Faculty of Engineering

Production Engineering Department

Theory of Metal Cutting

Lectures (3 & 4) Drilling and Reaming Processes

Dr. Amira Khattab

Faculty of Engineering Dr. Amira Khattab
Production Engineering Department 5 October 2018 Slide 2
What is Drilling?
• Drilling is a process of producing round holes in a solid material or
enlarging existing holes with the use of multi-point cutting tools called
drills or drill bits or twist drill.

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 3
What is Drilling?
• Drilling is a multi cutting edge machining operation

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Production Engineering Department 5 October 2018 Slide 4
Twist Drills

1- Lip
2- Face
3- Chisel edge
4- Flank
5- Flute
6- Land
7- Mark recess
8- Taper shank
9- Tang
Drill Terminology

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 6
Drill Angles
• Lip angle χ and the double lip angle 2 χ
(point angle)
• Transverse length of chisel lch

• Chisel edge inclination angle λch

• Distance between lips 2Kd

• Land width f
• Land inclination angle-flute helix λ. 1
Faculty of Engineering Dr. Amira Khattab
Production Engineering Department 5 October 2018 Slide 7
Twist Drill Classification
• General purpose drills may be classified as

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Production Engineering Department 5 October 2018 Slide 8
Twist Drill Classification

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Production Engineering Department 5 October 2018 Slide 9
 Twist Drill Classification (Helix Angle Types)
• Standard helix 30˚ point
angle 118 ˚ for drilling steel
and cast iron
• Low helix drills 20˚ point
angle 118 ˚ for drilling brass
and bronze, and 90 ˚ for
cutting plastics.
• Quick helix drills helix 40˚
and point angle 100 ˚for
softer materials e.g.
Aluminum alloys and copper
Faculty of Engineering Dr. Amira Khattab
Production Engineering Department 5 October 2018 Slide 10
Main Parts of Drilling Machine
• Spindle
• Sleeve
• Table
• Column
• Head
• Base

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Production Engineering Department 5 October 2018 Slide 11
Types of Drilling Machines
The general-purpose drilling machines are classified as
• Bench-type sensitive drill presses
• Upright drill presses
• Radial drills
• Multispindle drilling machines
• Column Drilling Machine
• CNC Drilling Machine

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 12
Types of Drilling machines

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Production Engineering Department 5 October 2018 Slide 13
1- Bench-type sensitive drill presses
• Small diameter holes of 0.25–12 mm
diameter using usually small size (φ≤ 10 mm)
drills.
• Manual feeding and that is why they are
called “sensitive.”
• High speeds are typical for bench-type
sensitive drill presses.
• Power: small capacity (≤ 0.5 kw)
• Mounted (bolted) on rigid table

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 14
2. Upright drill presses (Pillar Drills)
• Holes up to 50 mm in diameter in relatively small-size
work.
• It has a wide range of spindle speeds and feeds.
• Function: drilling, reaming, and tapping operations.
• Quite similar to the table top drilling machines but of
little larger size and higher capacity (0.55 ~ 1.1 kW)
• Grouted on the floor (foundation).
• Drill-feed and the work table movement are done
manually.
• These low cost drilling machines have tall tubular
columns and are generally used for small jobs and light
drilling.
Faculty of Engineering Dr. Amira Khattab
Production Engineering Department 5 October 2018 Slide 15
3. Radial Drilling Machines
• Machining holes in heavy and bulky WPs that
are inconvenient or impossible to machine on
the upright drilling machines.
• spindle axis is made to coincide with the axis of
the hole being machined by moving the spindle
in a system of polar coordinate to the hole,
while the work is stationary.
This is achieved by
1. Swinging the radial arm about the rigid column
2. Raising or lowering the radial arm on the
column by the arm-elevating and –clamping
mechanism to accommodate the WP height
3. Moving the spindle head along the guideways of
the radial arm

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 16
4. Multispindle drilling machines
• Used in lot production for machining WPs requiring simultaneous drilling,
reaming, and tapping of a large number of holes in different planes of the
WP.
• A single spindle drilling machine is not economical for such purposes, as
not only a considerably large number of machines and operators are
required but also the machining cycle is longer.
• There are three types of multiplespindle drilling machines: e.g.
Gang multispindle drilling machines

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 17
4. Multispindle drilling machines ( Gang Multispindle drilling machines)
• The spindles (2–6) are arranged in a
row, and each spindle is driven by its
own motor.
• The gang machine is in fact several
upright drilling machines having a
common base and single worktable.
• They are used for consecutive
machining of different holes in one
WP, or for the machining of a single
hole with different cutting tools.

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 18
5. Column drilling machine
• much more strong, rigid and powerful than the
pillar drills (Box shaped).
• In column drills the feed gear box enables
automatic and power feed of the rotating drill at
different feed rates as desired.
• Blanks of various size and shape are rigidly
clamped on the bed or table or in the vice fitted
on that.
• Such drilling machines are most widely used and
over wide range ( light to heavy) work.

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 19
6. CNC column drilling machine
• Versatile and flexibly automatic
drilling machine having box-column
type rigid structure the work table
movements and spindle rotation are
programmed and accomplished by
Computer Numerical Control (CNC).
• These modern sophisticated drilling
machines are suitable for piece or
batch production of precision jobs.

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 20
Kinematic System of general purpose drilling machine (Bench)

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Production Engineering Department 5 October 2018 Slide 21
Drives of a Drilling Machine

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Production Engineering Department 5 October 2018 Slide 22
Speed Gear Box
Input from
Main Cutting Motor
Motion

Bevel Gears Worm &

worm wheel

To feed gear
box
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Production Engineering Department 5 October 2018 Slide 23
Feed Gear Box

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Production Engineering Department 5 October 2018 Slide 24
Working of Bevel Gears

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Production Engineering Department 5 October 2018 Slide 25
Working Worm and Worm Wheel

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Production Engineering Department 5 October 2018 Slide 26
Small Workpiece clamping method

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Production Engineering Department 5 October 2018 Slide 27
Small Workpiece clamping method

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Production Engineering Department 5 October 2018 Slide 28
Large workpiece Clamping Method Clamp Kit (Step Blocks)

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Production Engineering Department 5 October 2018 Slide 29
Large workpiece Clamping Method

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Production Engineering Department 5 October 2018 Slide 30
Direct Clamping by Clamping Set

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Production Engineering Department 5 October 2018 Slide 31
Clamping Work for Drilling

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Production Engineering Department 5 October 2018 Slide 32
Geared Drill Chuck

Used for smaller sizes straight shank drills

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Production Engineering Department 5 October 2018 Slide 33
Drill Sleeve and Drill Socket

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 34
Drill Drifts
• Drill drifts are flat, tapered keys
with one rounded edge that are
designed to fit into a spindle
chuck’s slot to force a tapered
shank drill loose.

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 35
Chip Formation in Drilling Process
• conical Helical ribbon

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Production Engineering Department 5 October 2018 Slide 36
Drilling Process

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Production Engineering Department 5 October 2018 Slide 37
Specific Cutting Energy
FC = k .A
s c

Fc ⋅V
Pc = kW
60 ⋅10 3

Fc ⋅V
Pm = kW
3
60 ⋅10 ηm
Faculty of Engineering Dr. Amira Khattab
Production Engineering Department 5 October 2018 Slide 38
Elements of Undeformed Chip
• The feed rate f (mm/rev)
• Drill can be considered as a two lathe point tool, so:
• Chip area = axial feed X depth of cut

f d f ⋅d
A = ⋅ = mm 2
c 2 2 4 f/2

• d/2 = t = depth of cut for each tool

• f/2 = The distance by which every point of the cutting edge
will advance in the axial direction

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 39
 Elements of Undeformed Chip
h= undeformed chip thickness (mm)
b = undeformed chip width (mm)

mm 2
f/2
A = h .b
c
f/2
h f
sin x = ⇒ h = sin x
f
2 2
t t x = Lip Angle
sin x = ⇒ b = 2x = Point Angle
b sin x
f t f f d f ⋅d
=
A c h=.b sin x .
Faculty of Engineering
= =
.t
Production Engineering Department
=
. mm 2
Dr. Amira Khattab
5 October 2018 Slide 40
2 sin x 2 2 2 4
Chip Area in Enlarging Operation

f d − do f (d − do )
A = ⋅ =
c 2 2 4 f/2

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 41
Drilling Forces
• Axial Force component Ff and Ff (axially in the
feed direction)
• Main Cutting Force Fc and Fc (Tangentially in
the direction of cutting speed)
• Radial Force component Fr and Fr (radially
opposite to each other and normal to the drill
axis )
Ks: specific cutting Energy of the FC = k .A
wp material (N/mm^2)
s c
f ⋅d
FC = k ⋅ = k ⋅b ⋅ h
s 4 s
Faculty of Engineering Dr. Amira Khattab
Production Engineering Department 5 October 2018 Slide 42
Cutting Torque T
d
TC = FC .
2
2
d f d d f .d
TC k=.A . k .= . . k .
s c 2 s 2 2 2 s 8

2
f .d
TC =k . (N.m)
s 8 × 1000
Faculty of Engineering Dr. Amira Khattab
Production Engineering Department 5 October 2018 Slide 43
Drilling Power

P = Pcut + P
0 πdN
total feed V = m/min
1000

Fc ⋅V k s ⋅ f ⋅ d ⋅V
P= P=
c = kW
t 60 ⋅10 3 4 ⋅ 60 ⋅10 3

K ⋅ f ⋅ d ⋅V kW
Pm = s
4 ⋅ 60 ⋅103 ηm
Faculty of Engineering Dr. Amira Khattab
Pm: motor power
Where ɳm is the mechanicalSlideefficiency of the
Production Engineering Department 5 October 2018 44

drilling machine
Material Removal Rate (MRR)

πdN f .d
MRR = 10 ×V c × Ac = 10 × 3
× 3 3

10 4
π
MRR = × d × f × N
2 3
(mm / min)
4

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 45
 Drilling Time
L A x
t = m
f
min
m f .N d/2
L = l +l +l
m a o mm
A
l a= A + 1mm 1 mm
d
=la + 1 mm mm
2 tan x
d
=
la cot χ + 1 mm
2
For Blind Holes mm

= l +l
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L Production Engineering Department 5 October 2018 Slide 46

l = 1 − 2mm
m a
Drilling Operations

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 47
Drilling Operations

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 48
Rough Holes…. Why?
• Chip flow across the drill flutes which scratches the machined surface.

• Chip particles that are welded to the drill land and form the BUE.

• Drill feed marks.

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 49
For Machining Accurate Holes
• Use rigid machine tools

• Tool feed must be directionally stable.

• Cutting tools must be properly ground

• Axis of the spindle, sleeve, and the tool must coincide.

• Workpiece must be properly clamped.

Faculty of Engineering Dr. Amira Khattab
Production Engineering Department 5 October 2018 Slide 50
Errors in Hole Geometry

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Production Engineering Department 5 October 2018 Slide 51
Faculty of Engineering Dr. Amira Khattab
Production Engineering Department 5 October 2018 Slide 52
Reaming Process
• Reaming is a method of finishing
holes using a multipoint cutting tool
called the REAMER.
• Cutting edges ≥ 4
• Regarding the machining accuracy,
reaming is divided into preliminary
reaming where roughing and medium
accuracy are obtained.
• Finish reaming is used to finish holes
to a high degree of accuracy.

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 53
Finish Reamer Terminology

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 54
Number of Teeth
• The number of the cutting edges in the working part of the reamer Zc
Where d: is the nominal diameter of the reamer

Reamer diameter, 2-10 11-20 21-30 31-40 41-50 51-80 81-100

mm
No of teeth, Z c 6 8 10 12 14 16 18

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 55
Reaming Process
f
πdN
V = m/min
1000
f
fz = mm/edge
zc fz
f= feed rate: speed of rectilinear motion of
reamer (mm/rev)
fz = feed per cutting edge
Faculty of Engineering Dr. Amira Khattab
Production Engineering Department 5 October 2018 Slide 56
 Elements of Undeformed Chip in Finish Reaming

A = f Z ×t = h ×b 2 f
c
mm fz

h b
sin x = ⇒ h = f Z sin x
fZ
t t
sin x = ⇒ b = h
b sin x x fz
t t
A=c h=
.b f Z sin x .
sin x
d − d o f Z ⋅ (d − d o ) 2 d − do
Ac f =
Z .t fZ. =
Faculty of Engineering
mm
Production Engineering Department t= Slide 57

2 2 2
Force, Torque, and Power in Reaming

FC = k .A N
s c

Z .F
T c c ( d o + t ) N.m
1000 2 2
F V.
P = c KW
c 60 × 10 3

Faculty of Engineering Dr. Amira Khattab

Production Engineering Department 5 October 2018 Slide 58
 Reaming Time
L
= m f
t
m
min
A
f .N
td
L = l + lh + l mm
m a o A+ (2-3)

l a= A + (2 to 3) mm
d −do
la + (2 to 3) mm
2 tan x
d −do
la cot χ + (2 to 3) mm
2
Faculty of Engineering Dr. Amira Khattab
Production Engineering Department 5 October 2018 Slide 59
Faculty of Engineering Dr. Amira Khattab
Production Engineering Department 5 October 2018 Slide 60