Chapter 23 Drilling and Hole Making Processes. Materials Processing. Hole Making Processes. MET Manufacturing Processes
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1 MET Manufacturing Processes Chapter 23 Drilling and Hole Making Processes Before you begin: Turn on the sound on your computer. There is audio to accompany this presentation. Materials Processing Chapters Chapters Chapters Chapters Chapter 22 2 Hole Making Processes Chapter
2 Hole Making Process Steps required to produce a hole that is: Sized accurately Geometrically accurate. Located correctly. Chapter 23 4 Drilling Process 1. Small hole formed by the web (Chisel edge). 2. Chips formed by the rotating cutting edges (lips). 3. Drill guided by margins that contact wall of hole. 4. Chips removed from hole by screw action of helical flutes. Margin Chapter 23 5 Drilling Process Chapter
3 Drilling Process Drilling is a complex process: Two cutting edges. Cutting tool is relatively flexible. Cutting action inside workpiece. Chip removal must be along tool. Chip removal impedes cutting fluid. High levels of friction chip formation, chip motion on tool, and tool on work. Chapter 23 7 Cutting Parameters Spindle Speed (N s ) 12 V N S = D D = drill diameter V = cutting speed Chapter 23 8 Cutting Parameters Feed (f r ) ipr = Amount of material removed per revolution. Feed (f m ) ipm = f r x N S Depth of Cut (t) = f r / 2 Chapter
4 Cutting Parameters Cutting Time (T m ) L + A + AP L + A + A T m = = f r N s f m Allowance (A) D/2 (text) Length (L) = depth of effective diameter A P = Allowance for drill point D o Drill Included Angle A P = Tan P Chapter Cutting Parameters A P L A P = 0.3 x D (118 Drill Point) Chapter Cutting Parameters Material Removal Rate (MRR) 2 MRR = D f r N S 3 D V f r 4 D = drill diameter (inch) N S = spindle speed (RPM) V = cutting speed (sfpm) Chapter
5 Example Problem Material: ASTM A296 Grade CA 15 Stainless Steel 300 BHN Hole: 5/8 inch diameter x 2.0 deep Data from Reference Handbook: V = 50 fpm f r = ipr Chapter Example Problem Solution Chapter Example Problem Solution Chapter
6 Example Problem Solution Chapter Example Problem Material: ASTM A296 Grade CA 15 Stainless Steel 300 BHN Hole: 5/8 inch diameter x 2.0 deep Data from Reference Handbook: V = 50 fpm F r = ipr Chapter Example Problem Solution Chapter
7 Example Problem Solution Chapter Drill Nomenclature 1. Body: a. Flutes Spiral or helical grooves. b. Lands Area separating flutes. c. Margin Area of land to support and guide drill. d. Web Backbone between flutes. Relatively thin or narrow. e. Heel Area of flute opposite side of land from margin. Chapter Chapter
8 Drill Web Backbone between flutes. Relatively thin or narrow. Chapter Drill Nomenclature 1. Body (continued): f. Helix Angle Angle of flute to centerline. 24 Standard 30 used for deep holes and high feed rates used for soft materials (plastic, copper). 0 used for thin sheets or soft materials. Chapter Helix Angle Variations Type N standard helix for steel and cast iron. Type H slow helix for brass and similar materials. Type W quick helix for aluminum and similar materials. Chapter
9 Length Variations Chapter Drill Nomenclature 2. Point Cutting edges. a. Cone Angle Included point angle. Standard used soft materials used for hard materials. < 90º used for drilling plastics. Chapter Drill Nomenclature 2. Point (continued) b. Back Rake Angle determined by chisel edge, relief angle and helix angle. c. Chisel Edge Formed by web and cone angle. Tendency to walk due to chisel edge. Split Point (crankshaft) thinned web to reduce cutting force and improve centering. Chapter
10 Drill Nomenclature Chisel edge: negative rake angle / high thrust force required. Cutting edge: positive rake angle / lower thrust force required. Chapter Drill Nomenclature 3. Shank a. Straight Shank b. Taper Shank Tang for drill removal with drift and drive under heavy loads. c. Bit Shank Non powered hand drills. Chapter Drill Types Straight Flute Bit Shank Twist Taper Shank Twist Subland High-Helix Angle Twist Straight Shank Twist 3-Flute Core Chapter
11 Drill Types Chapter Drill Types Chapter Drill Types Chapter
12 Drill Types Chapter Drill Types Chapter Drill Types Spade Drill with and without coolant holes. Pivot Microdrill very small diameter holes. Chapter
13 Drill Types Deep Hole Deep hole drills are designed to drill to depths from 3x diameter to 12x diameter. Most designs incorporate a parabolic flute for chip clearance and heavy web for rigidity. Chapter Drill Types Insert Drills Chapter Drill Types Insert Drills Chapter
14 Drill Types Gundrill Chapter Drill Types Gundrill Chapter Drill Types Hole Saw Chapter
15 Drill Types Self Advancing Chapter Drill Type BTA BTA (Boring Trepanning Association) Deep hole drills. Horizontal Deep Hole Drilling Machine Chapter Drill Type Selection Chapter
16 Drill Type Selection Chapter Drill Size Series Millimeter series: starting mm in 0.01 to 0.50 mm increments. Number series: #80 (0.0135) to #1 (0.228). Letter series: A (0.234) to Z (0.413). Fractional series: 1/64 to 4. Chapter Drill Size Series Chapter
17 Other Hole Making Processes Chapter Other Hole Making Processes 1. Center Drilling Used to locate hole accurately. a. Start (Center) Drill center cutting drill which is short and stiff. b. Center Drill Countersink Combination 60 angle for lathe centers. Chapter Other Hole Making Processes 2. Reaming Accurate sizing and improved surface finish. a. Stock removal " b. 45 corner chamfer typical c. Types: chucking, taper, adjustable d. Speed = 2/3 x drill speed e. Feed = up to 2 x drill feed Chapter
18 Reamers Chapter Reamers Straight Flute Chucking Straight Flute Hand Straight Flute Rose Taper Chucking Shell Expansion Adjustable Insert Blade Chapter Other Hole Making Processes 3. Counterboring Enlarge existing hole with flat bottom. Tools typically incorporate pilot for concentricity. 4. Spotfacing Machine rough surface. Tools may or may not be piloted. 5. Countersinking Enlarge existing hole with beveled section. Bevel self centering so pilot not required. Chapter
19 Counterbores Chapter Toolholders 1. Drill Chucks for straight shank tools 2. Collet Holders for straight shank tools. 3. Taper Shank Holders. Chapter Cutting Fluids Chapter
20 Machine Tools for Drilling 1. Bench drill presses. a. Plain b. Sensitive 2. Upright drill presses. a. Single spindle b. Turret c. CNC Chapter CNC Drill Presses Chapter Belt and Gear Drive Chapter
21 Upright Turret Type Chapter Machine Tools for Drilling 3. Radial drill presses. a. Plain only vertical motion. b. Semi universal spindle pivots on vertical plane. c. Universal radial arm also rotates. Chapter Machine Tools for Drilling 4. Gang drill presses. 5. Multi spindle drill presses. 6. Deep hole drill presses. 7. Transfer machines. 8. Gun Drills. Chapter
22 Gang Type Drill Presses Chapter Multiple Spindle Types Chapter Multiple Spindle Drill Heads Chapter
23 Multiple Spindle Drill Heads Chapter Multiple Spindle Drill Heads Chapter Deep Hole Type Chapter
24 Gun Drill Type Chapter The End See Oncourse for Videos Chapter
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