workpiece being drilled; usually at right-
angles to the axis of the drill. On some machines the
table may be tilted to allow holes to be drilled at a pre-
set angle.

 The most common drill used is the twist drill 3

Drilling Machine & Parts
(1) Base - provides a solid foundation for
the machine, into which the pillar is
securely clamped.

(2) Pillar - provides a solid support for

the drill head and worktable.

WORKTABLE
(3) Worktable - provides a flat surface in
correct alignment with the drill spindle
upon which the workpiece can be
positioned. Tee slots are provided for PILLAR
clamping purposes. The worktable
can be raised, lowered and swung
about the pillar and be securely
BASE
clamped in the required position.

4
Drilling Machine & Parts
(4) Motor - provides the drive to the
spindle through a five-step pulley MOTOR
system and a two-speed gearbox,
HANDWHEEL

(5) Handwheel - provides feed to the

QUILL
drill by means of a rack and pinion on
the quill.

(6) Quill - this is the housing inside

which the spindle rotates. Only the
longitudinal movement is transmitted
by the quill, which itself does not
rotate.

5
Drilling Machine & Parts
(7) Spindle -The spindle holds the
drill chuck, which holds the DEPTH STOP
cutting tools such as twist drills.

(8) Depth stop - to be used

whenever a number of holes of STOP/START
the same depth are to be drilled
SPINDLE

(9) Stop/start button

6
Drilling Machine

7
TWIST DRILL

 Twist drills are the most common cutting tools used with
drilling machines.

 The designed of twist drill to make round holes quickly

and accurately in all material.

 They are called twist drills mainly because of the helical

flutes or grooves that wind around the body from the
point to the neck of the drill and appear to be twisted

8
TWIST DRILL
 There are two types of twist drill
 High-speed Steel Drills,
 Carbide-tipped Drills

 The design of twist drill very tough to withstand with

below condition:-
 High torque of turning
 Downward of pressure on drill
 High generated by friction

9
TWIST DRILL
Part of Twist Explanation
Drill
Axis An imaginary line through the center of the drill from end to end.

Point The entire conical shaped end of the drill containing the cutting
edge and chisel edge.
Web The external portion of the drill body that connects the land.

Cutting edge Lips cut like knives when fed and rotated into workpiece.

Body The fluted portion of a drill.

Margin The narrow surface along the flutes that determines the size of drill
and keep the drill aligned.
Flute The grooves that are formed in the body of the drill to allow fluid to
reach the point and remove chips from workpiece.
Neck The section of reduced diameter between the body and the shank
of a drill.
Shank It is the part held in the holding device.

Tang/Taper It useful to prevents the drill from slipping.

10
TWIST DRILL parts

11
Straight shank
 For drill size 13mm or less.
 Usually hold by chuck drill.

12
taper shank
 For drill size more 13mm.
 It install at spindle machine.

13
Drill Sizes System
The size of standard twist drill are determined by four
method

1) Fractional size

2) Number size

3) Letter size

4) Metric size

14
Fractional size
 These are called inch drill

 The size range 1/16 inch to 1 inch in diameter

(increments of 1/16 inch)

15
Number size
 Number series drill bits start at No. 80 to No. 1

 No. 80 (0.0135 inch) is smallest size and increase in size

up to No. 1 (0.2280 inch)

16
Letter size
 The series of drill designed by letter start with A to Z
 A is smallest size of drill bit and Z is biggest size of drill
bit

17
Metric size
 The drill size available from 0.2 mm to 100 mm

18
marking out before drilling
1. Use a scribber to draw two or more line to get the
centre at the intersection of the line.
2. A small dent is marked at centre of the hole by using
prick punch.
3. Draw two circle by using divider. One circle has
diameter of the hole required and another circle is
bigger than that.
4. Use the prick punch to mark a small indentation at the
circumference of the drilled circle.
5. Punch the small dent by using centre punch.
6. Check the alignment of the hole using outer circle.

19
Work holding Devices
Component to be drilled should secure firmly on the drilling
table. The following devices are used for holding the
workpiece.

a) Drill vice

b) V-block

c) Clamps & T-bolts

20
Work holding Devices
Drill vice V-block
 This is work holding  The device is used to
device in which the work holding round work piece.
piece is clamp between a
fixed jaw and movable
jaw.
 The vice is fastened to
the table by T-bolts.

21
Work holding Devices
Clamp & T-bolts
 Clamps and T-bolts are
used to clamping the
work
 There are such as:-
– Finger clamp
– Goose neck clamp
– U-strap clamp
– Straight clamp
– Bent clamp

22
Tools holding Devices
The following devices are used for holding the drills bit:-

a) Drill chuck

b) Drill Sleeve

c) Drilling machine spindle

d) Socket

23
Drill Chuck
 Its designed to hold straight shanks.
 The jaws of the chuck are tightened around the drill by
means of a chuck key.

24
Drill Sleeve
 Its designed to hold taper shanks drill whose taper is
less than hole of spindle.
 The outer taper of the sleeve matches with spindle hole
taper.

25
https://youtu.be/3LU5wl0quV8

26
Recall questions

27
 #1
Drilling is a process for
producing holes
………………………………... The
holes may be cut from the solid or
existing holes may be enlarged.

28
 #2
Name four drilling size system
1. Fractional Size
2. Number Size
3. Metric Size
4. Letter Size
29
 #3
Name types of twist drill
1. Straight Shank
2. Taper Shank

30
Speed, feed & machine time
CUTTING SPEED
The cutting speed in drilling is the surface speed of the
twist drill.

𝝅𝑫𝑵
𝑽=
𝟏𝟎𝟎𝟎

𝑉 = 𝑐𝑢𝑡𝑡𝑖𝑛𝑔 𝑠𝑝𝑒𝑒𝑑, 𝑚/𝑚𝑖𝑛

𝐷 = 𝑤𝑜𝑟𝑘 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑖𝑛 𝑚𝑚

𝑁 = 𝑟𝑜𝑡𝑎𝑡𝑖𝑜𝑛𝑎𝑙 𝑠𝑝𝑒𝑒𝑑 𝑜𝑓 𝑑𝑟𝑖𝑙𝑙 𝑖𝑛 𝑅𝑃𝑀

31
Speed, feed & machine time
FEED MACHIINING TIME IN
The distance the drill DRILLING
enters the work for each 𝑻𝒊𝒎𝒆 𝒇𝒐𝒓 𝒅𝒓𝒊𝒍𝒍𝒊𝒏𝒈 =
𝑳
revolution of drill 𝑭𝒓 × 𝑵
spindle. 𝑁 = 𝑅𝑃𝑀 𝑜𝑓 𝑡ℎ𝑒 𝑑𝑟𝑖𝑙𝑙
𝑭𝑴 = 𝑭𝒓 × 𝑵
𝐹𝑟 = 𝐹𝑒𝑒𝑑 𝑝𝑒𝑟 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛
𝐹𝑀 = 𝐹𝑒𝑒𝑑 𝑝𝑒𝑟 𝑚𝑖𝑛𝑢𝑡𝑒
𝐿 =𝑙+𝑎
𝐹𝑟 = 𝐹𝑒𝑒𝑑 𝑝𝑒𝑟 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛
𝑙 = 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑤𝑜𝑟𝑘𝑝𝑖𝑒𝑐𝑒
𝑁 = 𝑅𝑃𝑀 𝑜𝑓 𝑡ℎ𝑒 𝑑𝑟𝑖𝑙𝑙
𝑎 = 𝑎𝑝𝑝𝑟𝑜𝑎𝑐ℎ 𝑜𝑓 𝑑𝑟𝑖𝑙𝑙 = 0.3𝑑

𝑑 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑑𝑟𝑖𝑙𝑙

32
Speed, feed & machine time
MACHIINING TIME IN
DRILLING
𝑳
𝑻𝒊𝒎𝒆 𝒇𝒐𝒓 𝒅𝒓𝒊𝒍𝒍𝒊𝒏𝒈 =
𝑭𝒓 × 𝑵

𝑁 = 𝑅𝑃𝑀 𝑜𝑓 𝑡ℎ𝑒 𝑑𝑟𝑖𝑙𝑙

𝐹𝑟 = 𝐹𝑒𝑒𝑑 𝑝𝑒𝑟 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛

𝐿 =𝑙+𝑎+b

𝑙 = 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑤𝑜𝑟𝑘𝑝𝑖𝑒𝑐𝑒

𝑎 = 𝑎𝑝𝑝𝑟𝑜𝑎𝑐ℎ 𝑜𝑓 𝑑𝑟𝑖𝑙𝑙 = 0.3𝑑

𝑑 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑑𝑟𝑖𝑙𝑙

33
EXAMPLE
Calculate the cutting speed if the twist drill
diameter is 18mm and the rotation per minutes is
993.
Solution
𝝅𝑫𝑵
𝑽=
𝟏𝟎𝟎𝟎

𝝅(𝟏𝟖)(𝟗𝟗𝟑)
𝑽=
𝟏𝟎𝟎𝟎
𝑽 = 𝟓𝟔. 𝟏𝟔 𝒎/𝒎𝒊𝒏

34
EXAMPLE
Find the time required to drill 6 holes of 16
mm diameter each of flange. Assume flange
thickness = 30 mm, cutting speed 20 m/min,
feed = 0.2 mm/rev
Solution

35
Cutting fluid
 Cutting fluid as known as coolant is used to applied to
the workpiece, tool and chip zone.
 Below are advantage and disadvantage of cutting fluid
Advantages Disadvantages
• Increase tool life • Produce unpleasant odour
• Reduce temperature of the tool • Some cutting fluid causes skin
and workpiece allergy
• Give very fine surface finish to • Some cutting fluid is flammable
workpiece cause fire hazard
• Good rust protection • Poor heat dissipating

• Washes away chips and any dust • Can damaged the workpiece by
during the process chemical action or corrosion
• Reduce cutting forces and power • Increased risk of smoking
consumption
36
Types of Cutting fluid
 There are several types of cutting fluid such as:-

– Straight metalworking oils.

– Emulsifiable metalworking oils.

– Synthetic metalworking fluids.

– Semi-synthetic metalworking fluids.

37
Types of Cutting fluid
 Straight metalworking oils

– These fluids are mineral oil based

– They contain no water
– Usually use for stainless steel workpiece

Advantages Disadvantages
• Excellent lubricity • Poor heat dissipation
• Good rust protection • Increased risk of fire
• Good sump life • Increased risk of smoking
• Easy maintenance • Increased risk of misting
• Rancid resistant • Oil film on work piece

38
Types of Cutting fluid
 Emulsifiable metalworking oils

– They contain water-soluble oils

– Usually use for stainless steel workpiece

Advantages Disadvantages
• Good lubrication • Anti-bacteria additives
• Good cooling
• Maintenance are needed
capability
• Corrosion protection • Toxic mist
• Low cost
• Nonflammable

39
Types of Cutting fluid
 Synthetic metalworking fluids

– Its water based solutions (or emilsions) of synthetic lubricants

(soaps and other wetting agents)
– Used in a wide variety of metalworking operations.

Advantages Disadvantages
• Excellent microbial
• May cause misting
control
• Relatively nontoxic • May cause foaming
• Transparent • Reduced lubrication
• Good corrosion control
• Easy maintenance
40
Types of Cutting fluid
 Semi Synthetic metalworking fluids

– its water based mixture (solution and emulsion) of synthetic

lubricants

Advantages Disadvantages
• Relatively nontoxic • May cause misting
• Good cooling • May cause foaming
• Reduced misting /
• May cause dermatitis
foaming
• Easily contaminated by
• Good corrosion control
other fluids
• Easy maintenance
41
Standard operation of drilling
Standard Operating Procedure

Process: Using the Drilling Machine

Hazard: Flying metal, plastic, or wood debris, rotating chuck.
Personal Protective Equipment:
Safety glasses and face shield
Jacket/Apron
Safety boot
Hearing protection (during extended periods of operation)

Engineering Controls: Make sure all guards are in place and kill switch
is operational.

42
Standard operation of drilling
Special Handling Procedures:
5.1 Setting up the machine:
1. Make sure the item being worked on (stock) is tight in the vice
or clamp and adequately supported.
2. Always remove the chuck key after tightening the chuck to
avoid the chuck key from flying off during startup and causing
serious injury or death.
3. Select the appropriate tool for the job.
4. Make sure the bit is tight in the chuck.
5. Fold back long sleeves up to the elbow.
6. No rings, wrist watches, bracelets, or other jewelry that could
get caught in the equipment.

43
Standard operation of drilling
5.2 Using the equipment:
1. Make sure someone else knows that you are using the drill
press, is available in case of an emergency.
2. Keep hands and arms well clear of rotating chuck (if you have
long hair, make sure it is tied back and will not touch the
rotating chuck).
3. Use the appropriate speed for the bit and the stock (shape of
stock and the type of material – wood, plastic, etc.).
4. Tap a small dent into the stock where you will be drilling to help
the bit drill in the right place.
5. Feed the bit into the work smoothly. If the hole being drilled is
deep, withdraw the bit frequently to remove shaving on the bit
(do this only when the bit has stopped rotating).

44
Standard operation of drilling
5.3 When done:
1. Perform these steps only after the equipment has been turned
off, and the chuck has stopped turning.
2. Put away bit.
3. Clean up the shaving debris by using a brush or the shop
vacuum to avoid potential splinters from the shavings.

45
Standard operation of drilling
5.4 If repairs are necessary (if odd noise, excessive vibration, or if an
unsafe condition is observed):
1. Turn machine off.
2. Unplug machine
3. Do not repair it yourself.
4. Notify technician or authorized person, giving a description of
what happened and your contact information

46
END

47