Drilling

What is DRILLING?

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole in solid materials. The drill bit is a multipoint, end cutting tool. It cuts by applying pressure and rotation to the work piece, which forms chips at the cutting edge.

Drill Bits

Drill bits are cutting tools used to create cylindrical holes. Bits are held in a tool called a chuck, which rotates them and provides torque and axial force to create the hole. Specialized bits are also available for non-cylindrical-shaped holes.

Types of drill
Twist Drill:

Twist drill The twist drill is the most common type of drill. It has two cutting edges and two helical flutes that continue over the length of the drill body. The drill also consists of a neck and a shank that can be either straight or tapered. Core Drill:

Core drilling: to increase diameter of existing holes A core drill consists of the chamfer, body, neck and shank. This type of drill may have three or four flutes and an equal number of margins, which ensures superior guidance, thus resulting in high machining accuracy. Spade Drill:

Spade drill: for large, deep holes A spade drill is used for drilling large holes of 90 mm or more. The design of this type of drill results in a marked saving in tool cost as well as in tangible reduction in tool weight that facilitates its ease of handling. Moreover, this drill is easy to grind.

Step Drill:

Step drill: for stepped holes A multiple diameter drill with one set of drill lands which are ground to different diameters Gun Drill:

Gun drill with holes for coolant A gun drill is used for drilling deep hole. All gun drills are straight-fluted, and each has a single cutting edge. A hole in the body acts as a conduit to transmit coolant under considerable pressure to the tip of the drill. Center Drill:

Center drill bits are used in metalworking to provide a starting hole for a larger-sized drill bit or to make a conical indentation in the end of a work piece in which to mount a lathe center.

Types of holes Drill can make

Types of holes can be made: through holes, in which the drill exits the opposite side of the work blind holes , in which the drill does not exit

Through holes

Blind holes

Operations Related to Drilling

Reaming:

Reaming is used to slightly enlarge a hole, to provide a better tolerance on its diameter and to improve its surface finish. The tool is called a reamer and it usually has straight flutes.

Tapping:

This operation is performed by a tap and is used to provide internal screw threads on an existing hole.

Counter boring:

Counter boring provides a stepped hole, in which a larger diameter follows a smaller diameter partially into the hole. A counter boring hole is used to seat bolt heads into a hole so the heads do not protrude above the surface.

Countersinking:

This is similar to counter boring, except that the step in the hole is cone-shaped for flat head screws and bolts.

Centering:

Also called center drilling, this operation drills a starting hole to accurately establish its location for subsequent drilling. This tool is called a center drill.

Spot facing:

Spot facing is similar to milling. It is used to provide a flat machined surface on the work part in a localized area.

Types of drilling Machines

UPRIGHT SENSITIVE DRILL PRESS

The upright sensitive drill press is a light-duty type of drilling machine that normally incorporates a belt drive spindle head. This machine is generally used for moderate-to-light duty work.

UPRIGHT DRILL PRESS

The upright drill press is a heavy duty type of drilling machine normally incorporating a geared drive spindle head. This type of drilling machine is used on large hole-producing operations that typically involve larger or heavier parts.

RADIAL ARM DRILL PRESS

The radial arm drill press is the hole producing work horse of the machine shop. The press is commonly referred to as a radial drill press. The radial arm drill press allows the operator to position the spindle directly over the work piece rather than move the work piece to the tool.

GANG DRILLING MACHINE

The gang style drilling machine or gang drill press has several work heads positioned over a single table. This type of drill press is used when successive operations are to be done. For instance, the first head may be used to spot drill. The second head may be used to tap drill. The third head may be used, along with a tapping head, to tap the hole. The fourth head may be used to chamfer.

MULTIPLE SPINDLES DRILLING MACHINE

The multiple spindle drilling machines is commonly referred to as a multispindle drill press. This special purpose drill press has many spindles connected to one main work head. All of the spindles are fed into the work piece at the same time. This type of drilling machine is especially useful when you have a large number of parts with many holes located close together.

MICRO-DRILL PRESS

The micro drill press is an extremely accurate, high spindle speed drill press. The micro drill press is typically very small and is only capable of handling very small parts. Many micro drill presses are manufactured as bench top models. They are equipped with chucks capable of holding very small drilling tools.

TURRET TYPE DRILLING MACHINE

Turret drilling machines are equipped with several drilling heads mounted on a turret. Each turret head can be equipped with a different type of cutting tool. The turret allows the needed tool to be quickly indexed into position. Modern turret type drilling machines are computer-controlled so that the table can be quickly and accurately positioned.

Drill Construction (materials)

Soft low carbon steel bits are used only in wood, as they do not hold an edge and require frequent sharpening. Bits made from high carbon steel are an improvement on low-carbon steel due to the hardening and tempering capabilities of the material. These bits can be used on wood or metal, but lose their temper, resulting in a soft cutting edge, if overheated. High speed steel (HSS) is a form of tool steel; HSS bits are much more resistant to heat. They can be used to drill metal, hardwood, and most other materials at greater cutting speeds than carbon steel bits, and have largely replaced carbon steels in commercial applications. Cobalt steel alloys are variations on high speed steel which contain more cobalt. Their main advantage is that they hold their hardness at much higher temperatures, so they are used to drill stainless steel and other hard materials. The main disadvantage of cobalt steels is that they are more brittle than standard HSS. Tungsten carbide and other carbides are extremely hard materials that can drill in virtually all materials while holding an edge longer than other bits. Due to their brittleness and high cost they are mainly used for drill tips, small pieces of hard material fixed or brazed onto the tip of a bit made of less hard metal. However, it is becoming common in job shops to use solid carbide drills, and in certain industries, most notably PCB drills. Polycrystalline diamond (PCD) is among the hardest of all tool materials and is therefore extremely wear-resistant. It consists of a layer of diamond particles, typically about 0.5 mm (0.019") thick, bonded as a sintered mass to a tungsten carbide support.

Drill construction (coating)

Black oxide is an inexpensive black coating. A black oxide coating provides heat resistance and lubricity, as well as corrosion resistance. These result in a longer drill life than the typical uncoated high-speed steel drill. Titanium nitride (TiN) is a very hard ceramic material, and when used to coat a high-speed steel bit (usually twist bits), can extend the cutting life by three or more times. A titanium nitride bit cannot be properly sharpened, as the new edge will not have the coating, and will not have any of the benefits the coating provided. Titanium aluminum nitride (TiAN) is another coating frequently used. It is considered superior to TiN and can extend tool life five or more times. Titanium carbon nitride (TiCN) is another coating and is also superior to TiN. Diamond powder is used as an abrasive, most often for cutting tile, stone, and other very hard materials. Large amounts of heat are generated, and diamond coated bits often have to be water cooled to prevent damage to the bit or the work piece.

Drill point angle

Hold the drill vertically and rotate it until it looks like this. Note the angles that the top edges of the drill bit form to the vertical here, each face is at 59 degrees, giving an included angle of 118 degrees. This is a typical point angle for a general purpose drill bit.

Drill clearance angle

Rotate the drill bit in your fingers until you can look at the ramp behind one of the two cutting lips. If the drill bit is held vertically, the edge of the ramp forms an angle with the long axis of about 12 15 degrees. This is called the clearance angle.

Drill angle and helix angle

Machine drill rake angle of any cutting tools differ from material to material, correct clearance on drill angle and tip angle results in better product finishing and smoother cutting and better tool life.

Material to be drilled Steel, cast iron, Gray cast iron, malleable cast iron, German silver and nickel Brass, Cu Zn 40 Stainless steel Copper, Al alloys Austenitic steel, Magnesium alloys Engineering plastic Rubber, Marble, slate, coal Sinc Alloys

Tip angle 118

Helix angle 30

118 140 140 140 80 80 118

13 30 40 13 40 13 40

Low helix drill

Developed primarily to drill brass and thin materials Used to drill shallow holes in some aluminum and magnesium alloys Can remove large volume of chips formed by high rates of penetration

High helix drill

Designed for drilling deep holes in aluminum, copper, die-cast material, and other metals Material where chips have tendency to jam High helix angle (35 to 45) Wider flutes assist in clearing chips from hole

Securing the drill (how to use drill bit)

Choose the kind of bit based on the material you will be drilling through. Steel bits are the least expensive and are generally OK for soft woods. From there bits range up to cobalt, for drilling through stainless steel and other hard metals. Choose the bit type based on the purpose you will be using it for. Regular twist bits are used for most general purpose drilling. A brad point bit can be used in wood for boring and is excellent at removing wood chips as it drills. The spade bit looks somewhat like a little shovel. Spade bits are used for boring large holes in wood, from 1/2" up. Refer to the Lowe's reference link below for more information on specialized bit varieties. Refer to the drill manufacturer's instructions for specifics and limitations. Some drills work best with certain types of bit. There may be torque limitations on the drill that prevent specific bits from being used. Slow and steady wins the race. Trying to drill too fast can result in the bit binding up and stopping. If this does occur, slowly back the bit out and start again at a slow, steady pace. Once you push through to the other side of the material, work the drill back and forth a few times through the hole to remove any rough spots. For drilling through metal, use cutting oil to prevent the drill bit from overheating.

Drill bit shank

The shank is the part of a drill bit grasped by the chuck of a drill. The cutting edges of the drill bit are at one end, and the shank is at the other. Different styles of shank/chuck combination deliver different performance, such as allowing higher torque or greater centering accuracy.

Types of shank bits

Brace shank Straight shank Hex shank SDS shank Triangle shank Morse taper shank Square shank

Brace drill bit shank

At first, the tapered shank was just rammed into a square hole in the end of the drill. Over time, various chuck designs have been invented, and modern chucks can grasp and drive this shank effectively. Easy to make in a forge Very wide tolerances allowable (not very precise) Moderate torque transmission but without the slippage common to round shanks Hard to grasp with any precision without the proper chuck

Straight drill bit shank

The straight shank is the most usual style on modern drill bits, by number manufactured. It is almost always made the same diameter as the drill bit, for economy. It's then held in a 3-jaw drill chuck. Very small bits can have straight shanks larger than the drill diameter, often for holding in a standard size collet. Large drill bits can have straight shanks smaller than their drill diameter, so that medium-size chucks can be used to drill large holes. Such a drill bit is called reduced-shank or a blacksmith's drill. very accurate centering low torque transmission

Hexagonal shank

The flats of a hex shank can either be machined on a round shank, as in the photograph, or can be the natural flats of hex bar stock. A hex shank can be grasped by a 3-jaw drill chuck, or can be held in a custom chuck specifically for hex shanks. High torque transmission moderately accurate centring Cannot be held in a collet

SDS shank
The SDS bit was developed by Bosch in 1975 and the name comes from the German " Steck Dreh Sitz" (Insert Twist Stay). The SDS shank has the advantage of a simple spring-loaded chuck, so that bits can be chucked with a simple and quick hand action. Further, the shank and chuck are uniquely suited to hammer drilling in stone and concrete. The drill bit is not held solidly in the chuck, but can slide back and forth like a piston. The hammer of the drill acts to accelerate only the drill bit itself, and not the large mass of the chuck, which makes hammer drilling with an SDS shank drill bit much more productive than with other types of shank. So, SDS shanks are most often seen on masonry drills, for which hammer drilling action is most helpful.

SDS-plus drill bit shank Can only be held in an SDS chuck Not very accurate centering High torque transmission

SDS Plus (TE-C)

SDS Top (TE-T)

SDS Max (TE-Y)

Hilti TE-S

Triangle drill bit shank

The triangle shank is almost always made by machining three flats on round bar stock. It is intended as a minor modification of a straight shank, still allowing it to be held in a 3-jaw drill chuck, but allowing higher torque transmission and limited slipping. Moderately accurate centering Cannot be held in a collet

Morse taper shank

The Morse taper twist drill bits are used in metalworking. The full range of tapers is from 0 to 7. The Morse taper allows the bit to be mounted directly into the spindle of a drill, lathe tailstock or (with the use of adapters) into the spindle of milling machines. It is a self locking (or self holding) taper of approximately 5/8" per foot that allows the torque to be transferred to the drill bit by the friction between the taper shank and the socket. Cannot be held in a chuck or collet High torque transmission provided the bit is driven hard into the workpiece Very accurate centering

Square shank
Square taper drills were also used for large ratchet drills, for drilling large holes, or in thick plate. These bits would fit straight into a ratchet drill, and the ratchet drill would be used against a strong arm, for pressure to push the drill into the work piece.

Deep Hole Drills

What is considered a deep hole? In general any hole more than 4 to 5 times its Diameter, is considered a deep hole. With conventional drills such as twist drills several cycles or pecks would be required to clear chips from the flutes of the drill. With a dedicated deep hole drilling machine and proper tooling and fixturing the hole can be produced in one pass. Methods of Deep Hole Drilling 1. Gun drilling 2. BTA/STS 3. Ejector

Gun drilling

Gun drilling is an very old process of drilling long or deep holes, first used in the making of gun barrels more than 100 years ago. Today's technology with refined machinery and tool design has made gun drilling a reliable high production method for drilling short holes as well as deep holes. The gun drill consists of a hollow tube with a " V" shaped groove or flute along its length, and a carbide cutting tip designed in such a way as to produce it's own guide bushing as it drills the hole. High pressure coolant is introduced into the center of the drill tube through the spindle of the gun drilling machine to help break and evacuate the chips along the "V" groove of the tool and out of the hole. Gun drilling provides very close tolerance straight holes with excellent surface finish. Gun drilling is able to produce holes as small as .031"

BTA/ STS

BTA or STS (single tube system) drilling is a process developed in more recent years, with BTA drilling the coolant is introduced around the drill tube at the pressure head, and chips are evacuated through the center of the drill. The detachable drill head is comprised of individual carbide inserts and guide pads. Very high penetration rates can be achieved with this system along with good surface finish. Diameters as small as .500" (12.7 mm) or as large as 15.00" (381mm) can be produced with this type of system.

Ejector

Ejector drilling or two tube system is a process similar to the BTA process except in this case the drill tube consists of an inner and outer tube. Coolant is introduced at the spindle via a rotary connector and passes between the inner and outer tube, chips exit through the inner tube. Minimum diameter is limited to about .750 (19 mm) since there is less room for chip removal in the smaller diameter tube. The ejector system performs well in the case where the face of the part is irregular since the design of the rotary connector and drill head create a venturi effect to draw coolant and chips through the inner tube without relying on a good seal between part and bushing. The Ejector system is often adapted for use in lathes or machining centers.

Securing the Work piece

Using work piece holding 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 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.

Using Drilling Support Devices 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. 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.

Factors affecting the drilling operations

Cutting Speed (CS) Cutting speed of a material is the ideal number of Feet-per-Minute that the tool-bit should pass over the work-piece. This "Ideal" cutting speed assumes sharp tools and flood coolant. Adjustments need to be made for less than ideal cutting conditions. Different materials (High-Carbon/Low-Carbon Steels, Aluminums, Different kinds of Plastics) have different Cutting Speeds and can be worked/cut at different rates. In addition, some tools or processes (like threading, knurling, or cutting-off) will need to be worked at slower speeds than the Cutting Speed would indicate. Feed Rate (Milling Machine) Refers to how fast a milling-tool move through the material being cut. This is calculated using the Feed Per Tooth (FPT) to come up with the Inches Per Minute that a milling bit can move through a particular type of material. Thus, a Four-Flute End-Mill will cut through material at twice the speed of a Two-Flute End Mill. Feed Rates will decrease with dull tools, a lack of coolant, or deep cuts.

Feed Rate (Lathe) Refers to how fast a lathe-tool should move through the material being cut. This is calculated using the Feed per Revolution for the particular material. Lathe tools generally have only one tooth, so in most cases the FPT and FPR will be the same. Feed rates will decrease with dull tools, a lack of coolant/lubrication, or deeper cuts. Sharpening Before grinding a drill bit you must have very clear vision of what you are doing. This means the grinder must be brightly illuminated and, if you wear glasses for close-up work, you should have them on. The grinding wheel should be of fine grit and its face should be flat and square. The first step in sharpening a drill bit is to grind the point angle.

Stand slightly to the left of the grinding wheel, feet apart. Hold the drill about a quarter of the way along from the point, using the thumb and forefinger. Rest these fingers on the grinders tool rest. Use the other hand to hold the drill at its shank.

Cutting Fluids

Cutting fluids are used in metal machining for a variety of reasons such as improving tool life, reducing work piece thermal deformation, improving surface finish and flushing away chips from the cutting zone. Practically all cutting fluids presently in use fall into one of four categories: Straight oils Straight oils are non-emulsifiable and are used in machining operations in an undiluted form. They are composed of a base mineral or petroleum oil and often contains polar lubricants such as fats, vegetable oils and esters as well as extreme pressure additives such as Chlorine, Sulphur and Phosphorus. Straight oils provide the best lubrication and the poorest cooling characteristics among cutting fluids. Synthetic Fluids Synthetic Fluids contain no petroleum or mineral oil base and instead are formulated from alkaline inorganic and organic compounds along with additives for corrosion inhibition. They are generally used in a diluted form (usual concent ration = 3 to 10%). Synthetic fluids often provide the best cooling performance among all cutting fluids. Soluble Oil Soluble Oil Fluids form an emulsion when mixed with water. The concentrate consists of a base mineral oil and emulsifiers to help produce a stable emulsion. They are used in a diluted form (usual concentration = 3 to 10%) and provide good lubrication and heat transfer performance. They are widely used in industry and are the least expensive among all cutting fluids. Semi-syntheticfluids Semi-synthetic fluids are essentially combination of synthetic and soluble oil fluids and have characteristics common to both types. The cost and heat transfer performance of semi-synthetic fluids lie between those of synthetic and soluble oil fluids. Mineral Oil Mineral oil a mixture of liquid hydrocarbons from petroleum; used as a lubricant laxative, drug vehicle, and skin emollient and cleanser. Light mineral oil., of lesser density, is used similarly. Mineral oil a clear, colorless, oily liquid that is a by-product of the distillation of petroleum. Straight oils Soluble oils Semi synthetic fluids Synthetic fluids Mineral oils

Safety and Accident Prevention

Dressing Safely: 1. Own and wear safety glasses. 2. Do not wear loose fitting clothing. 3. Wear clothing that will cover and protect your body, but not get caught up in the moving parts the drill. 4. Use a dust mask if needed. 5. Hearing protection never hurt anyone. 6. Loose fitting gloves might get caught by moving devices

of

Tip: Avoid splintering: Wood tends to splinter as the bit breaks through the opposite side of the work piece. This can be avoided by clamping cardboard to the back of the work piece.

Proper Technique:

1. Maintain your drill and bits 2. Clamp and secure whatever youre working on as a general rule. 3. Mark the center of the hole or use a center punch to mark it. Then place the drill in the center of the hole. 4. Predrilled holes for woodscrews. 5. Start slowly and slowly increase speed. 6. Vary the pressure and dont let the drill bind. 7. Dont force the drill; let the machine do the work. 8. Slower speeds for thicker wood and high speed for metals. 9. Withdraw the bit often while drilling to remove chips. 10. Brush these away, blows on them and they could end up in your eyes. 11. Use a side handle and hold the drill firmly with both hands. 12. Take your time