Drilling

BACHELOR OF ENGINEERING

MANUFACTURING TECHNOLOGIES

DRILLING

by Endika Gandarias

2 by Endika Gandarias

Dr. ENDIKA GANDARIAS MINTEGI Mechanical and Manufacturing department Mondragon Unibertsitatea - www.mondragon.edu (Basque Country) www.linkedin.com/in/endika-gandarias-mintegi-91174653

http://www.mondragon.edu/eps

http://www.linkedin.com/in/endika-gandarias-mintegi-91174653







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CONTENTS BIBLIOGRAPHY INTRODUCTION MACHINE TYPES WORKHOLDING DEVICES TOOLHOLDING DEVICES DRILLING OPERATIONS SAFETY GUIDELINES APPLICATIONS GLOSSARY

by Endika Gandarias

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BIBLIOGRAPHY

BIBLIOGRAPHY

by Endika Gandarias

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The author would like to thank all the bibliographic references and videos that

have contributed to the elaboration of these presentations.

For bibliographic references, please refer to:

• http://www.slideshare.net/endika55/bibliography-71763364 (PDF file)

• http://www.slideshare.net/endika55/bibliography-71763366 (PPT file)

For videos, please refer to:

• www.symbaloo.com/mix/manufacturingtechnology

BIBLIOGRAPHY

by Endika Gandarias

http://www.slideshare.net/endika55/bibliography-71763364

http://www.slideshare.net/endika55/bibliography-71763366

http://www.symbaloo.com/mix/manufacturingtechnology

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INTRODUCTION

INTRODUCTION

by Endika Gandarias

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DRILLING TECHNOLOGY

INTRODUCTION

BASIC MOVEMENTS: – Mc Cutting movement (regarding the tool) – Ma Feed movement (regarding the tool)

Ma

Mc

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INTRODUCTION

Brace (tool), 1420

Bow drill (strap-drills) Upper Paleolithic era, 10,000 years ago

First table top drilling machine 1838

Pump drill Roman Era, 510 years BC

Gimlet, 1750 Auger, 1800

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INTRODUCTION

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Conventional drilling Irregular surface drilling

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INTRODUCTION

Typical applications:

1. Holes with clearance for bolts 2. Holes with a screw thread 3. Countersunk holes 4. Holes that have a good fit 5. Holes that form channels 6. Holes to remove weight for balancing

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2 3 4 5 6

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INTRODUCTION

At home… In industry…

by Endika Gandarias

VIDEO

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Drilling covers the methods of making cylindrical holes in a workpiece with metal cutting tools.

The machine tool is called a drill.

Typical operations: trepanning, counterboring, countersinking, reaming, boring, tapping, center and pilot hole drilling,…

Common to all these processes is a main rotating movement combined with a linear feed.

Demands on chipbreaking and the evacuation of chips is critical in drilling.

INTRODUCTION

by Endika Gandarias

fn

vc

N F

VIDEO

N Spindle speed (rpm)

Vc Cutting speed (m/min)

Dc Tool diameter (mm)

F Feed rate (mm/min)

ap Axial cutting depth (mm)

ap

Dc

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MACHINE TYPES

MACHINE TYPES

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Table top Drilling machine Turret Drilling machine

MACHINE TYPES

Higher cutting removal rate

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VIDEO

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Pillar Drilling machine

MACHINE TYPES

Radial Drilling machine

Higher cutting removal rate

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VIDEO VIDEO

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CNC Drilling machine

MACHINE TYPES

Multi Spindle or Gang Drilling machine

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Gang-drilling machine

Multi spindle machine VIDEO VIDEO

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WORKHOLDING DEVICES

WORKHOLDING DEVICES

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WORKHOLDING DEVICES

WO

RK

HO

LDIN

G D

EVIC

ES

Vise

Clamps

By hand

Special holding devices

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Plain vise Plain vise with swivel base Universal vise

Angle vise Compound vise

WORKHOLDING DEVICES

Vise

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Magnetic vise

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Clamps

Used for big size or irregular parts. Part is hold using clamps, t-slot bolts, screws, washers, nuts, parallels, step blocks,… It is important to keep in mind the efforts/deformations produced on the part.

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WORKHOLDING DEVICES

Step block

Toe mold clamp

Angle plate

Cam clamp

Washer

C clamp V block Swing clamp

T-nut T-slot bolt

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WORKHOLDING DEVICES

By hand

Using the hands (long parts)

Using a hand vise (short parts)

Special holding devices

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TOOLHOLDING DEVICES

TOOLHOLDING DEVICES

by Endika Gandarias

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TOOLHOLDING DEVICES

TOO

LHO

LDIN

G D

EVIC

ES

Drill chuck

Drill sleeve

Drill socket

Direct clamping

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Drill chuck

KEY TYPE CHUCK KEYLESS CHUCK

TOOLHOLDING DEVICES

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Morse Taper Shank

Straight Shank

It is used to hold cylindrical shank drills.

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Drill sleeve

TOOLHOLDING DEVICES

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It is used to hold tapered shank drills.

For too SMALL drills for the tapered hole in the spindle.

Drill socket

It is used to hold tapered shank drills.

For too LARGE drills for the tapered hole in the spindle.

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Direct clamping

TOOLHOLDING DEVICES

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Drifts

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MACHINING OPERATIONS


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Counter boring

DRILLING. Machining operations


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Reaming

Counter sinking

Tapping Center drilling

Spot facing

Tapered drilling

Redrilling

Step drilling

Drilling

Deep hole drilling

Trepanning

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5xD

10xD

Dc

15xD

L/Dc

Deep hole drilling

10 20 30 40 50 60 70 80 110

Trepanning

Solid carbide drill

Small length drill

Brazed carbide drill

Big diameter drill


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DRILLING. Drill types

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The lowest price per hole. Very versatile tool (capable of drilling, re-drilling, boring

and facing). Bigger diameter than solid carbide drills. Medium tolerances.


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Indexable insert drill

Solid carbide drill

Brazed carbide drill

For small diameter holes. Drilling depths up to 15xD Tight tolerances.

Alternative to solid carbide drill for large diameters and a high stability Is needed (less sensitive steel body).

VIDEO

VIDEO

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by Endika Gandarias


Standard diameters up to 80mm.

Standard diameters up to 110mm. Interesting when machine power is limited (lower power

consumption than using conventional driills).

Long diameters up to 72 x D.

Big diameter drill

Trepanning

Deep hole drill

VIDEO

VIDEO

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Layout work


Placing of the prick punch

Scribing with height gauge scriber

Scribing with steel scriber and steel straight edge

Scribing with steel scriber and try square

Steps when scribing with dividers

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SCRIBING PUNCH MARKING

When the manual hole center is done before going to the drill.

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Spot drilling / Center drilling


The purpose of spot drilling is to drill a hole that will act as a guide for drilling the final hole. Used in milling and drilling machines.

The purpose of center drilling is to drill a hole that will act as a center of rotation for possible following operations. Used in turning machines.

It is the most common drilling operation, where a hole is drilled in solid material.

by Endika Gandarias

Drilling

Through hole Blind hole

SPOT DRILLING

CENTER DRILLING

VIDEO

VIDEO

http://jimmore.en.alibaba.com/productgrouplist-213185715/Nine9_NC_Spot_Drill.html

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Trepanning


Trepanning is commonly used for creating larger diameter holes (up to 1.000 mm) where a standard drill bit is not feasible or economical.

The trepanning tool does not machine the whole diameter, only a ring at

the periphery.

In horizontal set-ups, long and heavy cores may require a core support to prevent the core from falling down (not in vertical).

This method is for through-hole applications.

Redrilling or boring

It consists on increasing the hole size.

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VIDEO

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Counterboring

Countersinking


The tool is called “counterbore”, and it has a pilot to guide the cutting action.

It is commonly used for: enlarging a hole to make a bolt head fit

flush with the surface. spot facing in workpieces that are forged or

casted.

This process is similar to counterboring, but the step in the hole is cone-shaped.

The tool is called “countersink”.

A common use is: to allow the head of a countersunk bolt or screw, when placed in the

hole, to sit flush with or below the surface of the surrounding material. to remove the burr left from a previous drilling or tapping operation. to enhance pin entry.

by Endika Gandarias

VIDEO VIDEO

VIDEO

VIDEO

VIDEO

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a) Manual reamers: long entry (A) and length (L)

b) Milling reamers: short entry (A) and length (L)

c) Reamer with no shank or separated shank.

VIDEO


The reamer never should be spinned counterclockwise.

Reaming

Straight flute Axial coolant supply

For blind holes

Spiral flute Lateral coolant supply

For through holes

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RIGHT WRONG

Objective: To achive a good surface roughness and good dimensional tolerances (H7) in a pre-drilled hole.

High penetration rates and small depths of cut.

The tool is called “reamer”.

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Taper drilling


Taper drills were engineered to be used to pre drill the pilot holes for the shank and threaded portion of a wood screw.

Step drilling The tool is called “step drill”.

The transition between this ground diameter and the original diameter is

either straight, to form a counterbore, or angled, to form a countersink. These drills are limited to use on thin material (e.g. sheet-metal work).

Improves production times, reduces number of drills.

by Endika Gandarias

VIDEO

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Brazed drill head Diameter range 15 - 65mm 150 x Dc IT9, Ra 2 µm

Deep hole drilling


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Gun drill Diameter range 1 - 40mm 100 x Dc IT9, Ra 0,1–3,20 µm

Insert drill head Diameter range 25 - 65mm 150 x Dc IT10, Ra 2 µm

Counterboring head Diameter range 20 - 280mm 150 x Dc IT 9-10, Ra 1 µm

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The tool is called “tap”.

It is commonly used for small threads.

Used for manual or automatic operations.

Straight flute tap Spiral point tap

Spiral flute tap Forming tap

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Tapping


1- Tapping:

Rough

Intermediate

Finish

MANUAL OPERATION

Hand tap wrench

T-handle tap wrench

AUTOMATIC OPERATION

VIDEO VIDEO

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The tool is called “die”.

It is commonly used for small threads.

Used for manual operations.

a) Within the lathe.

b) In a bench vise.

Main spindle (chuck)

Part

Die

Stock (handle)

VIDEO

2- Die threading:

b)

a)

Die

Stock (handle)


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Die handle

Tapping

MANUAL OPERATION

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SAFETY GUIDELINES

by Endika Gandarias

SAFETY GUIDELINES

42 by Endika Gandarias

Goggles

safety guards or machine encapsulation

Ear muff or Ear plug

Gloves

Clothing

Shoes

SAFETY GUIDELINES

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DRILLING APPLICATIONS

by Endika Gandarias


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STACK DRILLING Steel


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ROTOR BLADE Composite or carbon fiber

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GLOSSARY

by Endika Gandarias

GLOSSARY

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GLOSSARY

by Endika Gandarias

ENGLISH SPANISH BASQUE

Angle plate Placa angular Plaka angeluar Auger Barrena Laztabin Axial cutting depth Profundidad de pasada axial Sakontze sakonera Balancing Equilibrado Orekatze Blade Álabe Alabe Blind Ciego Itsu Bolt Tornillo Torloju Boring Mandrinado Mandrinaketa Bow drill Taladradora de arco Arkuzko zulagailua Brace Berbiqui Birabarki Brazed carbide drill Broca soldada de carburo Karburozko soldatutako barautsa C clamp Sargento Sarjenta Cam Leva Espeka Center drill Broca de centrar Zentratzeko barautsa Center drilling Punteado Punteaketa Chip Viruta Txirbil Clamp Brida Brida Clearance Holgura Lasaiera Coolant Refrigerante Hozkarria Counterboring Avellanado Abeilanaketa Counterclockwise Giro antihorario Erloju orratzen aurkako biraketa Countersinking Lamado Lamaketa Die Terraja Terraila Drill chuck Portabrocas Barauts etxea Drill drift Cuña Ziri / Falka Drill sleeve Manguito reductor Zorro murriztaile Drill socket Manguito ampliador Haunditze zorroa Drilling Taladrado Zulaketa

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GLOSSARY

by Endika Gandarias


Ear muff / Ear plug Orejera de casco Entzumen kaskoak Feed rate Avance por minuto Aitzinamendua minutuko Finish Acabado Akabera Fit Ajuste Doikuntza Flute Estría Ildaska Gang Grupo Multzo Gimlet Barrena Laztabin Gloves Guantes Eskularruak Goggles Gafas de seguridad Segurtasun betaurrekoak Height gauge Medidor de altura Altuera neurgailua Key Llave Giltza Lathe Torno Tornu Pillar Columna Zutabe Prick punch Granete Granete Reaming Escariado Otxabuketa Redrilling Retaladrado Birzulaketa Removal rate Tasa de arranque Harroketa tasa Ring Anillo Eraztun Rough Desbaste Arbastaketa Safety guidelines Normas de seguridad Segurtasun arauak Scribing Trazado Marraketa Shank Mango Kirten Solid carbide drill Broca enteriza de carburo Karburozko pieza bakarreko barautsa Spindle Cabezal Buru Spindle speed Velocidad de giro Biraketa abiadura Spotting drill Broca de puntear Punteatzeko barautsa Stack Apilar Metatu Step block Calzo escalonado Altxagarri mailakatua

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GLOSSARY

by Endika Gandarias


Step drilling Taladrado escalonado Zulaketa mailakatua Swing clamp Brida oscilante Brida kulunkari Swivel base Base giratoria Oinarri birakorra Table top Escritorio Mahai gaineko Tang Espiga Mihi / Ziri Tap Macho de roscar Hariztatzeko ardatza Taper Cónico Koniko Tapping Roscado con macho Ardatzarekin egindako hariztaketa Through hole Pasante Aldez aldeko Tight Estrecho Estu Toolhonding device Sistema de amarrar herramientas Erramintak lotzeko sistemak Trepanning Trepanado Trepanaketa Try square Escuadra Eskuaira Turret Torreta Torreta Vise Mordaza Baraila Washer Arandela Zirrindola Workholding device Sistema de amarrar piezas Piezak lotzeko sistemak Wrench Llave Giltza

Engineering

Drilling