1.

DRILLING

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-section in
solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit is pressed against the
work piece and rotated at rates from hundreds to thousands of revolutions per minute. This forces
the cutting edge against the work piece, cutting off chips (swarf) from the hole as it is drilled.
Exceptionally, specially-shaped bits can cut holes of non-circular cross-section; a square cross-
section is possible.
A drilling machine, called a drill press, is used to cut holes into or through metal, wood, or other
materials. Drilling machines use a drilling tool that has cutting edges at its point. This cutting tool is
held in the drill press by a chuck or Morse taper and is rotated and fed into the work at variable
speeds. Drilling machines may be used to perform other operations. They can perform
countersinking, boring, counter boring, spot facing, reaming, and tapping. Drill press operators
must know how to set up the work, set speed and feed, and provide for coolant to get an acceptable
finished product. The size or capacity of the drilling machine is usually determined by the largest
piece of stock that can be centre-drilled. For instance, a 15-inch drilling machine cans centre-drill a
30-inch-diameter piece of stock.

Other ways to determine the size of the drill press are by the largest hole that can be drilled, the
distance between the spindle and column, and the vertical distance between the worktable and
spindle. After a work piece is laid out and properly mounted, the drilling process can begin. The
drilling process, or complete operation, involves selecting the proper twist drill or cutter for the job,
properly installing the drill into the machine spindle, setting the speed and feed, starting the hole on
centre, and drilling the hole to specifications within the prescribed tolerance. Tolerance is the
allowable deviation from standard size. The drilling process must have some provisions for
tolerance because of the over sizing that naturally occurs in drilling. Drilled holes are always
slightly oversized, or slightly larger than the diameter of the drills original designation. For
instance, a l/4-inch twist drill will produce a hole that may be several thousandths of an inch larger
than l/4-inch. Over sizing is due to several factors that affect the drilling process: the actual size of
the twist drill, the accuracy of the drill point, the accuracy of the machine chuck and sleeve, the
accuracy and rigidity of the drilling machine spindle, the rigidity of the entire drilling machine, and
the rigidity of the work piece and setup. Field and maintenance shop drilling operations allow for
some tolerance, but over sizing must be kept to the minimum by the machine operator.
CHARACTERISTICS

All drilling machines have the following construction characteristics: a spindle, Sleeve or quill,
column, head, worktable, and base.

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 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 work. 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.
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.
 1.1 DRILLING PROCESSES

DRILLING PROCESSES

COUNTER COUNTER
TAPPING REAMING BORING
BORE SINK

1.1.1 TAPPING

Tapping is cutting a thread in a drilled 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.
 1.1.2 REAMING

Reaming a drilled hole is another operation that can be

performed on a drilling machine. It is difficult, if not
impossible, to drill a hole to an exact standard
diameter. When great accuracy is required, the holes
are first drilled slightly undersized and then reamed to
size. Reaming can be done on a drilling machine by
using a hand reamer or using a machine reamer. When
you must drill and ream a hole, it is best if the setup is not changed. For example, 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.

1.1.3 COUNTER BORE

Counter boring is the process of using a counterbore

to enlarge the upper end of a hole to a predetermined
depth and machine a square shoulder at that depth.
Spot facing is the smoothing off and squaring of a
rough or curved surface around a hole to permit level
seating of washers, nuts, or bolt heads (Figure 4-40).
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 counterbore cutters. Counterbore
cutters have a pilot to guide the counterbore accurately into the hole to be enlarged. If a
counterbore is used without a pilot, then the counterbore flutes will not stay in one spot, but
will wander away from the desired hole. The shank of counterbores can be straight or
tapered. The pilots of counter bores can be interchangeable with one another so that many
hole combinations can be accomplished.
 1.1.4 COUNTER SINK

Countersinking is the tapering or bevelling of the end of

a Machine countersinks for machining recessed screw
heads hole with a conical cutter called a machine
countersink. Often commonly have an included angle of
82. Another common a hole is slightly countersunk to
guide pins which are to be countersink has an included
angle of 60 machining lathe driven into the work piece; but more commonly, centers. Some
countersinks have a pilot on the tip to guide the countersinking is used to form recesses for
flathead screws countersink into the recess. Since these pilots are not and is similar to
counter boring. Interchangeable, these types of countersinks can be used for only one size of
hole and are not practical for field or maintenance shops.

1.1.5 BORING

Occasionally a straight and smooth hole is

needed which is too large or odd sized for
drills or reamers. A boring tool can be
inserted into the drilling machine and bore
any size hole into which the tool holder will
fit. A boring bar with a tool bit installed is
used for boring on the larger drilling
machines. To bore accurately, the setup
must be rigid, machine must be sturdy, and power feed must be used. Boring is not
recommended for hand-feed drilling machines. Hand feed is not smooth enough for boring
and can be dangerous. The tool bit could catch the work piece and throw it back at the
operator. First, secure the work and drill a hole for the boring bar. Then, insert the boring
bar without changing the setup. Use a dial indicator to set the size of bored hole desired by
adjusting the tool bit in the boring tool holder; then, set the machine speed and feed. The
speed is set at the speed recommended for drilling a hole of the same size. Feed should be
light, such as 0.005 to 0.010 inch per revolution. Start the machine and take a light cut.
Check the size of the hole and make necessary adjustments. Continue boring with a rougher
cut, followed by a smoother finishing cut. When finished, check the hole with an internal
measuring device before changing the setup in case any additional cuts are required.
 1.2 TYPES OF DRILLING MACHINES

DRILLING MACHINES

PORTABLE BENCH RADIAL PILLAR GANG MULTIPLE

MACHINE MACHINE MACHINE MACHINE MACHINE MACHINE

1.2.1 PORTABLE MACHINE

WORK HOLDING
TOOL HOLDING
SAFETY PRECAUTION

Following safety procedures during drilling operations will help eliminate accidents, loss of time,
and materials. Listed below are safety procedures common to most types of drilling machines found
in the machine shop.

Do not support the workplaces by hand. Use a holding device to prevent the work piece from
being tom from the operators hand.

Never make any adjustments while the machine is operating.

Never clean away chips with your hand. Use a brush.

Keep all loose clothing away from turning tools.

Make sure that the cutting tools are running straight before starting the operation.

Never place tools or equipment on the drilling tables.

Keep all guards in place while operating.

Ease up on the feed as the drill breaks through the work to avoid damaged tools or
workplaces.

Remove all chuck keys and wrenches before operating.

Always wear eye protection while operating any drilling machines.

Lubrication is important because of the heat and friction generated by the moving parts.

Remove chips to avoid damage to moving parts.

If machines are operated under extremely dusty conditions operate at the slowest speeds to
avoid rapid abrasive wear.

Metal becomes very brittle in extreme cold. So do not strike the machines with hard tools.