Drilling Machines & Their Static and Dynamic Analysis MEC 302

Navneet Saharan
Regd.no.10905933 Roll no.rk4901b46 Lovely Professional University Chaheru, (Punjab)

This term-paper enlighten us about the drilling machine and its behavior during static and dynamic position. It also describes the different types of operation performed on a drilling machine, and characteristic of the drilling machine.

II. Keywords

III. Introduction to Drilling Machine The powered drill press was developed by James Nasmyth around 1846, which permitted drilling of accurate holes in metal.Drilling is a machining operation used to create a round hole in a work-part. This contrast with boring, which can only be used to enlarge an existing hole. Drilling is usually performed with a rotating cylindrical tool that has two cutting edges on its working end. This tool is called a drill bit or drill. The rotating drill feeds into the stationary work-part to form a hole whose diameter is equal to the drill diameter. Drilling is customarily performed on a drill press, although other machining tools also perform this operation. Drilling Figure-1 shows a typical figure of a Drilling Machine, in this figure each & every part is named for more clarification, working of each and every part is described further In this term paper. IV. Operations Related to Drilling Machine Several operations are related to drilling. These are illustrated in the figure-2 and described in this section. Most of the

Machines may be used to perform other operations. They can perform countersinking, boring, counter-boring, spot facing, reaming, and tapping.

Operations follow drilling; a hole must be made first by drilling, and then the hole is modified by one of the other operations. Centering and spot facing are exceptions to this rule. All of the operations use rotating tools. a) Reaming Reaming is used to slightly enlarge a hole, to provide a better tolerance on is diameter, and to improve its surface finish. The tool is called a reamer, and it usually has straight flutes. Reaming can be done on a drilling machine by using a hand reamer or using a machine reamer. When we must drill and ream a hole, it is best if the setup is not changed. For example, we should drill the hole (slightly undersized) and then ream the hole before moving to another hole. This method will ensure that the reamer is accurately aligned over the hole. If a previously drilled hole must be reamed, it must be accurately realigned under the machine spindle. Most hand and machine reamers have a slight chamfer at the tip to aid in alignment and starting. b) Tapping This operation is performed by a tap and is used to provide internal screw threads on an existing hole. Tapping is accomplished on the drilling machine by selecting and drilling the tap drill size, then using the drilling machine chuck to hold and align the tap while it is turned by hand. The drilling machine is not a tapping machine, so it should not be used to power tap. To avoid breaking taps, ensure the tap aligns with the center axis of the hole, keep tap flutes clean to avoid jamming, and clean chips out of the bottom of the hole before attempting to tap. c) Counter-boring

counter-bored hole is used to seat bolt heads into a hole so the head do not protrude above the surface as shown in figure-3.

Counter-bored holes are primarily used to recess socket head cap screws and similar bolt heads slightly below the surface. Both counter-boring and spot-facing can be accomplished with standard counter-bore cutters. d) Counter-sinking This is similar to counter-boring, except that the step in the hole is cone-shaped for flat head screws and bolts. In other words, Countersinking is the tapering or beveling of the end of a hole with a conical cutter called a machine countersink. Often a hole is slightly countersunk to guide pins which are to be driven into the work-piece; but more commonly, countersinking is used to form recesses for flathead screws. If we talk about the types of counter-sinking, Machine countersinks for machining recessed screw heads commonly have an included angle of 82. Another common countersink has an included angle of 60 machining lathe centers. Some countersinks have a pilot on the tip to guide the countersink into the recess. Since these pilots are not interchangeable, these types of countersinks can be used for only one size of hole and are not practical for field or maintenance shops.

Counter-boring provides a stepped hole, in which a large diameter follows a smaller diameter partially into the hole. A

e)

Centering

can also say that Spot facing is basically the same as counterboring, using the same tool, speed, feed, and lubricant. The operation of spot facing is slightly different in that the spot facing is usually done above a surface or on a curved surface as shown in figure-5. Rough surfaces, castings, and curved

Also called center drilling, this operation drills a starting hole to accurately establish its location for subsequent drilling. This tool is also called a center drill. To start a twist drill into the work-piece, the point of the drill must be aligned with the center-punched mark on the work-piece. Some drilling operations may not require a precise alignment of the drill to the work, so alignment can be done by lining up the drill by hand and eye alone. If a greater precision in centering alignment is required, than more preparation is needed before starting to drill. The best method to align and start a hole is to use the combination countersink and drill, known as the center drill figure-4. Set the drilling machine speed for the diameter

of the tip of the center drill, start the machine, and gently lower the center drill into contact with the work, using hand and eye coordination. The revolving center drill will find the center punched mark on the work-piece and properly align the hole for drilling. The depth of the center-drilled hole should be no deeper than two third the length of the tapered portion of the center drill. f) Spot Facing Surfaces are not at right angles the cutting tool causing great strain on the pilot and counter-bore which can lead to broken tools. Care must be taken when starting the spot facing cut to avoid too much feed. If the tool grabs the work-piece because of too much feed, the cutter may break or the work-piece may be damaged. Ensure that the work is securely mounted and that all backlash is removed from drilling machine spindle. Spot facing is similar to milling. It is used to provide a flat machined surface on the work-part in a localized area. We

V. Types of Drilling Machine Drilling machine is categorized on the different bases like on the basis of its construction and on the basis of its feed. a. On the basis of construction

It is used primarily for low production. It is not as much applicable in industry, where mass production rate is required.

It has not a great accuracy. In this drilling machine, spindle head is fixed with respect to the base of the drilling machine.

On the basis of its construction it is divided into six types, which are described below with figure, one by one. i. Portable Drilling Machine. Hand operated drill is one of the simplest examples of portable drilling machines. Most portable drill is equipped with small electric motors by which they can be operated at high speed. Usually they accommodate up to Drill 12mm diameter. ii. Sensitive Drilling Machine. The figure-6 shown below is the typical figure for a sensitive drilling machine. It can perform with different qualities:

Only the tables of the drilling machine can move with respect to the column vertically. iii. Radial Drilling Machine.

The figure-7 shown below is the typical figure for a radial drilling machine. It has also different specialties other than the sensitive drilling machine:

It can Drill a holes from 1.5 to 15mm Operator senses the cutting action so sensitive drilling machine. It is the largest and most versatile used for drilling medium to large and heavy work pieces. Its Drill Head can slide on its radial arm horizontally

It has Light weight-light duty.

Its radial arm can also slide on the column due to elevating screws as shown in figure-7. v. Gang Drilling Machine.

It has two different electric motors; on is for giving rotational motion to the drill, and another motor is for elevating screw.

The typical diagram for a Gang Drilling Machine is shown in the figure-9. It is a multi-purpose drilling machine.

It is capable to do the large work. In this type of drilling machine, Work-piece is stationary. iv. Up-right Drilling Machine. It is equipped with more than one spindle. It has multi-head arrangement. Still, it has single table. It is mainly used for production set-up. It is able to do multiple operations at one location (drill, ream, tap, csink, cborte etc.). vi. Multi-spindle Drilling Machine The Typical Diagram of a Multi-Spindle Drilling Machine is shown below in the figure-10. As its name suggest, it has more than one spindle as shown in the figure.

A Typical Diagram for The Upright Drilling Machine is shown below in the figure-8. It has its own specialties and is an improved version of the previous available drilling machine: It is larger in size than the sensitive Drilling Machine. It can be equipped with a gearbox and variable speed head. It has both Hand and automatic feed mechanism. It has automatic coolant system Its table can move on a rack and pinion system Drill holes up to 50mm.

b.

On the basis of feed

On the basis of feed system drilling machine is divided into two types: 1) Hand Driven Drilling Machine The hand-feed drilling machines (Figure-11) are the simplest and most common type of drilling machines in use today.

hand pressure. The speeds available on power-feed machines can vary from about 50 RPM to about 1,800 RPM. The slower speeds allow for special operations, such as counter-boring, countersinking, and reaming.

These are light duty machines that are hand-fed by the operator, using a feed handle. So that the operator is able to feel the action of the cutting tool as it cuts through the workpiece. These drilling machines can be bench or floor mounted. They are driven by an electric motor that turns a drive belt on a motor pulley that connects to the spindle pulley. Hand-feed machines are essentially high-speed machines and are used on small workplaces that require holes 1/2 inch or smaller. Normally, the head can be moved up and down on the column by loosening the locking bolts. This allows the drilling machine to drill different heights of work. 2) Power Driven Drilling Machine The power-feed drilling machines (Figure-12) are usually larger and heavier than the hand-feed. They are equipped with the ability to feed the cutting tool into the work automatically, at a preset depth of cut per revolution of the spindle, usually in thousandths of an inch per revolution. These machines are used in maintenance shops for medium duty work, or work that uses large drills that require power feeds. The power-feed capability is needed for drills or cutting took that are over 1/2 inch in diameter, because they require more force to cut than that which can be provided by using VI. Parts of Drilling Machine Base: The vertical column is mounted on the base, it supports whole machine. Column: It is a vertical member of the machine; it supports table head containing all the driving mechanisms. It should be rigid. The sizes of these machines generally range from 17-inch to a 22-inch center-drilling capacity, and are usually floor mounted. They can handle drills up to 2 inches in diameter, which mount into tapered Morse sockets. Larger workplaces are usually clamped directly to the table or base using T-bolts and clamps, while small workplaces are held in a vise. A depth-stop mechanism is located on the head, near the spindle, to aid in drilling to a precise depth.

Table: It may be round or rectangular in shape. It has T slots with which work is directly mounted on the table. Table can be adjusted vertically, horizontally and rastially.

Head: The drill head is mounted on the top of the column and houses the driving and feeding mechanism for the spindle.

Spindle and drill head assembly: The spindle is a vertical shaft which holds the drill. It receives its motion from the top shaft through Bevel gears. A key way is cut on the spindle and bevel gear is connected to it by the sliding key. Rack teeth are cut on the outer surface of the sleeve. The sleeve may be moved up and down by rotating a pinion which meshes with the rack and this movement is imparted to the spindle to give the required feed. The lower end of the spindle accommodates drill. With the drift is removed from the spindle. The spindle holds the drill or cutting tools and revolves in a fixed position in a sleeve. In most drilling machines, the spindle is vertical and the work the spindle drive is supported on a horizontal table. The sleeve or quill assembly does not revolve but may slide in its bearing in a direction parallel to its axis. When the sleeve carrying the spindle with a cutting tool is lowered, the cutting tool is fed into the VII. Construction Characteristic of a Drilling Machine work: and when it is moved upward, the cutting tool is withdrawn from the work. Feed pressure applied to the sleeve by hand or power causes the revolving drill to cut its way into the work a few thousandths of an inch per revolution. The column of most drill presses is circular and built rugged and solid. The column supports the head and the sleeve or quill assembly. The head of the drill press is composed of the sleeve, spindle, electric motor, and feed mechanism. The head is bolted to the column.

Spindle

Drive

Mechanism:

mechanism has a pair of step cone pulleys for obtaining multiple speeds to various machining conditions.

All drilling machines have the following construction characteristics as shown in Figure-12: a spindle. Sleeve or quill, Column, head, worktable, and base.

The worktable is supported on an arm mounted to the column. The worktable can be adjusted vertically to accommodate different heights of work. or it may be swung completely out of the way. It may be tilted up to 90 in either direction, to allow for long pieces to be end or angled drilled.

The base of the drilling machine supports the entire machine and when bolted to the floor, provides for vibration-free operation and best machining accuracy. The top of the base is similar to a worktable and maybe equipped with T-slots for mounting work too large for the table. VIII. Drill Nomenclature b) Shank

Drill is composed of three principle parts namely Point, Shank & Body. We will Discuss All of these along with its sub-component. For all of this we refer the figure-14 a) Point The point is the cone shaped end and does the cutting. It consists of the following: Dead Centre: it is the sharp edge at the extreme tip of the drill. This should always be in the exact center of the drill axis. Lips: These are cutting edges of the drill. Heel: It is the portion of the point back from the lips of cutting edge. Lip Clearance: It is the amount by which the surface of the point is relieved back from the lips.

Portion of drill which is damped in the spindle. Shanks are two types, may be straight or tapered. Straight shank drills are of two types may be straight or tapered. Straight shank drills are used with a chuck. Tapered shanks have self-holding tapers. At the end of tapered end shank there is the long. This fits into the slot in the spindle. Tong also offers a means of separating the taper from the holding device. c. Body

Portion between shank and point is called the body of the drill. Flutes: Flutes are two or more spiral (or parallel) grooves that run the length of the drill body. It curls the chip tightly. These are the channels through which the chip escapes from the hole being drilled. Lubricant and coolent get down to the cutting edge. Margin: It is the narrow strip extending back the entire length of the flute. It is full diameter of the drill. Body Clearance: it is reduced to cut down the friction between the drill and wall of hole.

Wele: it is the metal column that separates the flutes. It gradually increases in thickness towards the shank to give added strength. d. Others

rotation. To set the desired cutting speed in drilling, it is necessary to determine the rotational speed of the drill for its diameter. Let N represents the spindle ,

Rake Angle: The angle between the flute and the axis of the drill that forms the cutting edge is known as the rake angle as shown in the figure-8d. Generally, the rake angle is between 180 and 450, with 30 being the most common. Drills used on armor plate or other very hard materials need a reduced rake angle to increase the support behind the cutting edge. Soft materials, like brass and bronze, also use a reduced rake angle to prevent the drill from grabbing. The rake angle partially governs the tightness with which the chips curl and the amount of space they occupy. If the rake angle is too small, the lips may be too thin and break under the strain of drilling. Too large of a rake angle makes the drill chatter and vibrate excessively. Where, . Where = cutting speed, and D = the

drill diameter, mm (in). In some drilling operations, the work piece is rotated about a stationary tool, but the same formula applies. Feed in drilling is specified in

Recommended feeds are roughly proportional to drill diameter; higher feeds are used with larger diameter drills. Since there are (usually) two cutting edges at the drill point, the uncut chip thickness (chip load) taken by each cutting edge is half the feed. Feed can be converted to feed rate using the same equation as for turning operation:

Drilled holes are either through holes or blind holes or blind holes, figure-15 & figure-16 shows the through holes or blind holes respectively. In through holes, the drill exists the opposite side of the work; in blind holes, it does not. The machining time required to drill a through hole can be determined by the following formulae;

IX. Cutting Condition in drilling The cutting speed in a drilling operation is the surface speed at the outside diameter of the drill. It is specified in this way for convenience, even though nearly all of the cutting is accurately performed at lower speeds closer to the axis of

Where, thickness, mm (in); and

= work = an approach allowance that

accounts for the drill point angle, representing the distance the

drill must feed into the work before reaching full diameter, as shown in figure-15; this allowance is given by The rate of metal removal in drilling is determined as the product of the drill cross-sectional area and the feed rate: Where Drill point angle.

This equation is valid only after the drill reaches full diameter and excludes the initial approach of the drill into the work.

X. Drill Materials The two most common types of materials used in drills are a) High Speed Steel Drills As its name suggest, this Drill is designed to machine at speeds higher than previously possible. First produced in the early 1900s, high speed steels are the most highly alloyed of the tool steels. This material is used because of its following properties: It can operate at High Positive-Rake-Angle (i.e. small included angle). It can also be used for Interrupted cuts It has good wear resistance. It is relatively inexpensive the biggest factor for India. In a blind-hole, hole depth d is defined as the distance from the work surface to the point of the hole, as shown in the Figure-16. By this definition, the drill point angle allowance does not affect the time to drill the hole. Thus, for a blind hole, machining time is given by It can also be used as a machine tools that are subject to vibration and chatter because of their low stiffness. There are basically two types of High speed steels: Molybdenum (M Series) and Tungsten (T Series). The M series contains up to about 10% molybdenum, with chromium,

vanadium, tungsten, and cobalt as alloying elements. The T Series contains 12 to 18% tungsten, with chromium, vanadium, and cobalt as alloying elements. The M Series generally has higher abrasion resistance than the T Series, undergoes less distortion during heat treating, and is less expensive. Consequently 95% of all high speed steel tools produced in the United States are made of M Series steels. High Speed Steel tools are available in wrought, cast, and sintered conditions. They can also be coated for improved performance and may also be subjected to surface treatments, such as case hardening, for improved hardness and wear resistance.

c)

Other materials for Drill

There are still some other options as a drill material which is listed below. Solid Carbide drill. TiN coated drills. Carbide coated masonry drills. Parabolic drills. Split point drills. XI. Drill Holding Device

b) Carbide-Tipped drills Most of the tool materials have the limitations, such as they cannot be used as effectively where high cutting speeds, and hence high temperatures, are invoked, and their tool life can be relatively short. Carbides, also known as cemented or sintered carbides, were introduced in the 1930s to meet the challenge of higher machining speeds for higher production rates. Because of their high hardness over a wide range of temperatures, high elastic modulus and thermal conductivity, and low thermal expansion, carbides are among the most important, versatile, and cost effective tool and die materials for a wide range of applications. However, stiffness of the machine tool is important and light feeds, low cutting speeds, and chatter can be determined, thats why this material is used as drill. The two basic groups of carbides used for Drilling operations are tungsten carbide and titanium carbide. In order to differentiate them from coated tools or tipped tools, plain carbide tools are usually referred to as uncoated carbides.

The revolving vertical spindle of the drilling machine holds and drives the cutting tool. In order to use various sizes and shapes of drills in various machines three types of drill holding devices, which fit the spindle of the drilling machines, are used: the geared drill chuck, the drill sleeve, and the drill socket as shown in figure-17. The larger drilling machines have a spindle that has a standard Morse taper at the bottom end. There are three types of drill holding devices: the geared drill chuck, the drill sleeve, and the drill socket. a) Geared Drill Chuck Drills with straight shanks are held in geared drill chucks which have three adjustable jaws to clamp onto the drill. Smaller size drills are made with straight shanks because of the extra cost of providing these size if tapered. Geared drill chucks come in various sizes, with the 3/8 or 1/2-inch capacity chuck being the most common. The shank of the chuck is set into the spindle of the drilling machine by inserting the chucks shank into the spindles internal taper and seating the shank into the taper with a light blow with a soft hammer.

sizes and hole shank taper combinations. Sockets, sleeves, and taper shank drills are mounted into the aligning slots of the spindle and lightly tapped with a soft hammer to seat in place. c) Drill Drifts

Drill drifts are flat, tapered keys with one rounded edge that are designed to fit into a spindle chucks slot to force a tapered shank drill loose. The rounded top of the small end of the drill drift is designed to face upward while inserting the drift into the slot. There are two types of drill drifts, the standard type and the safety type as shown in Figure-18. The standard drift

Both the internal and external taper surfaces must be clean and free of chips for the shank to seat and lock properly. The drill is locked into the chuck by using the chuck key to simultaneously tighten the three chuck jaws. Geared drill chucks can also come with a Morse tapered shank and may have a different method of attaching they may screw on, have a Jarno taper, or a Jacobs back taper. b) Drill sleeve & Drill Socket Morse taper shank drills come in several sizes, thus, adapters must be used for mounting them into various drilling machine spindles. Drill sleeves and drill sockets are designed to add to or subtract from the Morse taper for fitting a drill into the chuck spindle. For example, it is common for a 3/4 inch twist drill to have a Morse taper of size #2, #3, or #4. It is also common for a drilling machine spindle to have a Morse taper of size #3 or #4, and it can be adapted for many other Morse taper sizes, depending on the size of the drill. A drill too small for the machine spindle may be fitted into a socket or sleeve which has a taper hole of the proper size to hold the drill and a taper shank of the proper size to fit the drill spindle. Sometimes, more than one socket or sleeve is needed to build up the shank to tit into the drilling machine spindle. Sockets and sleeves may be obtained in a number of different XII. Work Holding and Drilling Devices Work holding devices are used to hold the work steady for an accurate hole to be drilled, and so a safe drilling operation can be accomplished. Drilling support devices are used to keep the work-piece above the worktable or vise surface and to keep must be inserted into the chucks slot and then struck with a soft hammer to jar the taper shank drill loose. The drill will fall quickly if not held by the hand and could break or cause injury. The safety drill drift has a sliding hammer weight on the drift itself to allow for a free hand to stay constantly on the drill as it comes loose.

the work-piece aligned for drilling. Some devices are fairly simple and are used for drilling operations that do not require a perfect hole. Other devices are very intricate and designed for more accurate drilling. Many work holding devices are used with one another to produce the most stable work setup for drilling. a) Machine Table vises A machine table vise is equipped with jaws which clamp against the work-piece, holding it secure. The vise can be bolted to the drilling table or the tail can be swung around to lay against the column to hold itself steady. Below are listed many types of special purpose machine table vises available to machine operators.

The angle vise is very similar to the table vise. Except this vise can be tilted to 90. To be perpendicular to the work table as shown in Figure19.

Many other vises are available. They include the compound vise. Universal vise, magnetic vise, and contour vise. b) Step Blocks

These holding devices are built like stairs to allow for height adjustments in mounting drilling jobs and are used with strap clamps and long T-slot bolts as shown in figure-20.

The standard machine table vise is the simplest of all vises. It is equipped with two precision ground jaws for holding onto the work and a lead screw to tighten the one movable jaw to the work as shown in Figure19. c) Clamps

The swivel vise is a machine vise that has an adjustable base that can swivel through 360 on a horizontal plane as shown in Figure-19.

Clamps are small, portable vises or plates which bear against the work-piece and holding devices to steady the job. Clamps are made in numerous shapes to meet various work-holding needs. Common types of clamps are the C-clamp, the parallel

clamp, the machine strap clamp, the bent-tail machine clamp, the U-clamp, and the finger machine clamp, examples are shown in the figure-20. d) V-Blocks V-blocks are precision made blocks with special slots made to anchor clamps that hold workplaces. The V-slot of the block is designed to hold round workplaces. The V-block and clamp set is usually used to hold and drill round stock e. Angle Plates

Blocks are used with clamps to aid in securing and supporting the work. These blocks are usually precision ground of hard steel for long life.

Parallels are precision ground rectangular bars are used to keep the work-piece parallel with the worktable when the work-piece must be raised above the worktable surface, such as when drilling completely through a work-piece as shown in Figure21. Parallels come in matched sets and can be solid or adjustable as needed.

Angle plates are made in a 900 angle with slots and bolt holes for securing work to the table or to other work holding devices, examples are shown in the figure-20. f. T-Slot Bolts

These specially made bolts have a T-shaped head that is designed to slide into the T-slots of the drilling machines worktable. A heavy duty washer and nut are used with the Tbolt to secure the work. XIV. g. Jigs Cutting Fluids

Cutting fluids, lubricants, and coolants are used in drilling work to lubricate the chip being formed for easier removal, to help dissipate the high heat caused by friction, to wash away the chips, to improve the finish, and to permit greater cutting speeds for best efficiency. In drilling work, the cutting fluid can be sprayed, dripped, or machine pumped onto the work and cutting too! to cool the action and provide for maximum

Drill jigs are devices designed for production drilling jobs. The workplaces are clamped into the jig so that the holes will be drilled in the same location on each piece. The jig may guide the drill through a steel bushing to locate the holes accurately. XIII. Drilling Support Devices

tool life. Drilling, reaming, and tapping of various materials can be improved by using the proper cutting fluids. Cuttingfluids can be produced from animal, vegetable, or mineral oils. Some cutting fluids are very versatile and can be used for any operation, while other cutting fluids are specially designed for only one particular metal. References:-

These devices are important to keep the work-piece parallel while being supported above the worktable or vise surface and to keep the drill from cutting into the holding device or worktable. The following two devices are the most common used.

1) www.bhavyamachinetools.com 2) www.saimm.co.za/Journal/v103n08p515.pdf 3) www.linkinghub.elsevier.com/retrieve/pii/004579497 6900730 4) www.scientific.net/AMM.48-49.1106.pdf