DRILLING MACHINE TOOL · Introduction to Drilling Drilling is an operation through which a drilled...

DRILLINGDRILLINGMACHINE TOOLMACHINE TOOL

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

DRILLINGDRILLINGMACHINE TOOLMACHINE TOOL

V.GunasegaranV.GunasegaranAssistant Professor

Department of Mechanical EngineeringSchool of Mechanical Sciences

BSAU, Chennai - 48

Introduction to DrillingIntroduction to Drilling Drilling is an operation

through which a drilledhole (round hole) isproduced in a job

Cutting tool: twist drillor drill bit

Machine tool: Drillingmachine or drill press

Drilling is an operationthrough which a drilledhole (round hole) isproduced in a job

Cutting tool: twist drillor drill bit

Machine tool: Drillingmachine or drill press

Photography of Drill pressPhotography of Drill press

Types of holesTypes of holes

(a) through-hole (b) blind hole

Types of Drilling machinesTypes of Drilling machinesDrill press / Pillar drilling m/cUp-Right drilling machineHand drillingPilot drilling / Portable drillingRadial drillingMulti spindle drillingGang drilling

Drill press / Pillar drilling m/cUp-Right drilling machineHand drillingPilot drilling / Portable drillingRadial drillingMulti spindle drillingGang drilling

Drill press machineDrill press machine

The work piece is heldstationary ie. Clampedin position and the drillrotates to make a hole

Drill holes from 1.5 to15mm

Operator senses thecutting action

The work piece is heldstationary ie. Clampedin position and the drillrotates to make a hole

Drill holes from 1.5 to15mm

Operator senses thecutting action

Contd.,Contd.,

UpUp--Right Drilling MachineRight Drilling Machine

Drill holesupto 50mm

Table canmovevertically andradially

Drill holesupto 50mm

Table canmovevertically andradially

Hand drillHand drill

Pilot drillPilot drill

Radial drilling machineRadial drilling machine

Contd.,Contd., It the largest

and mostversatile usedfro drillingmedium tolarge andheavy workpieces

It the largestand mostversatile usedfro drillingmedium tolarge andheavy workpieces

Multi Spindle drillingMulti Spindle drilling

Gang drillingGang drilling

Drilling OperationDrilling Operation

Belt drive systemBelt drive system

Tool Holding devicesTool Holding devices Drills and similar tools with

parallel shanks are held ina drill chuck.

By rotating the outersleeve, the jaws can beopened and closed.

To ensure maximum grip,the chuck should betightened using the correctsize of chuck key. Thisprevents the drill fromspinning during use andchewing up the drill shank

Drills and similar tools withparallel shanks are held ina drill chuck.

By rotating the outersleeve, the jaws can beopened and closed.

To ensure maximum grip,the chuck should betightened using the correctsize of chuck key. Thisprevents the drill fromspinning during use andchewing up the drill shank

Drill bit is only gripped by the shank

Contd.,Contd.,

Holding taper shank drills Strike here to remove

Work holding devicesWork holding devices

Step BlocksClampsV-BlocksAnglesJigsT- Slots Bolt

Twist drillTwist drill

The twist drill or drill bit is made fromHigh Speed Steel, tempered to givemaximum hardness throughout theparallel cutting portion.Flutes are incorporated to carry away

the chips of metal and the outsidesurface is relieved to produce a cuttingedge along the leading side of eachflute.

The twist drill or drill bit is made fromHigh Speed Steel, tempered to givemaximum hardness throughout theparallel cutting portion.Flutes are incorporated to carry away

the chips of metal and the outsidesurface is relieved to produce a cuttingedge along the leading side of eachflute.

Basic difference in twist drillBasic difference in twist drill

Fit in chuck

Fit direct into spindle

NomenclatureNomenclature

Contd.,Contd.,

Other cuttersOther cutters Reamers Multi tooth cutting tool Accurate way of sizing and finishing the

pre-existing hole Accuracy of 0.005mm can be achieved

Boring Tool Single point cutting tool Boring tool is held in the boring bar which

has the shank Accuracy of 0.005mm can be achieved

Reamers Multi tooth cutting tool Accurate way of sizing and finishing the

pre-existing hole Accuracy of 0.005mm can be achieved

Boring Tool Single point cutting tool Boring tool is held in the boring bar which

has the shank Accuracy of 0.005mm can be achieved

Contd.,Contd., Countersinks Special angled cone shaped enlargement

at the end of the hole Cutting edges at the end of conical surface Cone angles of 60°, 82°, 90°, 100°, 110°,

Counter Bore Tool Special cutters uses a pilot to guide the

cutting action Accommodates the heads of bolts

Countersinks Special angled cone shaped enlargement

at the end of the hole Cutting edges at the end of conical surface Cone angles of 60°, 82°, 90°, 100°, 110°,

Counter Bore Tool Special cutters uses a pilot to guide the

cutting action Accommodates the heads of bolts

Contd.,Contd.,

Tapping tool Tool called a tap Multi cutting

edge tool Minor dia of the

thread is drilledand then tappingis done

Tapping tool Tool called a tap Multi cutting

edge tool Minor dia of the

thread is drilledand then tappingis done

Drill MaterialsDrill MaterialsThe two most common types are

1. HSS drill• Low cost

2. Carbide- tipped drills• high production and in CNC machines

3. Other types• Solid Carbide drill, TiN coated drills, carbide

coated masonry drills, parabolic drills, splitpoint drill

The two most common types are1. HSS drill

• Low cost2. Carbide- tipped drills

• high production and in CNC machines3. Other types

• Solid Carbide drill, TiN coated drills, carbidecoated masonry drills, parabolic drills, splitpoint drill

Other OperationsOther Operations

A reamer enters the workpiece axially

and enlarges an existing hole to the

diameter of the tool

A reamer is a multi-point tool that has

many flutes, which may be straight or

in a helix

Reaming removes a minimal amount of

material and is often performed after

drilling to obtain both a more accurate

diameter and asmoother internal finish

ReamingReaming

A reamer enters the workpiece axially

and enlarges an existing hole to the

diameter of the tool

A reamer is a multi-point tool that has

many flutes, which may be straight or

in a helix

Reaming removes a minimal amount of

material and is often performed after

drilling to obtain both a more accurate

diameter and asmoother internal finish

BoringBoring

Operation of enlarging

and truing drilled hole

with single point cutting

For producing special

diameter hole

Operation of enlarging

and truing drilled hole

with single point cutting

For producing special

diameter hole

CountersinkingCountersinking A countersink tool enlarges the top

portion of an existing hole to a cone-

shaped opening.

Countersinking is performed after drilling

to provide space for the head of a

fastener, such as a screw, to sit flush with

the workpiece surface.

Common included angles for a

countersink include 60, 82, 90, 100, 118,

and 120 degrees

A countersink tool enlarges the top

portion of an existing hole to a cone-

shaped opening.

Countersinking is performed after drilling

to provide space for the head of a

fastener, such as a screw, to sit flush with

the workpiece surface.

Common included angles for a

countersink include 60, 82, 90, 100, 118,

and 120 degrees

CounterboringCounterboring A counterbore tool enlarges the top

portion of an existing hole to the

diameter of the tool.

Counterboring is often performed

after drilling to provide space for the

head of a fastener, such as a bolt, to

sit flush with the workpiece surface.

The counterboring tool has a pilot on

the end to guide it straight into the

existing hole

A counterbore tool enlarges the top

portion of an existing hole to the

diameter of the tool.

Counterboring is often performed

after drilling to provide space for the

head of a fastener, such as a bolt, to

sit flush with the workpiece surface.

The counterboring tool has a pilot on

the end to guide it straight into the

existing hole

Used to provide internal

screw threads on an

existing hole

Tapping is performed

either by hand or by

machine

TappingTapping

Used to provide internal

screw threads on an

existing hole

Tapping is performed

either by hand or by

machine

Spot facingSpot facing Spot facing provides a seat or flat surface at the

entrance and surrounding area of a hole This flat surface allows the bottom of a screw or

bolt to seat squarely with the material Spot facing is commonly done on castings where

irregular surfaces are found Spot facing may be performed on a drill press

with a counterbore of suitable size for theoperation

A proper size pilot must be used whenever thisis done on the drill press

Spot facing provides a seat or flat surface at theentrance and surrounding area of a hole

This flat surface allows the bottom of a screw orbolt to seat squarely with the material

Spot facing is commonly done on castings whereirregular surfaces are found

Spot facing may be performed on a drill presswith a counterbore of suitable size for theoperation

A proper size pilot must be used whenever thisis done on the drill press

Contd.,Contd.,

spotface

Deep hole drillingDeep hole drilling Deep hole drilling is the machining of holes with a

relatively large depth to diameter ratio.

Whereas normal drilling techniques produce holeswhere the depth is rarely more than five times thediameter

In deep hole drilling the ratio may reach 150:1, andany hole deeper than ten times the diameter shouldcertainly be considered a deep hole, requiring aspecialized drilling technique

Deep hole drilling is the machining of holes with arelatively large depth to diameter ratio.

Whereas normal drilling techniques produce holeswhere the depth is rarely more than five times thediameter

In deep hole drilling the ratio may reach 150:1, andany hole deeper than ten times the diameter shouldcertainly be considered a deep hole, requiring aspecialized drilling technique

Contd.,Contd.,

BROACHINGBROACHINGMACHINE TOOLMACHINE TOOL

Introduction toIntroduction to BroachingBroachingBroaching is a machining process for

removal of a layer of material ofdesired width and depth

Usually in one stroke by a slender rodor bar type cutter having a series ofcutting edges with gradually increasedprotrusion

Broaching is a machining process forremoval of a layer of material ofdesired width and depth

Usually in one stroke by a slender rodor bar type cutter having a series ofcutting edges with gradually increasedprotrusion

Photography of BroachPhotography of Broach

Principle of BroachingPrinciple of Broaching In shaper, attaining full depth requires a number of

strokes to remove the material in thin layers step – by– step by gradually infeeding the single point tool

Whereas, broaching enables remove the wholematerial in one stroke only by the gradually risingteeth of the cutter called broach

In shaper, attaining full depth requires a number ofstrokes to remove the material in thin layers step – by– step by gradually infeeding the single point tool

Whereas, broaching enables remove the wholematerial in one stroke only by the gradually risingteeth of the cutter called broach

Broaching machineBroaching machine

ClassificationsClassifications

According to purpose of use– general purpose– single purpose– special purpose

According to nature of work– internal broaching– external (surface) broaching

According to configuration– horizontal– vertical

According to purpose of use– general purpose– single purpose– special purpose

According to nature of work– internal broaching– external (surface) broaching

According to configuration– horizontal– vertical

Contd.,Contd.,

According to number of slides or stations– single station type– multiple station type– indexing type

According to tool / work motion– intermittent (one job at a time) type– continuous type

According to number of slides or stations– single station type– multiple station type– indexing type

According to tool / work motion– intermittent (one job at a time) type– continuous type

Horizontal machineHorizontal machine Horizontal broaching machines are the most versatile in

application and performance and hence are most widelyemployed for various types of production. These are used forinternal broaching but external broaching work are alsopossible. The horizontal broaching machines are usuallyhydraulically driven and occupies large floor space.

Horizontal broaching machines are the most versatile inapplication and performance and hence are most widelyemployed for various types of production. These are used forinternal broaching but external broaching work are alsopossible. The horizontal broaching machines are usuallyhydraulically driven and occupies large floor space.

Vertical MachineVertical Machine

Vertical broachingmachines– occupies less floor

space– are more rigid as the

ram is supported by base– mostly used for external

or surface broachingthough internal broachingis also possible andoccasionally done.

Vertical broachingmachines– occupies less floor

space– are more rigid as the

ram is supported by base– mostly used for external

or surface broachingthough internal broachingis also possible andoccasionally done.

Continuous machineContinuous machine Broaching operation and broaching machines

are as such high productive but its speed ofproduction is further enhanced by;– incorporating automation in tool – job mounting

and releasing– increasing number of workstations or slides for

simultaneous multiple production– quick changing the broach by turret indexing– continuity of working

Broaching operation and broaching machinesare as such high productive but its speed ofproduction is further enhanced by;– incorporating automation in tool – job mounting

and releasing– increasing number of workstations or slides for

simultaneous multiple production– quick changing the broach by turret indexing– continuity of working

Contd.,Contd.,

Broach constructionBroach constructionConstruction of cutting tool is

characterized mainly by

Configuration

Material

Cutting edge geometry

Construction of cutting tool ischaracterized mainly by

Configuration

Material

Cutting edge geometry

ConfigurationConfiguration

Contd.,Contd., Both pull and push type broaches are made

in the form of slender rods One or more rows of cutting teeth with

increasing height (and width occasionally) Push type broaches are subjected to

compressive load and hence are madeshorter in length to avoid buckling

The general configuration of pull typebroaches, which are widely used forenlarging and finishing preformed holes

Both pull and push type broaches are madein the form of slender rods

One or more rows of cutting teeth withincreasing height (and width occasionally)

Push type broaches are subjected tocompressive load and hence are madeshorter in length to avoid buckling

The general configuration of pull typebroaches, which are widely used forenlarging and finishing preformed holes

Geometry of broaching teethGeometry of broaching teeth

Material of broachMaterial of broach Being a cutting tool, broaches are also made of

materials having the usual cutting tool materialproperties, i.e., high strength, hardness,toughness and good heat and wear resistance

Broaches are mostly made of HSS (high speedsteel)

Cemented carbide segments (assembled) orreplaceable inserts are also used for strongerand harder work materials.

TiN coated carbides provide much longer toollife in broaching

Being a cutting tool, broaches are also made ofmaterials having the usual cutting tool materialproperties, i.e., high strength, hardness,toughness and good heat and wear resistance

Broaches are mostly made of HSS (high speedsteel)

Cemented carbide segments (assembled) orreplaceable inserts are also used for strongerand harder work materials.

TiN coated carbides provide much longer toollife in broaching

Classification of broachesClassification of broachesBroaches can be broadly classified in

several aspects such as,– Internal broaching / External broaching

– Pull type / Push type

– Ordinary cut / Progressive type

– Solid, Sectional / Modular type

– Profile sharpened / form relieved type

Broaches can be broadly classified inseveral aspects such as,– Internal broaching / External broaching

– Pull type / Push type

– Ordinary cut / Progressive type

– Solid, Sectional / Modular type

– Profile sharpened / form relieved type

Internal broachesInternal broaches

External broachesExternal broaches

External broaching tools may be bothpull and push type.

OrdinaryOrdinary –– cut andcut andProgressive type broachProgressive type broach

Solid, sectional and modularSolid, sectional and modulartype broachestype broaches

Selection of broachSelection of broach

There are various types of broachesavailable. The appropriate one has to beselected based on– type of the job; size, shape and material– geometry and volume of work material to

be removed from the job– desired length of stroke and the broach– type of the broaching machines available

or to be used

There are various types of broachesavailable. The appropriate one has to beselected based on– type of the job; size, shape and material– geometry and volume of work material to

be removed from the job– desired length of stroke and the broach– type of the broaching machines available

or to be used

Selection of broachingSelection of broachingmachinemachine Broaching machine has to be selected based

on– The type, size and method of clamping of the

broach to be used– Size, shape and material of the workpiece– Strength, power and rigidity required for

the broaching machine to provide thedesired productivity and process capability.

Broaching machine has to be selected basedon– The type, size and method of clamping of the

broach to be used– Size, shape and material of the workpiece– Strength, power and rigidity required for

the broaching machine to provide thedesired productivity and process capability.

Broaching procedureBroaching procedureSelection of broach and broaching

machineMounting and clamping the broach in the

broaching machine Fixing workpiece in the machinePlanning tool - work motionsSelection of the levels of the process

parameters and their settingConducting machining by the broach

Selection of broach and broachingmachineMounting and clamping the broach in the

broaching machine Fixing workpiece in the machinePlanning tool - work motionsSelection of the levels of the process

parameters and their settingConducting machining by the broach

AAdvantagesdvantages Very high production rate High dimensional and form accuracy and

surface finish of the product Roughing and finishing in single stroke of the

same cutter Needs only one motion (cutting), so design,

construction, operation and control aresimpler

Extremely suitable and economic for massproduction

Very high production rate High dimensional and form accuracy and

surface finish of the product Roughing and finishing in single stroke of the

same cutter Needs only one motion (cutting), so design,

construction, operation and control aresimpler

Extremely suitable and economic for massproduction

LimitationsLimitations Only through holes and surfaces can be

machined Usable only for light cuts, i.e. low chip load and

unhard materials Cutting speed cannot be high Defects or damages in the broach (cutting edges)

severely affect product quality Separate broach has to be procured and used

whenever size, shape and geometry of the jobchanges

Economic only when the production volume is large.V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Only through holes and surfaces can bemachined

Usable only for light cuts, i.e. low chip load andunhard materials

Cutting speed cannot be high Defects or damages in the broach (cutting edges)

severely affect product quality Separate broach has to be procured and used

whenever size, shape and geometry of the jobchanges

Economic only when the production volume is large.

GEAR CUTTINGGEAR CUTTING

Introduction to GearIntroduction to GearManufacturingManufacturing Gear manufacturing refers to the making of

gears Gears are widely used in various

mechanisms and devices to transmit powerand motion positively (without slip)– without change in the direction of rotation– with change in the direction of rotation– without change of speed (of rotation)– with change in speed at any desired ratio

Gear manufacturing refers to the making ofgears

Gears are widely used in variousmechanisms and devices to transmit powerand motion positively (without slip)– without change in the direction of rotation– with change in the direction of rotation– without change of speed (of rotation)– with change in speed at any desired ratio

Feature of gear and teethFeature of gear and teethprofileprofile

Gear TerminologyGear Terminology

Types of GearTypes of Gear

Contd.,Contd.,

Specification Of GearsSpecification Of Gears

Gears are generally specified by their– Type; e.g. spur, bevel, spiral etc.– Material– Size or dimensions– Geometry– Special features, if any

MaterialsMaterials

Gray cast ironNodular and ductile cast iron( Good

casting property )Carburizing steelNitride steelBronzeNon-metals as plastics, reinforced

laminatesV.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Gray cast ironNodular and ductile cast iron( Good

casting property )Carburizing steelNitride steelBronzeNon-metals as plastics, reinforced

laminates

Gear ManufacturingGear ManufacturingProcessesProcesses1. Machining2. Casting3. Stamping4. Coining5. Cold Drawing6. Rolling7. Extrusion8. Powder metallurgy9. Plastic Moulding

1. Machining2. Casting3. Stamping4. Coining5. Cold Drawing6. Rolling7. Extrusion8. Powder metallurgy9. Plastic Moulding

Machining (Gear Cutting)Machining (Gear Cutting)There are three machining processes

for gear manufacturing ,Form Cutting

- Same profile cutters are used

Generating Process- Combination of straight movement of tool and

rotation of work piece by spindle

There are three machining processesfor gear manufacturing ,Form Cutting

- Same profile cutters are used

Generating Process- Combination of straight movement of tool and

rotation of work piece by spindle

Form CuttingForm Cutting In Form cutting tool or cutter having

profile corresponding to the tooth space.

Accuracy depends on accuracy ofcutter.

Example : Spur ,helical and bevel gear

Machine tool: Milling and Broaching

In Form cutting tool or cutter havingprofile corresponding to the tooth space.

Accuracy depends on accuracy ofcutter.

Example : Spur ,helical and bevel gear

Machine tool: Milling and Broaching

Contd.,Contd.,

Form millingForm milling

BroachingBroaching

Generating processGenerating process

Gear shaping (pinion cutter)

Gear planing (Rack cutter)

Gear hobbing

Gear shaping (pinion cutter)

Gear planing (Rack cutter)

Gear hobbing

Gear ShapingGear Shaping

Contd.,Contd.,

GearGear PlaningPlaning

Contd.,Contd.,

GearGear hobbinghobbing

Hobbing is a process of generating a gearusing a rotating tool called “Hob”

The hob has helical threads The threads have grooves cut parallel to the

axis to provide cutting edges The gear teeth are cut into the workpiece by

a series of cuts made by the hob It is the most widely used gear cutting

process for creating spur and helical gears

Hobbing is a process of generating a gearusing a rotating tool called “Hob”

The hob has helical threads The threads have grooves cut parallel to the

axis to provide cutting edges The gear teeth are cut into the workpiece by

a series of cuts made by the hob It is the most widely used gear cutting

process for creating spur and helical gears

HobsHobs

Gear generation processGear generation process

Both the hob and the workpiece revolveconstantly as the hob is fed across the facewidth of the gear blank.

They rotate in a timed relationship A proportional feed rate is maintained

between the gear blank and the hob Several teeth are cut on a progressive basis It is used for high production runs

Both the hob and the workpiece revolveconstantly as the hob is fed across the facewidth of the gear blank.

They rotate in a timed relationship A proportional feed rate is maintained

between the gear blank and the hob Several teeth are cut on a progressive basis It is used for high production runs

Contd.,Contd.,

Gear generation comparisonGear generation comparison

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