Chapter-3 MP(10010303)

3
Drilling Machines
Drilling Machines: Purpose and field of application of drilling machines, Types of drilling machines,
Drilling and allied operation: drilling, boring, reaming, tapping, counter sinking, counter boring, spot facing;
deep hole drilling, alignment tests of drilling machine.

Introduction

Drilling
Drilling is a process of making hole or enlarging a hole in an object by forcing a rotating tool
called “Drill”.

— The drill 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 it. The sharp edges of the conical surfaces ground at the
lower end of the rotating twist drill cut the material by peeling
it circularly layer by layer when forced against a workpiece. The
removed material chips get curled and escape through the
helical grooves 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. Fig.-1. Drilling operation.

Drilling Machine
A power operated machine tool which holds the drill in its spindle rotating at high speeds and
when manually actuated to move linearly simultaneously against the workpiece produces a hole is called
drilling machine.
• Drilling machine is one of the simplest, moderate and accurate machine tool used in production
shop and tool room. It consists of a spindle which imparts rotary motion to the drilling tool, or
mechanism for feeding the tool into the work, a table on which the work rests and a frame. It is
considered as a single purpose machine tool since its chief function is to make holes. However, it
can and does perform operations other than drilling also.
Specifications of a Drilling Machine
A drilling machine is specified as follows (Refer to Fig.-2)
1. Size of the drilling machine table.
2. Largest bit the machine can hold.
3. Maximum size of the hole that can be drilled.
4. Maximum size of the workpiece that can be held.
5. Power of the motor, spindle speed or feed.

Fig.-2. Block diagram of a drill press.

Prepared by: Mr. Vipal R Panchal

Chapter-3 MP(10010303)

Specifically, the various types of drilling machines are specified as follows :

● Portable drilling machine—Maxi- mum diameter of drill which can be held.
● Sensitive and upright drilling machines—The diameter of the largest workpiece that
can be drilled.
● Radial drilling machine—The length of the arm and column diameter.

● Multiple spindle drilling machine—The drilling area, the size and number of holes a
machine can drill.
Types of Drilling Machines
Drilling machines are manufactured in various sizes and varieties to suit the different types of
work. They can, however, be broadly classified as follows :
1. Portable drilling machine.
2. Sensitive or bench drilling machine.
3. Upright drilling machine.
4. Radial drilling machine.
5. Gang drilling machine.
6. Turret machine.
7. Deep hole drilling machine.
8. Multiple spindle drilling machine.
9. Automatic drilling machines.

1. Portable drilling machine : Refer to Fig.-3

Portable drilling machine is a very small, compact and
self contained unit carrying a small electric motor inside it.
● It is very commonly used to drill holes in the following
cases :
(i) when the component is bigger in size such that
it can not be shifted to the shop floor ;
(ii) when the space is restricted so that no other
type of drilling machine can be used.
● Usually they are made to hold drills upto a maxi- mum
diameter of 12 mm. However, portable drills of upto Fig.-3. Portable drilling machine.
18 mm dia. capacity are available.

2. Sensitive or bench drilling machine : Refer to Fig.-4

These are light duty machines used in workshops. They are normally mounted on work benches
and hence the name. As the operator can feel the cutting operation while applying pres- sure using the
feed lever, the machine is known as sensitive drilling machine.
It consists of a cast iron base with a vertical column mounted over it. The vertical column is
made of hollow steel pipe on which the table slides up and down. The table can be fixed to the required
position by means of a table clamp. The table can also be swung radially at any desired position. The
top of the column houses the drive consisting of endless belt running over the V-pulleys. Based on the
speed of spindle required, V-belt can be shifted to different grooves of the pulleys. To drill small
diameter holes, a twist-drill is fitted in the drill chuck, which in turn fits into the spindle of the machine.
If the drill size is more, twist drill is directly fitted in the tapered portion of the spindle. The spindle
can be moved up or down by means of drill feed handle or lever.
● This design is used to drill hole from 1.5 mm to 15 mm diameter. The controls are light and
delicate speeds from 800 to 900 r.p.m. are a typical range.

Prepared by: Mr. Vipal R Panchal

Chapter-3 MP(10010303)

Fig.-4. Sensitive or bench drilling machine.

3. Upright drilling machine :

Upright drills similar to sensitive drills have power-feed mechanisms for rotating drills and
are designed for heavier work.
A box column machine is more rigid than a round column machine and consequently, is
adapted to heavier work. These drilling machines tap as well as drill.

4. Radial drilling machine : Refer to Fig.-5.

A radial drilling machine is used to perform the drilling operations on the workpieces which are
too heavy and also may be too large to mount them on the worktable of the vertical spindle drilling
machine.
It consists of a heavy base and a vertical
column with a long horizontal/radial arm
extending from it and can be rapidly raised,
lowered and swing in horizontal plane about the
main column to any desired location. The drilling
head can move to and fro along the arm and can
be swivelled only in the universal radial drilling
machines, to drill holes at an angle. The
combinations of motions of the radial arm and
drilling head offer a great deal of flexibility in
moving the drill to any position.
The main advantage of the radial drilling
machine is that the drilling can be carried out on
heavy workpieces in any position without moving
them.
This type of drilling machine is used in tool
rooms and in large scale die manufacturing units. Fig.-5. Radial drilling machine.

Prepared by: Mr. Vipal R Panchal

Chapter-3 MP(10010303)

5. Gang drilling machine :

When several drilling spindles are mounted on a
single table, it is known as a gang drill (Fig.-6 shows a
three- spindle schematic).
In this type of drill, each of these spindles can be
independently set for different speed and depth of cut.
● Such machines are useful when number of holes
of different sizes are to be drilled on the same
workpiece.
● Apart-from drilling, a number of other
machining operations like reaming, counter
Fig.-6. Gang drilling machine.
boring, tapping etc ; can also be performed at a
time on this ma- chine.

6. Turret drilling machine:

A turret machine overcomes the floor space restric-
tion caused by a gang drill press.
A six-turret NC drill press is shown in Fig.-7
— The stations are set up with a variety of tools.
Numerical control is also available.
— Two fixtures can be located side by side on the
worktable, thus permitting loading and
unloading of one part while the other part is
being machined; this reduces the machine cycle.
Fig.7. Turret drilling machine.
7. Deep-hole drilling machines:
— These machines are used for drilling holes whose
depth exceed normal drill size. These machines are
operated at high speed and low feed.
— These machines are either horizontal or
vertical. The work or the drill may revolve. Most
machines are of horizontal construction using a
center-cut gun drill, which has a single cutting edge
with a straight flute running throughout its length
(see Fig.-8). Oil under high pressure is forced to the Fig.-8. Gun drilling machine.
cutting edge through a lengthwise hole in the drill.
In gun drilling the feed must be light to avoid deflecting the drill and causing it to meander
through it length.
— These machines are very useful for drilling deep holes in rifle travels, crankshafts etc.

8. Multispindle drilling machines :

These machines are vertical type machines. They permit drilling of several holes of different
diameters simultaneously. Generally the spindles numbering 2 or 3 or even more are driven by only
one gear in the head through universal joint linkages. Each spindle is mounted with a twist drill. A jig
is used to guide the twist drills.
● These machines are mostly used in continuous production shops where several holes of same
diameter or different diameters are to be drilled simultaneously and accurately.

Prepared by: Mr. Vipal R Panchal

Chapter-3 MP(10010303)
9. Automatic drilling machines :
Automatic drilling machines are production machines arranged in series to perform a number
of different operations in sequence at successive work stations.
— The workpieces, after completion of an operation at one station, are automatically trans-
ferred to the next station for another operation. Thus, it works as a transfer line.
— Several different operations like drilling, boring, tapping, milling, housing, etc. can be
performed on a job in succession on these machines.

Classification of Drills
The tool used for drilling is called a drill. The commonly used drills may be classified in several
ways, as follows :
1. According to the type of shank :
(i) Parallel shank.
(ii) Taper shank.
2. According to the type of flutes :
(i) Flat or spade drills (parallel longitudinal flutes)
(ii) Twist drills (spiral/helical fultes)
3. According to length.
(i) Short series drills.
(ii) Stub series drills.
(iii) Long series drills.
4. According to applications :
(i) Core drills.
(ii) Drills for long hole drilling.
(iii) Centre drills.
(iv) Masonry drill
5. According to the tool material :
(i) High speed steel drills.
(ii) Carbide tipped drills.

Drill holding devices :

The drill holding devices are listed below :
1. Spindle
2. Sleeve
3. Socket
4. Drill chuks.
Drilling machine tools :
Drilling machine tools include the following :
1. Flat drill 6. Centre drill
2. Straight drill 7. Reamer
3. Twist drill 8. Centre punch
4. Taper shank core drill 9. Drift
5. Oil tube drill 10. Hammer.
9.8.1. Twist Drill Nomenclature

Prepared by: Mr. Vipal R Panchal

Chapter-3 MP(10010303)
Fig.-9 shows the elements of a twist drill (dotted lines at the shank portion indicates the
straight shank and firm line of the shank indicates the taper shanks.

Fig. 9. Elements of a twist drill.

Fig.-10. shows the twist drill nomenclature.

Fig.-10. Twist drill nomenclature.

The twist drill consists of mainly two parts body and shank. Both are separated by a neck. Two

Prepared by: Mr. Vipal R Panchal

Chapter-3 MP(10010303)
long and diametrically opposite helical grooves called flutes run throughout the length of the drill.
1. Body:
The body is the portion of the drill which extends from its extreme point upto the neck or shank
of the drill. It consists of body clearance, chisel edge, face, flank, flutes, heel, land or margin, point, lip
and web.
(i) Body clearance. It is the portion of the body surface with reduced diameter which provides
diametral clearance.
(ii) Face. It is the portion of the flute adjacent to the lip on which chip flows as it is cut from the
workpiece.
(iii) Flank. It is the conical surface of a drill point which extends behind the lip to the following
flute
(iv) Flutes. These are helical grooves cut on the cylindrical surface of the drill and provide the
lip. They serve the following purposes :

● Ensure easy escape and flow of chips.

● Cause the chips to curl and provide passages for their flow.
● Form the lips and cutting edges on the point.
● Allow the cutting fluids to reach the cutting edges thus reducing their friction.
(v) Heel. It is the edge formed by the intersection of flute surface and the body clearance.
(vi) Land. It is the cylindrically ground narrow strip on the leading edges of drill flutes. It keeps
the drill aligned. It is also known as “margin”.
(vii) Point. It is the cone shaped sharpened end of the drill that produces lips, faces, flanks and
chisel edge of the drill.
(viii) Lips. The lips, also known as “cutting edges”, are the edges formed by the intersection of
flanks and faces. They are two in number with identical length and angle.
(ix) Web. It is the thickness of the drill between the flutes which extends from point towards
the shank. The point end of the web forms the chisel edge

2. Shank :
The shank is the cylindrical portion of the drill which is used to hold and drive the drill. It
extends from the neck and it may be either straight or papered.
— Tapered shanks are used in drills of bigger sizes.
Tang. It is flattened end of the taper shanks which fits into socket or drill holder. It ensures
positive drive of the drill from the drill spindle.
Advantages of twist drills :
The advantages of using twist drills are :
1. For the same size and depth of the hole they need less power in comparison to other forms
of drills.
2. Cutting edges are retained in good condition for a fairly long time, thus avoiding the
frequent regrinding of the drill.
3. The chips and cuttings of the metal are automatically driven out of the hole through the
flute.
4. Heavier feeds and speeds can be employed quite safely, resulting in a considerable saving
of time.

Prepared by: Mr. Vipal R Panchal

Chapter-3 MP(10010303)

Work Holding Devices

The type of work holding device used on drilling machines depends upon the shape and size of
the workpiece, the required accuracy and the rate of production. Some of the work holding devices
are :
1. Machine vice.
2. V-blocks.
3. Strap clamps and T-bolts.
4. Drilling jigs.
5. Angle plate.

Drilling Machine Operations

In addition to drilling, the following operations are carried out on a drilling machine :
1. Reaming 5. Spot facing
2. Boring 6. Tapping
3. Counter-boring 7. Trepanning.
4. Counter-sinking
1. Reaming
Reaming is the operation of finishing an
existing hole very smoothly and accurately in size. (See
Fig.-11).
A drill will not produce a hole having sufficiently
good qualities of finish and accuracy for many purposes.
Therefore, when a very accurate, smooth hole is
required the hole is first drilled a little undersize. Then
it is reamed to the correct size.
— The accuracy to be expected is within
± 0.005 mm.
● A reamer is a multi-tooth cutter which
rotates and moves linearly into an already Fig.-11. Reaming for finishing to size a
existing hole. drilled hole.
● The previous operation could be drilling or
preferably boring. Reaming provides a smooth surface as well as close tolerance on the
diameter of the hole. Generally the reamer follows the already existing hole and the,
therefore, will not be able to correct the hole misalignment.
● The reamers are of following types :

(i) Hand reamers [See Fig.-12(a)].

(ii) Chucking or machine reamers [see Fig.-12 (b)].
(iii) Adjustable reamers.
(iv) Expansion reamers.
(v) Taper reamers.
(vi) Taper pin reamers.
(vii) Shell reamers.
(viii) Carbide tipped reamers.

Some other important forms of reamers are :

(i) Socket reamer for morse taper.
(ii) Machine bridge reamers;
(iii) Stub screw machine reamers ;
(iv) Die maker’s reamers.

Prepared by: Mr. Vipal R Panchal

Chapter-3 MP(10010303)

Fig.-12. Hand and machine reamers.

2. Boring
It is an operation of enlarging an existing 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.-13. By lowering
the tool while it is continuously rotating, the size of
the hole is increased to its entire depth.

Fig.-13. Boring.

Prepared by: Mr. Vipal R Panchal

Chapter-3 MP(10010303)
3. Counterboring
It is an operation of enlarging a drilled hole
partially, that is for a specific length. (Fig.-14)
— The counterboring forms a large sized recess
or a shoulder to the existing hole.
— The cutting tool will have a small cylindrical
projection known as pilot to guide the tool while
counterboring. The diameter of the pilot will
always be equal to diameter of the previously
drilled hole. Interchange- able pilots of different
diameters are also used for counterboring holes
Fig.-14. Counterboring.
of different diameters.
— The speeds for counterboring must be two thirds of the drilling speed of the corresponding size of
the drilled hole.
● Generally, the counterboring is done on the holes to accommodate the socket head screws, or

grooved nuts, or round head bolts.

4. Countersinking
It is an operation of forming a conical shape at the
end of a drilled hole. (Fig.-15). It is done using a
countersink tool.
— The cutting speeds for countersinking must be
about one-half of that used for similar size drill.
— The countersunk holes are used when the coun-
tersunk screws are to be screwed into the holes
so that their top faces have to be in flush with the
top surface of the workpiece.
— The countersinking process may also be
employed for deburring holes. Fig.-15 Countersinking.

5. Spot facing
It is the operation of smoothing and squar- ing the
surface around a hole for the seat for the nut or the head of a
screw. (Fig.-16).
Spot facing may be done with a counter- boring tool
or using a special spot facing tool.
6. Tapping
It is an operation in which external threads are cut in Fig.-16.Spotfacing.
the existing hole.
Fig.-17 shows tapping operation which uses a fluted
threaded tool called tap. A tap is a cutting tool with threads
cut accurately on its periphery. These threads are hardened
and ground and act a cutting edge. The tap removes metal
when screwed into the hole and generates internal threads.
A hole of required size in which internal threads are to
be generated is drilled using a twist drill. The drill spindle is
fitted with a tap and the feeding is done by operating the feed
lever like conventional drilling operation.
Fig.-17. Tapping operation and a tap.

Prepared by: Mr. Vipal R Panchal

Chapter-3 MP(10010303)
During this operation spindle speed should be much lower than that used in conventional drilling.
7. Trepanning
It is the operation of producing a hole by removing the
metal along the circumference of a hollow cutting tool (Fig.-18)
This operation is performed for producing large holes.

Fig.-18. Trepanning.

Cutting Speed, Feed and Depth of Cut

Cutting speed. It is the peripheral speed of a point on the surface of the drill in contact with the
workpiece. It is usually expressed in meters per minute.
pDN
Mathematically, Vc =
1000

where, Vc = Cutting speed (surface), m/min,

D = Diameter of the drill, mm, and
N = Rotational speed of the drill, r.p.m.

The cutting speed depends upon the following factors:

(i) The type of material being drilled.
(ii) Cutting tool material.
(iii) The quality of hole desired.
(iv) The efficient use of cutting fluid.
(v) The way in which the work is set up or held.
(vi) The size and type of drilling machine.

Feed (f). It is the distance the drill moves into the work at each revolution of the spindle.
It is expressed in mm/rev. It may also be expressed as feed per minute.
The correct feeds for different sizes of drill are given below:

Drill size, mm Feed, mm/rev

3.2 and less 0.025—0.050
3.2 to 6.4 0.050—0.10
6.4 to 12.7 0.10—0.18
12.7 to 25.4 0.18—0.38
25.4 and large 0.38—0.64
— A twist drill gives satisfactory performance if it is run at correct cutting speed and feed.
The following factors help in running the drill at correct cutting speed and feed:
(i) The drill is correctly selected and ground for the material being cut. The selection of drill
depends upon the following factors:
(a) Size of drill hole.
(b) Material of workpiece.
(c) Point angle of drill.
(ii) The work is rigidly clamped.

Prepared by: Mr. Vipal R Panchal

Chapter-3 MP(10010303)
(iii) The machine is in good condition.
(iv) A coolant is used if required.
— The rates of feed and cutting speed for twist drill are lower than most other machining
operation because of the following reasons:
(i) The twist drill is weak compared with other cutting tools.
(ii) It is relatively difficult for the drill to eject chips.
(iii) It is difficult to keep the cutting edges cool when they are enclosed in the hole.

Depth of cut (d). It may be defined as the distance from the machined surface to the drill axis.
That is,
D
d=
2

● The choice of operating conditions in drilling operations becomes more critical with increase
in the hole depth. As the depth of hole increases, (i) the chip ejection becomes more difficult,
and (ii) the fresh cutting fluid is not able to reach to the cutting zone. These factors lead to
overheating of the drill and shortens its life. Hence, for machining of lengthy holes, reduced
feeds are used.
— For machining holes of very large length, a special type drilling process, known as gun
drilling, is used. By this process, it is possible to machine the holes having length greater than
300 times of the diameter.

Machining Time in Drilling. Refer to Fig.-19.

Machining time,

tm = Lj + l1 + l2. , min
fN

where, Lj = Hole length or depth mm,

l1 = Tool approach » 0.29 D (with point angle of 118°), and
l2 = Tool overtravel, 1 to 2 mm
Fig.-19. Drilling operation.

Prepared by: Mr. Vipal R Panchal