Drilling PDF

PowerPoint to accompany
Technology
of Machine Tools
WORKSYOP
6th Edition
TECHNOLOGY
1
Krar Gill Smid
Drilling Machines
Copyright The McGraw-Hill Companies, Inc.

Permission required for reproduction or display.
38-2
Drilling Machines
Probably first mechanical device developed
Principle of rotating tool to make hole
One of most common and useful machines
in industry
Come in several types and sizes
From hand-fed to computer-controlled
38-3
Drilling Press
Drilling machine
Spindle
Turns drill to advance into work (hand or
automatically)
Work table
Holds workpiece rigidly in place as hole drilled
Used primarily to produce holes in metal

Other operations: tapping, reaming, boring,
counterboring, countersinking, spot-facing
38-4
Standard Operations
Drilling
Operation of producing hole by
removing metal from solid mass
using twist drill
Countersinking
Operation of producing tapered
or cone-shaped enlargement
to end of hole
38-5
Standard Operations
Reaming
Operation of sizing and producing
smooth, round hole from previously
drilled or bored hole
Boring
Truing and enlarging hole by
means of single-point cutting tool
38-6
Standard Operations
Tapping
Cutting internal threads in hole
with cutting tool called tap
Counterboring
Enlarging top of previously
drilled hole to given depth
to provide square shoulder for
head of bolt or capscrew
38-7
Standard Operations
Spot Facing
Smoothing and squaring surface around
hole to provide seat for head of cap screw
or nut
Boring bar fitted with
double-edged cutting
tool
Pilot section on end
to fit into existing hole
38-8
Principal Types of
Drilling Machines
Wide variety of drill presses
Size of drill press may be designated in
different ways by different companies
Some state size as distance from center of
spindle to column of machine
Others state size by diameter of largest circular
piece that can be drilled in center
38-9
Sensitive Drill
Press Parts
Only hand feed
mechanism
Control downfeed
pressure
Manufactured in bench
and floor model
Four main parts
Base, column, table
and drilling head
38-10
Radial
Drilling
Machine

39-11
Versatility of the Drill Press

Greatly increased by various accessories
Two categories
Tool-holding devices
Used to hold or drive cutting tool
Work-holding devices
Used to clamp or hold workpiece
39-12
Tool-Holding Devices
Drill press spindle provides means of
holding and driving cutting tool
End may be tapered or threaded for
mounting drill chuck
Most common
Drill chucks
Drill sleeves
Drill sockets
39-13
Drill Chucks
Most common devices used for holding
straight-shank cutting tools
Most contain three jaws that move
simultaneously when outer sleeve turned
Hold straight shank of cutting tool securely
Two common types

Key
Keyless
39-14
Chucks
Hold straight-shank drills
Mounted on drill press spindle
Taper
Threads
Held in spindle by self-holding

taper in larger machines
Four types of drill chucks
39-15
Types of Drill Chucks

Key-type
Most common
Three jaws move simultaneously
when outer sleeve turned
Tighten with key
Keyless
Chuck loosened or tightened by
hand without key
Precision keyless
Holds smaller drills accurately
39-16
Types of Drill Chucks

Jacobs impact keyless chuck
Hold small or large drills
accurately using
Rubber-Flex
collets
Gripped or released
quickly and easily by
means of built-in
impact device in chuck
39-17
Drill Sleeves and Sockets

Drill Sleeves
Used to adapt cutting
tool shank to machine
spindle if taper on tool is
smaller than tapered hole in spindle
Drill Socket
Used when hole in spindle of drill press to small
for taper shank of drill
Used also as
extension sockets
39-18
Drill Drift
Used to remove tapered-shank drills or
accessories from drill press spindle
Always place rounded edge up so this edge
will bear against round slot in spindle
Use hammer to tap drill drift and loosen
tapered drill shank
Use board or piece of masonite to protect
table
39-19
Work-Holding Devices
Angle vise
Angular adjustment on base to allow operator to
drill holes at an angle without tilting table
Drill vise
Used to hold
round, square
or odd-shaped
rectangular, pieces
Bolt vise to table for stability
39-20
Contour vise
Has special movable jaws that automatically
adjust to shape of odd-shaped workpiece
V-blocks
Made of cast iron or hardened steel
Used in pairs to support round work for drilling
Step blocks
Used to provide support for outer end of strap
clamps
Various sizes and steps
39-21
Angle plate
L-shaped piece of cast iron or hardened steel
machined to accurate 90
May be bolted or clamped to table
Variety of sizes
Drill jigs
Used in production for drilling holes in large
number of identical parts
Eliminate need for laying out a hole location
39-22
Clamps or straps
Used to fasten work to drill table or an angle
plate for drilling
Various sizes
Finger clamp
Usually supported at
end by step block and
bolted to table by T-bolt
U-clamp
that fits into table T-slot
Modifications are doublefinger and gooseneck clamps

Straight clamp
39-23
Clamping Stresses
Dont want stresses to cause springing or
distortion of workpiece
Clamping pressures should be applied to
work, not step block
Step block should be
slightly higher than
work
Bolt close to work
39-24
Clamping Hints
1. Always place bolt close to workpiece
2. Have packing block slightly higher than
work surface being clamped
3. Insert piece of paper between machine
table the workpiece to prevent shifting
4. Place metal shim between clamp and
workpiece
5. Use sub-base or liner under rough casting
6. Shim parts that do not lie flat to prevent
rocking
40-25
Twist Drills
End-cutting tools
Used to produce holes in most types of
materials
Two helical grooves, or flutes, are cut
lengthwise around body of drill
Provide cutting edges and space for cuttings to
escape during drilling process
40-26
Twist Drill Parts

Most made of high-speed steel
Replaced carbon-steel drills for two reasons
Can be operated at double the cutting speed
Cutting edge lasts longer
Stamped with letters H.S or H.S.S.
Carbide-tipped drills
Speeds for production have increased up to
300% over high-speed drills
40-27
Three Main Parts

of a Drill
Point
Body
Shank

40-28
Shank
Straight-shank drills
Held in drill chuck
Up to in.
in diameter
Tapered-shank drills
Fit into internal taper of drill press spindle
Tang provided on end to prevent drill from
slipping
40-29
Body
Portion of drill between shank and point
Consists of number of parts for cutting
Flutes
Two or more helical grooves cut around body
of drill
Form cutting edges, admit cutting fluid, allow
chips to escape hole
Body Clearance
Undercut portion of body between margin and
flutes
40-30
Body, cont.
Margin
Narrow, raised section on body of drill
Next to flutes and extends entire length of flutes
Provides full size to drill body and cutting edges
Web
Thin partition in center
of drill, extends full length of flutes
Forms chisel edge at cutting end of drill
40-31
Point

40-32
Lip Clearance
Is the relief ground on point of drill

extending from cutting lips back to the heel
40-33
Drill Point Characteristics

The use of various point angles and lip
clearances, in conjunction with thinning
of the drill web, will allow:
1. Control size, quality and straightness of

drilled hole
2. Control size, shape and formation of chip
3. Control chip flow up flutes
40-34
4. Increase strength of drill's cutting edges

5. Reduce rate of wear at cutting edges
6. Reduce amount of drilling pressure
required
7. Control amount of burr produced

8. Reduce amount of heat generated
9. Permit use of various speeds and feeds for
more efficient drilling
40-35
Conventional Point (118)

Most commonly used drill point
Gives satisfactory results for most generalpurpose drilling
Lip clearance of 8 to 12 for best results
Too much weakens cutting
edge and causes drill to chip
Too little results in use of
heavy drilling pressure
40-36
Long Angle Point (60 to 90)

Used on low helix drills for drilling of
nonferrous metals, soft cast irons, plastics,
fibers, and wood
Lip clearance generally from 12 to 15
Flat may be ground on face
of lips to prevent drill
from drawing itself into
the soft material
40-37
Flat Angle Point (135 to 150)

Used to drill hard and tough materials
Lip clearance on flat angle point drills only
6 to 8 to provide as much support as
possible for cutting edges
Shorter cutting edge tends
to reduce friction and
heat during drilling
40-38
Four Systems of Drill Sizes

Fractional
Range from 1/64 to 4 in. (steps of 1/64th )
Number
Range from #1 (.228 in.) to #97 (.0059 in.)
Letter
Range from A to Z (A = .234 in., Z = .413 in.)
Millimeter (Metric)
Miniature (0.04 to 0.09 mm, steps of 0.01 mm)
Straight-shank standard (0.5 to 20 mm)
Taper-shank (8 up to 80 mm)
40-39
Types of Drills
Wide variety manufactured to suit specific
drilling operations and materials
Design of drills vary
Number and width of flutes

Amount of helix or rake angle of flutes
Shape of land or margin
Shape of flute: straight or helical
Whether helix is right-hand or left-hand
40-40
Twist Drills
Manufactured from three main materials
Carbon-steel drills
Used in hobby shops not for machine shop work
Cutting edges wear down quickly
High-speed steel drills

Used in machine shop work
Cutting edges withstand more heat and wear
Cemented-carbide drills
Operated at high speeds, withstand higher heat, and
can drill hard materials
40-41
General-Purpose Drill
Has two Helical flutes
Designed to perform well on wide variety
of materials, equipment and job conditions
Can be made to suit different conditions
and materials by varying point angle,
speeds and feeds
Straight-shank drills called general-purpose
jobbers length drills
40-42
Oil Hole Drills

Have one or two oil holes running from
shank to cutting point
Compressed air, oil, or cutting fluid can be
forced through when deep holes being drilled
Used on turret lathes and screw machines

Cutting fluid cools drill's cutting edges and
flushes chips out of hole

40-43
Step Drills
Used to drill and countersink or drill and
counterbore different sizes of holes in one
operation
May have two or more diameters ground
Each size or step separated by square or
angular shoulder

40-44
Saw-Type Hole Cutter

Cylindrical-diameter cutter with twist drill
in center to provide guide for cutting teeth
on hole cutter
Made in various diameters
Used for drilling
holes in thin materials
Little burr produced
40-45
Drilling Facts and Problems
Excessive speed
Excessive clearance
Examples of each
Excessive feed
on following slides
Insufficient clearance
Cutting lips with unequal angles
Cutting lips with unequal in length
Loading and galling
40-46
Excessive speed will cause wear at outer corners

of drill. This permits fewer regrinds of drill due
to amount of stock to be removed in reconditioning.
Discoloration is warning sign of excess speed.

40-47
Excessive clearance results in lack of support

behind cutting edge with quick dulling and poor
tool life. Despite initial free cutting action.
Clearance angle behind cutting lip for general
purposes is 8 to 12.

40-48
Excessive feed sets up abnormal end thrust, which

causes breakdown of chisel point and cutting lips.
Failure induced by this cause will be broken or
split drill.

40-49
Insufficient clearance causes the drill to rub behind

the cutting edge. It will make the drill work hard,
generate heat, and increase end thrust. This results
in poor holes and drill breakage.

40-50
The web is the tapered central portion of the

body that joins the lands.

40-51
Cutting lips with unequal angles will cause one

cutting edge to work harder than the other. This
causes torsion strain, bellmouth holes,
rapid dulling, and poor tool life.

40-52
Cutting lips unequal in length cause chisel point

to be off center axis and will drill holes oversize
by approximately twice the amount
of eccentricity.

40-53
Loading and galling is

caused by poor chip
removal with insufficient
dissipation of heat so that
material anneals itself to
the cutting edge and flute.
This condition frequently
results from using wrong
drills for the job or
inadequate cutting fluid
application.
40-54
Characteristics of a Properly
Ground Drill
Length of both cutting lips equal

Angle of both cutting lips be the same
Lips should be free from nicks or wear
No sign of wear on margin
Note: Resharpen drill if it does not meet

all of these requirements.
40-55
Conditions That Indicate Drill

Be Examined and Reground
Color and shape of chips change

More drilling pressure required
Drill turns blue because of excessive heat
Top of hole out of round
Poor finish produced in hole
Drill chatters when it contacts metal
Drill squeals and may jam in hole
Excessive burr left around drilled hole
40-56
Factors Causing Premature

Dulling of Drill
Drill speed may be too high for hardness of
material being cut
Feed may be too heavy and overload cutting
lips
Feed may be too light and cause lips to
scrape rather than cut
May be hard spots or scale on work surface
40-57
More Factors
Work or drill may not be supported
properly, resulting in springing and chatter
Drill point may be incorrect for material
being drilled
Finish on lips may be poor
40-58
Procedure to Grind a Drill

1. Wear approved safety glasses
2. Check grinding wheel and dress it to
sharpen and/or straighten wheel face
3. Adjust grinder tool rest so it is within
.060 in. of wheel face
4. Examine drill point and margins for wear
40-59
5. Hold drill near point with one hand, other

hand hold shank of drill slightly lower
than point
6. Move drill so it is approximately 59 to
face of grinding wheel
7. Hold lip or cutting edge of drill parallel to
grinder toolrest
8. Bring lip of drill against grinding wheel

and slowly lower drill shank
40-60
9. Remove drill from wheel without moving

position of body or hands, rotate drill onehalf turn, and grind the other cutting edge
10. Check angle of drill point and length of
lips with drill point gage
11. Repeat operations 6-10 until cutting edges
are sharp and lands are free from wear
nicks

41-61
Cutting Speeds and Feeds

Two important factors
Diameter and material of cutting tool
Type of material being cut
Speed of twist drill referred to as cutting

speed, surface speed or peripheral speed
Distance point on circumference of drill will
travel in 1 min
41-62
Recommended Cutting Speeds

For every job, choose the drill speed that will
result in the best production rates!
Steel Casting
Tool Steel
Drill Size Cutting Speeds in Feet per Min or Meters per Min
in mm
40 ft/min 12 m/min 60 ft/min 18 m/min
1/16 2
2445
1910
3665
2865
1/8 3
1220
1275
1835
1910
3/16 4
815
955
1220
1430
Portion of Table 41.1 from text
41-63
Economical Drilling Speed

Variables
Type and hardness of material

Most important!
Diameter and material of drill
Depth of hole
Type and condition of drill press
Efficiency of cutting fluid employed
Accuracy and quality of hole required
Rigidity of work setup
41-64
Revolutions per Minute

Compute correct number of r/min of drill
press spindle for given size drill
Type of material to be drilled
Recommended cutting speed of material
Type of material from which drill is made
41-65
Formula (Inch)
CS (feet per minute) x12
r / min
D(drill circumfere nce in inches)
where CS = recommended cutting speed in
feet per minute for the material being drilled
D = diameter of drill being used
Revolution per minute = number of revolutions
of the drill necessary to attain proper cutting
speed for metal being machined.
41-66
Simplified Formula
Since not all machines can be set to exact calculated
speed, pi () divided into 12 to simplify formula
CS x 4
r / min
D
Example: Calculate r/min required to drill a in hole
in cast iron (CS 80) with a high-speed steel drill.
80 x 4 320
r / min
640
1/ 2
1/ 2
41-67
Feed
Distance drill advances into work for each
revolution
May be expressed in decimals, fractions of
an inch, or millimeters
Three factors govern rate of feed
Diameter of drill
Material of workpiece
Condition of drilling machine
41-68
Drill Feeds
General purpose Work
Drill Size
in.
18 and smaller
Feed per Revolution
mm
3 and smaller
in.
mm
.001 to .002
0.02 to 0.05
0.05 to 0.1
18 to
3 to 6
. 002 to .004
to
6 to 13
. 004 to .007
0.1 to 0.18
to 1
13 to 25
. 007 to .015
0.18 to 0.38
1 to 1
25 to 38
. 015 to .025
0.38 to 0.63
Table 41.2 Drill feeds
41-69
Drill Feeds
General rule: feed rate increases as drill size
increases
Too coarse chip cutting edges
Too light chattering noise, dulls cutting edge
Hard steels or alloys use slower feed

Softer metals drilled with faster feed
Blue steel chips indicate too much heat at
cutting edge
Dull cutting edge or too high speed
41-70
Cutting Fluids
Provide both cooling and lubrication
Properties of an effective liquid in
dissipating heat
Able to absorb heat rapidly
Have good resistance to evaporation
Have high thermal conductivity
Oil: good lubricant, poor coolant
Water: best coolant, no lubricating value (promotes rust)
34-71
Cutting Fluids
Essential in metal-cutting operations to
reduce heat and friction
Centuries ago, water used on grindstones
100 years ago, tallow used (did not cool)
Lard oils came later but turned rancid
Early 20th century saw soap added to water
Soluble oils came in 1936
Chemical cutting fluids introduced in 1944
34-72
Economic Advantages to Using

Cutting Fluids
Reduction of tool costs
Reduce tool wear, tools last longer
Increased speed of production

Reduce heat and friction so higher cutting speeds
Reduction of labor costs

Tools last longer and require less regrinding, less
downtime, reducing cost per part
Reduction of power costs

Friction reduced so less power required by
machining
34-73
Heat Generated During

Machining
Heat find its way into one of three places
Workpiece, tool,
Act aschips
disposable
heat sink
Too much, cutting edge

will break down rapidly,
reducing tool life
Too much, work

will expand
34-74
Heat Dissipation
Ideally most heat taken off in chips
Indicated by change in chip color as heat
causes chips to oxidize
Cutting fluids assist taking away heat
Can dissipate at least 50% of heat created during
machining
34-75
Characteristics of a Good
Cutting Fluid
1. Good cooling capacity
2. Good lubricating
qualities
3. Resistance to
rancidity
4. Relatively low
viscosity
5. Stability (long life)
6.
7.
8.
9.
Rust resistance
Nontoxic
Transparent
Nonflammable
34-76
Types of Cutting Fluids

Most commonly used cutting fluids
Either aqueous based solutions or cutting oils
Fall into three categories

Cutting oils
Emulsifiable oils
Chemical (synthetic) cutting fluids
34-77
Oil Categories
Sulfurized mineral oils
Contain .5% to .8% sulfur
Light-colored and transparent
Stains copper and alloys
Sulfochlorinated mineral oils

3% sulfur and 1% chlorine
Prevent excessive built-up edges from forming
Sulfochlorinated fatty oil blends

Contain more sulfur than other types
34-78
Inactive Cutting Oils

Oils will not darken copper strip immersed
in them for 3 hours at 212F
Contained sulfur is natural
Termed inactive because sulfur so firmly
attached to oil very little released
Four general categories

Straight mineral oils, fatty oils, fatty and
mineral oil blends, sulfurized fatty-mineral oil
blend
34-79
Emulsifiable (Soluble) Oils

Mineral oils containing soaplike material
that makes them soluble in water and causes
them to adhere to workpiece
Emulsifiers break oil into minute particles
and keep them separated in water
Supplied in concentrated form (1-5 /100 water)
Good cooling and lubricating qualities

Used at high cutting speeds, low cutting
pressures
34-80
Functions of a Cutting Fluid

Prime functions
Provide cooling
Provide lubrication
Other functions
Prolong cutting-tool life
Provide rust control
Resist rancidity
34-81
Functions of a Cutting Fluid:

Cooling
Heat has definite bearing on cutting-tool wear
Small reduction will greatly extend tool life
Two sources of heat during cutting action

Plastic deformation of metal
Occurs immediately ahead of cutting tool
Accounts for 2/3 to 3/4 of heat
Friction from chip sliding along cutting-tool face
Water most effective for reducing heat (rust)
34-82
Functions of a Cutting Fluid:

Lubrication
Reduces friction between chip and tool face
Shear plane becomes shorter
Area where plastic deformation occurs
correspondingly smaller
Extreme-pressure lubricants reduce amount

of heat-producing friction
EP chemicals of synthetic fluids combine
chemically with sheared metal of chip to
form solid compounds (allow chip to slide)
34-83
Cutting-Tool Life
Heat and friction prime causes of cuttingtool breakdown
Reduce temperature by as little as 50F, life
of cutting tool increases fivefold
Built-up edge
Pieces of metal weld themselves to tool face
Becomes large and flat along tool face,
effective rake angle of cutting tool decreased
34-84
Application of Cutting Fluids

Cutting-tool life and machining operations
influenced by way cutting fluid applied
Copious stream under low pressure so work
and tool well covered
Inside diameter of supply nozzle width of
cutting tool
Applied to where chip being formed
42-85
Drill Press Safety

1. Do not operate before understanding
mechanism and how to stop
2. Always were approved safety glasses
3. Never attempt to hold work by hand
4. Keep your head back from revolving parts
5. As drill begins to break through work,
ease up on drill pressure
42-86
6. Always remove burrs from drilled hole

with file or deburring tool
7. Never leave chuck key in drill chuck
8. Never attempt to grab work that may have
caught in drill
Stop machine first
9. Always keep floor around drill press clean

and free of tools, chips, and oil
42-87
Drilling Hints
1. Treat cutting tools with care
2. Always examine condition of drill point
before use do not use dull tools
3. Make sure drill point angle correct for
type of material to be drilled
4. Set correct revolutions per minute for size
of drill and workpiece material
42-88
5. Set up work so drill will not cut into

machine as it breaks through workpiece
6. Work should always be clamped securely
7. End of workpiece farthest from hole
should be placed on left-hand side of table
so it will not swing toward operator
8. Always clean tapered drill shank, sleeve,
and machine spindle before inserting drill
9. Use shortest drill length possible and/or
hold it short in chuck
42-89
10. Good practice to start each hole with

center drill
Provides guide for drill to follow
11. Thin workpieces should be clamped to

hardwood block for drilling
12. Chips from each flute should be same
shape; if blue during drilling, check drill
point condition
13. Drill squeak usually indicates dull drill
14. When increased pressure must be applied
during drilling, reason usually dull drill or
chip caught in hole between drill and work
42-90
Measuring Size of a Drill

Good practice to always check drill for size
before drilling
Check for size
Drill gage
Micrometer
Most accurate
Check measurement across margin of drill
42-91
Lathe Center Holes

Use a combination drill and countersink
Commonly called
center drill
Must be drilled to correct

size and depth
Too shallow or deep,
poor support for work
42-92
Spotting Hole Location With a

Center Drill
Chisel end on drill wider than center-punch
mark on work
Spot center-punch mark with center drill
Small point on center drill will accurately follow

center-punch mark and provide guide for larger drill
42-93
Spotting Hole Location

With a Center Drill
1. Mount small-size center drill in drill chuck
2. Mount work in vise
Do not clamp
3. Set drill speed to 1500 r/min

4. Bring point of center drill into centerpunch mark and allow work to center itself
with drill point
5. Continue drill until one-third of tapered
section of center drill has entered work
6. Spot all holes to be drilled
42-94
Spotting Hole

42-95
Drilling Work Held in a Vise

1. Spot hole location with center drill
2. Mount correct-size drill in drill chuck
3. Set drill press to proper speed for size of
drill and type of material to be drilled
4. Fasten clamp or stop on left side of table
5. Mount work on parallels in drill vise and
tighten it securely
42-96
6. With vise against table stop, locate

spotted hole under center of drill
7. Start drill press spindle and begin to drill
Holes up to 12 in. hold vise against table

Holes over 12 in. Clamp vise to table
Drill until full drill point into work

With drill revolving, deep drill point in work and
tighten clamp holding vise
8. Raise drill occasionally and apply cutting

fluid during drilling
9. Ease up on drilling pressure as drill starts
to break through workpiece
42-97
Drilling to an Accurate Layout

1. Clean and coat surface with layout dye
2. Locate position of hole from
two machined edges of
workpiece and scribe lines
3. Lightly prick-punch where two lines
intersect
4. Check accuracy of punch mark
42-98
5. Scribe circle to indicate

diameter of hole
6. Scribe test circle .060 in. smaller than hole

7. Punch four witness marks
on circles up to .750 in. in
diameter and eight witness
marks on larger circles
8. Deepen center of hole location with center
punch to provide larger indentation for
drill to follow
42-99
9. Center drill work to just beyond depth of

drill point
10. Mount proper size drill in machine and

drill hole to depth equal to one-half to twothirds drill diameter
11. Examine drill indentation;
should be concentric with
inner proof circle

42-100
12. If spotting off center, cut

shallow V-grooves with cape
or diamond-point chisel on
side toward which drill must be moved
13. Start drill in spotted and grooved hole
Drill will be drawn toward direction of
grooves
14. Continue cutting grooves
into spotted hole until drill
point drawn to center
15. Continue to drill hole to desired depth
42-101
Drilling Large Holes

Drills increase in size; thickness of web also
increases to give drill strength
Thicker web, thicker point of drill
Thick web not follow center-punch mark easily
Two methods to overcome poor cutting

action of thick web on large drills
Web is thinned
Lead, or pilot, hole is drilled
42-102
Using Pilot Hole with

Large Holes
Drill pilot hole diameter which is slightly

larger than thickness of web
Care must be taken to drill pilot hole on
center
Pilot hole then followed with larger drill
Problems when pilot hole too large
Cause chattering
Drill hole out-of-round
Spoil top (mouth) of hole
42-103
Procedure for Drilling

Large Holes with Pilot Hole
1. Check print and select proper drill
2. Measure thickness of web at point
Select pilot drill with diameter slightly larger

than web thickness
3. Mount workpiece on table

4. Adjust height and position of table so drill
chuck can be removed and larger drill
placed in spindle after pilot hole drilled
and lock table
42-104
5. Place center drill in drill chuck, set proper

spindle speed, accurately drill center hole
6. Using proper-size pilot drill, drill pilot hole
7. Shut off machine, leaving pilot drill in hole
8. Clamp work securely to table
9. Raise drill spindle, remove drill and chuck
10. Clean taper shank of drill and spindle hole
11. Mount large drill in spindle
12. Set spindle speed, feed and drill hole to
required depth
42-105
Drilling Round Work in V-Block

1. Select V-block to suit diameter of work
2. Mount work in V-block and rotate it until
center-punch mark is in center of work
Check distance from both sides equal
3. Tighten U-clamp securely or hold work in

vise
4. Spot hole location with center drill
5. Mount proper drill size and set speed
6. Dill hole (do not hit V-block or vise when
drill breaks through work)
43-106
Reamers
Rotary cutting tool with several straight or
helical cutting edges along body
Used to accurately size and finish hole
previously formed by drilling
Two classifications
Hand
Machine
43-107
Reamer Parts
Three main parts

1. Shank
2. Body
3. Angle of chamfer
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
43-108
Hand Reamers
Finishing tools
Holes bored to .003-.005 in.
Square on shank for wrench
Teeth on end tapered so can enter hole easily
Never turn backwards
Taper hand reamers
Remove frequently to
clean

43-109
Machine Reamers
Used in any machine tool for both roughing
and finishing hole
Called chucking reamers for holding method
Wide variety of types and styles
Rose reamers
Fluted reamers
Carbide-tipped reamers
43-110
Fluted Reamers
Have more teeth than rose reamers for
comparable diameter
Lands relieved for entire length
Fluted reamers cut along side as well as at
chamfer on end
Considered finishing tools and used to
bring hole to size

43-111
Carbide-tipped Reamers
Similar to rose or fluted reamers, except
carbide tips been brazed to cutting edges
Resist abrasion and maintain sharp cutting
edges even in high temperatures
Outlast high-speed steel reamers

Can run at higher speeds and still maintain
their size

43-112
Shell Reamers
Reamer heads mounted on driving arbor
Shank of driving arbor may be straight or
tapered
Two slots in end of
reamer fit into lugs
on driving arbor
Sometimes locking
screw in arbor
43-113
More Reamers
Adjustable reamers
Have inserted blades that can be adjusted
approximately at .015 in over or under nominal
reamer size
Adjusting nuts on either end
Emergency reamers
Drills whose corners have been slightly rounded
and honed if reamer of particular size not
available
43-114
Another Reamer
Expansion reamers
Amount expanded limited
Body slotted and tapered, threaded plug fitted
into end
Turning this plug will allow 1 in. reamer to
expand up to .005 in.

43-115
Reamer Care
1. Never turn reamer backward; ruin edges
2. Always store reamers in separate containers
to prevent cutting edges from being nicked
3. Never roll or drop reamers on metal surfaces
4. When not in use, reamer should be oiled
5. Fine, free-cutting grinding wheel should be
used for resharpening reamers
43-116
Reaming Allowances
Amount of material left in hole for reaming
operation depends on number of factors
Type of machining operation prior to reaming
Hole punched, rough-drilled, bored
General rules for amount of material to

leave in hole for machine reaming
Holes up to .500 in. diameter, allow .015 in.
Holes over .500 in. diameter, allow .030 in.
43-117
Reaming Speeds
Factors for determining most efficient speed
Type of material being reamed
Rigidity of setup
Tolerance and finish required in hole
Generally reaming speed 1/2 to 2/3 speed used for

drilling same material
High speed used when setup rigid
Lower speed used when setup less rigid
Coolants improve surface finish and allow speed
43-118
Reaming Feeds
Feed used for reaming usually two to three
times greater than that used for drilling
Rate varies with material reamed
Generally .001 to .004 in. per flute per rev
Feed too low: glazing, excessive reamer
wear, chatter
Feed too fast: reduce hole accuracy, poor
surface finish
Exception: tapered holes need light feed
43-119
Reaming Hints
1. Examine reamer and remove all burrs from
cutting edges with hone
2. Cutting fluid should be used in reaming
operation to improve hole finish and
prolong life of reamer
3. Helical-fluted reamers should always be
used when long holes and those with
keyways or oil grooves are reamed
43-120
5. Straight-fluted reamers generally used

when extreme accuracy required
6. Use roughing reamer first and then
finishing reamer to obtain hole accuracy
and good surface finish
7. Never turn reamer backwards
8. Never attempt to start reamer on uneven
surface
9. Select reamer with incremental cut to
avoid chatter
10. Always use stub center in drill press
spindle to keep reamer aligned
43-121
Hand Reaming a Straight Hole
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
43-122
Procedure for Hand Reaming a

Straight Hole
1. Mount work on parallels in vise and clamp
it securely to table
2. Drill hole to proper size, leaving
allowance for hand reamer to be used
3. Do not move location of work or table;
remove drill and mount stub center in drill
chuck
4. Start end of reamer in drilled hole
43-123
5. Fasten tap wrench on reamer

6. Engage stub center in center hole on end of
reamer
7. With downfeed lever, apply slight pressure
while turning reamer clockwise by hand
8. Apply cutting fluid and ream hole
9. When removing reamer, turn it clockwise,
never counterclockwise
43-124
Machine Reaming a
Straight Hole
1. Mount work on parallels in vise and
fasten securely to table
2. Select proper-size drill for reaming
allowance required and drill hole
3. Mount proper reamer in drill press
4. Adjust spindle speed to suit reamer and
work material
43-125
5. Start drill press and carefully lower

spindle until chamfer on reamer starts to
cut
6. Apply cutting fluid and feed reamer by
applying enough pressure to keep reamer
cutting
7. Remove reamer from hole by raising
downfeed handle
8. Shut off machine and remove burr from
edge of hole
44-126
Counterboring
Operation of enlarging end of hole that has
been drilled previously
Depth slightly greater than head of bolt, cap
screw or pin it is to accommodate
Supplied in variety of styles

Each have pilot in end to keep tool in line with
hole
Some interchangeable pilots to suit variety of holes
44-127
Procedure to
Counterbore a Hole
1. Set up and fasten work securely
2. Drill proper size of hole in workpiece to suit body
of pin or screw
3. Mount correct size of counterbore in drill press
4. Set drill press speed to approximately one-quarter
that used for drilling
5. Bring counterbore close to work to see that the
pilot turns freely in drilled hole
6. Start machine, apply cutting fluid and counterbore
44-128
Countersinking
Process of enlarging top end of hole to
shape of cone to accommodate conicalshaped heads of fasteners
Head will be flush with or below surface
Countersinks available with various

included angles
60, 82, 90, 100, 110, and 120
44-129
Countersinking
82 countersink used to enlarge top of hole
so it will accommodate a flat-head machine
screw
Holes to be threaded
countersunk slightly
larger than tap diameter
Speed is approximately
1/4th of drilling speed
44-130
Procedure to Countersink a Hole

for a Machine Screw
1. Mount an 82 countersink in drill chuck
2. Adjust spindle speed to about that used
for drilling
3. Place workpiece on drill table
4. With spindle stopped, lower countersink
into hole
Clamp work if necessary
44-131
5. Raise countersink slightly, start machine,

and feed countersink by hand until proper
depth is reached.
Diameter checked by placing inverted screw

in countersunk hole
6. If several holes to
do, set depth stop
7. Countersink all
holes to depth
set on gage
44-132
Tapping
Performed by hand or under power with
tapping attachment
Done immediately after drilling operation
Hand taps
In sets containing taper, plug, bottoming tap
Machine taps
Designed to withstand torque required to
thread hole and clear chips
44-133
Set of Hand Taps
Taper
Plug
Bottoming
44-134
Types of Machine Taps
Gun
Stub-flute
Spiral-flute
44-135
Fluteless Tap
Actually a forming tool used to produce
internal threads in ductile material
Copper, brass, aluminum, and leaded steels
Fluteless tap
Lobes of the tap
44-136
Procedure to Tap a Hole by

Hand in a Drill Press
1. Mount work on parallels with centerpunch mark on work in line with spindle
and clamp work securely to drill press
table
2. Adjust drill press table height so drill may
be removed after hole has been drilled
without moving table or work
3. Center drill hole location
44-137
4. Drill hole to correct tap drill size for

tap to be used
5. Mount stub center in drill chuck
Or remove drill chuck and mount special

center in drill press spindle
6. Fasten suitable tap wrench on end of tap

7. Place tap in drilled hole, lower drill press
spindle until center fits into center hole
in tap shank
8. Turn tap wrench clockwise to start tap
9. Continue to tap hole, applying light pressure
44-138
Tapping Attachment
Mounted in a drill press spindle to rotate tap
by power
Built-in friction clutch that drives tap clockwise
when drill press spindle fed downward
Reversing mechanism to back tap out of hole
Two- , three-fluted machine or gun taps

used for power
Ability to clear chips
Tapping speed ranges from 60 100 r/min

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PowerPoint to accompany

Copyright The McGraw-Hill Companies, Inc.

Used primarily to produce holes in metal

Copyright The McGraw-Hill Companies, Inc.

Versatility of the Drill Press

Two common types

Held in spindle by self-holding

Types of Drill Chucks

Types of Drill Chucks

Drill Sleeves and Sockets

Modifications are doublefinger and gooseneck clamps

Twist Drill Parts

Stamped with letters H.S or H.S.S.

Three Main Parts

Copyright The McGraw-Hill Companies, Inc.

Copyright The McGraw-Hill Companies, Inc.

Is the relief ground on point of drill

Drill Point Characteristics

1. Control size, quality and straightness of

4. Increase strength of drill's cutting edges

7. Control amount of burr produced

Conventional Point (118)

Long Angle Point (60 to 90)

Flat Angle Point (135 to 150)

Four Systems of Drill Sizes

Number and width of flutes

High-speed steel drills

Oil Hole Drills

Used on turret lathes and screw machines

Copyright The McGraw-Hill Companies, Inc.

Copyright The McGraw-Hill Companies, Inc.

Saw-Type Hole Cutter

Drilling Facts and Problems

Excessive speed will cause wear at outer corners

Copyright The McGraw-Hill Companies, Inc.

Excessive clearance results in lack of support

Copyright The McGraw-Hill Companies, Inc.

Excessive feed sets up abnormal end thrust, which

Copyright The McGraw-Hill Companies, Inc.

Insufficient clearance causes the drill to rub behind

Copyright The McGraw-Hill Companies, Inc.

The web is the tapered central portion of the

Copyright The McGraw-Hill Companies, Inc.

Cutting lips with unequal angles will cause one

Copyright The McGraw-Hill Companies, Inc.

Cutting lips unequal in length cause chisel point

Copyright The McGraw-Hill Companies, Inc.

Loading and galling is

Length of both cutting lips equal

Note: Resharpen drill if it does not meet

Conditions That Indicate Drill

Color and shape of chips change

Factors Causing Premature

Procedure to Grind a Drill

4. Examine drill point and margins for wear

5. Hold drill near point with one hand, other

8. Bring lip of drill against grinding wheel

9. Remove drill from wheel without moving

Copyright The McGraw-Hill Companies, Inc.

Cutting Speeds and Feeds

Speed of twist drill referred to as cutting

Recommended Cutting Speeds

Economical Drilling Speed