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DRILLING MACHINE
Working Principle of Drilling Machine
Drilling is a metal cutting process carried out by a rotating cutting tool to make circular holes
in solid materials. The tool which makes the hole is called a drill.
It is generally called as twist drill, Since it has a sharp twisted edges formed around a cylindrical
tool provided with a helical groove along its length to allow the cut material to escape through
the sharp edges of the conical surfaces ground at the lower end of the rotating twist drill cuts
the material by peeling it circularly layer by layer when forced against a work piece.
The removed material chips get curled and escapes through the helical groove provided in the
drill. A liquid coolant is generally used while drilling to remove the heat of friction and obtain
a better finish for the hole.

Construction and parts of drilling machines

Base: It is the main body of the machine. All main components are bolted on it. It is usually made
by cast iron due to its high compressive strength and high lubrication quality. It is made by casting
process and bolted on floor space.
Column: It support for rotating the Swivel table and holding the power transmission system.
Swivel Table: It is attached to the column which can hold the machine vice on which the work
pieces are clamped carry out the drilling operation. The Swivel table can move up and down as
well as rotate about the column as axis. This can be done by means of rotational motion and can
be locked to the column by means of locking nut.
Drill Feed Handle: By the rotation of hand-wheel, the spindle moves up and down in the vertical
direction in order to give the necessary amount of feed to the work.
Spindle: It is used to hold the drill. This spindle is connected to motor shaft. Once the motor is
switched on the spindle starts rotating.
Power Transmission system: To control the speed of the tool rotation, power transmission system
is used. It consists of motor, stepped pulley, V-belt, and the Spindle.

Operations on Drilling Machine

1. Drilling
2. Reaming
3. Boring
4. Tapping
5. Counter boring
6. Counter sinking

1. Drilling:
Drilling is the operation of producing a cylindrical hole by removing metal from the
rotating edge of a cutting tool called the drill. The centre of the hole is located on the
workpiece by drawing two lines at right angles to each other and then a centre punch is
used to produce an indentation at the centre. The drill point is pressed at this centre point
to produce the required hole. The internal surface of the hole so generated by drilling
becomes rough and the hole is always slightly oversize than the drill used due to the
vibration of the spindle and the drill.
2. Boring:
Boring is done on a drilling machine to increase the size of an already drilled hole.
When a suitable size drill is not available, initially a hole is drilled to the nearest size and
using a single point cutting tool, the size of the hole is increased as shown in Fig. By
lowering the tool while it is continuously rotating, the size of the hole is increased to its
entire depth. Fig shows when the boring operation is in progress. It will be continued till
the lower surface of the work piece.

3. Reaming
Reaming is the process of smoothing the surface of the drilled holes with a reamer. A
reamer is similar to the twist drill, but has straight flutes. After drilling the hole to a slightly
smaller size, the reamer is mounted in place of twist drill and with the speed reduced to
half of that of the drilling, reaming is done in the same way as drilling. It removes only a
small amount of material and produces a smooth finish on the drilled surfaces.
Introduction
 3D printing or additive manufacturing is a process of making three dimensional solid
objects from a digital file.
 The creation of a 3D printed object is achieved using additive processes. In an additive
process an object is created by laying down successive layers of material until the object is
created. Each of these layers can be seen as a thinly sliced cross- section of the object.
 3D printing is the opposite of subtractive manufacturing which is cutting out / hollowing
out a piece of metal or plastic with for instance a milling machine.
 3D printing enables you to produce complex shapes using less material than traditional
manufacturing methods.
How Does 3D Printing Work?
 It all starts with a 3D model. It can be created from the ground up or downloaded from a
3D library.

3D Software
 There are many different software tools available. From industrial grade to open source.
 Now that a printable file is available, the next step is to prepare it for the 3D printer. This
is called slicing.
Slicing: From printable file to 3D Printer
 Slicing basically means slicing up a 3D model into hundreds or thousands of layers and is
done with slicing software.
 When the file is sliced, it’s ready for 3D printer. Feeding the file to the printer can be done
via USB, SD or Wi-Fi. The sliced file is now ready to be 3D printed layer by layer.

Examples of 3D Printing
 consumer products (eyewear, footwear, design, furniture)
 industrial products (manufacturing tools, prototypes, functional end-use parts)
 dental products
 prosthetics
 architectural scale models & maquettes
 reconstructing fossils
 replicating ancient artefacts
 reconstructing evidence in forensic pathology
 movie props
3D Printing
Typical manufacturing techniques are known as ‘Subtractive Manufacturing’ because the process
is one of removing material from a preformed block. Processes such as Milling and Cutting are
subtractive manufacturing techniques. This type of process creates a lot of waste since; the
material that is cut off generally cannot be used for anything else and is simply sent out as scrap.

What is 3D Printing?

Additive manufacturing or 3D printing (commonly called) is a process that creates a physical

object from a digital design. There are different 3D printing technologies and materials you can
print with, but all are based on the same principle: a digital model is turned into a solid three-
dimensional physical object by adding material layer by layer 3D printing enables you to
produce complex shapes using less material than traditional manufacturing methods.

Steps or stages of 3d printing

 DESIGN OR MODELING IN CAD: In order to produce a 3D object first have to have
its virtual design. This 3D modeling software like Blender, Sketch Up, Auto Cad, Solid
Works, Maya, Photo Shop, Thinker Cad or others to create your own designs. SCAN is
Another way to create a three-dimensional digital file is through 3D scanning.
 GENERATING AN STL OR 3MF FILE: Once the CAD file is developed, the next
thing one has to consider is converting it into specific file formats. The file formats are
specified based on the technology of printing being employed by that particular 3D
printer. (standard tessellation language)
 SLICING: This is the process of translating the 3D File into instructions for the 3D
printer to follow. Slicing is dividing or chopping the 3D model into hundreds or
thousands of horizontal layers, telling the machine exactly what to do, step by step. After
the files are Sliced, a new file format is generated called G-code, G-code contains printer
commands, so what slicing does is, it takes the STL file’s geometry data and creates a list
of instructions the printer must follow to print the model. G-code is the most widely used
numerical code programming language,
 PRINTING: The printing machines are made of many moving and intricate parts, and
they demand correct maintenance and calibration to produce successful prints. Most 3D
Printers do not need to be monitored after the printing has begun. The machine will
follow the automated G-code instructions, so as long as there is no software error or the
machine doesn’t run out of raw material, there should not be a issues during the printing
process. the removal of a part is a technical process that requires professional skills and
specialized equipment within a controlled environment.
 POST-PROCESSING: Post-processing is an important step for the aesthetic and
function of the parts, In the majority of cases 3D printed parts are rough and do not have
finished feel but can be vastly improved with the right techniques and craftsmanship.
Through sanding, painting, polishing, and other post-processing methods, printed parts
can accurately become a real-world model of the initial concept

Types of 3D Printing Technologies

1. Fused deposition modeling (FDM)

2. Stereolithography (SLA)
3. DLP 3D printing
4. Photopolymer Phase Change Inkjets (PolyJet)
5. Selective laser sintering (SLS) – Direct metal laser sintering (DMLS)
6. Plaster-based 3D printing (PP) – Powder bed and inkjet head 3D printing
7. Thermal Phase Change Inkjets
 8. Laminated object manufacturing (LOM)

Fused Deposition Modeling:

It is an additive manufacturing technology commonly used for modeling, prototyping,
and production applications. FDM works on an "additive" principle by laying down material in
layers. A plastic filament or metal wire is unwound from a coil and supplies material to an
extrusion nozzle which can turn the flow on and off. The nozzle is heated to melt the material
and can be moved in both horizontal and vertical directions by a numerically controlled
mechanism, directly controlled by a computer-aided manufacturing (CAM) software package.
The model or part is produced by extruding small beads of thermoplastic material to form layers
as the material hardens immediately after extrusion from the nozzle. Stepper motors or servo
motors are typically employed to move the extrusion head .

Advantages and disadvantages of 3d PRINTING

 FLEXIBILITY:

Another big advantage of 3D printing is that any given printer can create almost anything
that fits within its build volume. With traditional manufacturing processes, each new part or
change in part design, requires a new tool, mold, die, or jig to be manufactured to create the
new part.
 RAPID PROTOTYPING

3D printing can manufacture parts within hours, which speeds up the prototyping process.
This allows for each stage to complete faster. When compared to machining prototypes, 3D
printing is inexpensive and quicker at creating parts as the part can be finished in hours .
 PRINT ON DEMAND
Print on demand is another advantage as it doesn’t need a lot of space to stock inventory,
unlike traditional manufacturing processes. This saves space and costs as there is no need to
print in bulk unless required.
 STRONG LIGHTWEIGHT PARTS

The main 3D printing material used is plastic, although some metals also can be used for
3D printing. However, plastics offer advantages as they're lighter than their metal
equivalents.

 MINIMIZING WASTE

The production of parts only requires the materials needed for the part itself, with little or
no wastage as compared to alternative methods which are cut from large chunks of non-
recyclable materials.
 COST EFFECTIVE
As a single step manufacturing process, 3D printing saves time and therefore costs
associated with using different machines for manufacture. 3D printers can also be set up and
left to get on with the job, meaning that there is no need for operators to be present the entire
time.
 ENVIRONMENTALLY FRIENDLY
As this technology reduces the amount of material wastage used this process is inherently
environmentally friendly.
 ADVANCED HEALTHCARE
3D printing is being used in the medical sector to help save lives by printing organs for the
human body such as livers, kidneys and hearts.
 LIMITED MATERIALS

While 3D Printing can create items in a selection of plastics and metals the available
selection of raw materials is not exhaustive. This is due to the fact that not all metals or
plastics can be temperature controlled enough to allow 3D printing.
 RESTRICTED BUILD SIZE

3D printers currently have small print chambers which restrict the size of parts that can
be printed. Anything bigger will need to be printed in separate parts and joined together after
production. This can increase costs and time for larger parts due to the printer needing to
print more parts before manual labour is used to join the parts together .
 POST PROCESSING
Although large parts require post-processing, as mentioned above, most 3D printed parts
need some form of cleaning up to remove support material from the build and to smooth the
surface to achieve the required finish. Post processing methods used include water jetting,
sanding, a chemical soak and rinse, air or heat drying, assembly and others .
 LARGE VOLUMES
3D printing is a static cost unlike more conventional techniques like injection moulding,
where large volumes may be more cost effective to produce. While the initial investment for
3D printing may be lower than other manufacturing methods, once scaled up to produce large
volumes for mass production, the cost per unit does not reduce as same as with injection
moulding.
 PART STRUCTURE

With 3D printing (also referred to as Additive Manufacturing) parts are produced layer-
by-layer. Although these layers adhere together it also means they will delaminate under
certain stresses or orientations.
 REDUCTION IN MANUFACTURING JOBS

Another of the disadvantages of 3D technology is the potential reduction in human

labour, since most of the assembly is automated and done by printers.
 COPYRIGHT ISSUES
As 3D printing is becoming more popular and accessible there's a greater possibility for
people to make fake and counterfeit products and it'll almost be impossible to inform the
difference. This has evident issues around copyright also as for internal control

Applications of 3D Printing
 Consumer Products (Eyewear, Footwear, Design, Furniture)
 Industrial Products (Manufacturing Tools, Prototypes, Functional End-use Parts)
 Architectural Scale Models & Maquettes
 Prototyping
 Specialized Parts – Aerospace, Military, Biomedical Engineering, Dental
 Hobbies And Home Use
 Future Applications– Medical (Body Parts), Buildings And Cars