HOLEMAKING

Design Concept Drilling

P. S. Rajkumar
Asst. Manager, Application Engg (Round Tools)

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Solid Carbide Indexable

Carbide Modular

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Drill Definition
A drill is a rotary-end
cutting tool with one or
more cutting edges or lips
and one or more straight
or helical grooves called
flutes, designed for the
passage of chips, cutting
fluids and coolants.

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Basic Drill Components

Point Body Shank

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 Chisel Edge

Chisel-Edge
Angle Chisel Edge

Drill
Diameter

Chisel Edge
Length

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Common Chisel Styles

Conventional

Split Spiral
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 Chisel Effects

The chisel edge deforms material; cutting does not usually

start until “lips” engage.

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 Chip Formation
Mid cutting lip

End of
chisel edge
start of
cutting lip

Mid chisel
edge

Drill center

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Chip Formation

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Basic Cutting Tool Geometry

SCEA

Side Cutting Edge Angle

Back Rake
Side Rake

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Drill Point & Rake Angles

Axial
Rake

Radial Point
Rake Angle

Cutting Edge
(Lip)

Outer Corner
(Cutting Point)

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 Rake Angle Effect
(+) Rake Angle

Chip

Depth of Cut

Tool
E

Work

Shear Plane

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 Rake Angle Effect
(-) Rake Angle

Chip

Depth of Cut
Tool
E

Work

Shear Plane

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 Angle Equivalents

Thrust
(Feedforce)
Drills Single Point
Point Angle = SCEA (Lead)

Helix Angle = Back Rake

Torque
(Axial Rake)

Chisel Angle = Side Rake

(Radial Rake)

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Material cross
Point Angle
section (118
degree) at
exit is too thin
to be cut.
Material is
pushed out
forming an
exit burr.

Leads
to

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Effects of Helix Angle on Axial Rake

Higher Axial Rake Angle-freer cutting +

+
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Axial Rake Angle Comparison

~30°
0°

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 Effects of Point Angle on Rake
The effective rake angle is the
angle taken in a plane at right
angles to the cutting edge
Small included angle = small effective rake
•Lower thrust

Effective Rake
Angle
Larger included angle = higher
effective rake
•Approaches helix angle
•Freer cutting
•Higher thrust
Effective Rake
Angle 20
 Point Angle vs. Chip Management
Force
Force Force

Chip forced
Chip forced Theoretical flute
into web
up flute
Thinner Chip
Thicker Chip Thickest Chip

.016 Programmed Feed

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 Common Angles
These Angles Determine The Effective
Back Rake Angle!

Point Angles – 90 150° (180°?)

Helix Angles
Low – 15 20°
Drills Single Point
Medium – 25 33° Point Angle = SCEA (Lead)

High – 35 40° Helix Angle = Back Rake

(Axial Rake)

Chisel Angle = Side Rake

(Radial Rake)

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Point Geometry Effects
Torque Thrust
Point
Angle

Helix
Angle

Radial
Rake

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 Point Style

TX SE TF

Centering Ability +

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 Clearance Angles
Margin
(No Radial Clearance)

Lip Relief
Angle

Flank

Body Point
Clearance Angle
(Radial)
Drill
Diameter

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 Drill Body
Body Length
Flute Length
Helix
Core Angle

Fluted Flute Back

Land Taper
Web Land Heel
Thickness

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Flute Form

• Affects Shape &

Strength of The
Cutting Lip

• Affects Chip
Evacuation Space

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 NEW
Flute Profile
OLD
KSEC
Patented High
Performance SE KSE

New:
•Flute Design
•TiAlN Coating
•Flute Polish

+ Chip Evacuation

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 Flute Profiles
Conventional Profile Optimized Profile
• Higher Rigidity
• Improved Chip Flow

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 Flute Design Concepts
Rolling Heel

Taper Web

Parabolic Flute Drill

Parallel Web

Conventional Drill

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 Drill Body
Body Length
Flute Length
Helix
Core Angle

Fluted Flute Back

Land Taper
Web Land Heel
Thickness

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 Cores / Webs
Web
Thickness
“The thickness of the web at
the point unless another Flute
specific location is indicated” “Run-out”

Web (Core)
“The central portion of the
body that joins the lands”

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 Web Thickness Effects
Thrust

Web
Thickness
A 0.020”(.5mm)
2 .12
⎡d d ⎤
Thrust = Kf 0 .7 ⎢ + 0 ⎥ increase in web
⎣5 d ⎦ thickness can
Which Means…..
K = Material Factor result in a 50%
f = Feedrate increase in
d = Drill Diameter thrust!
d 0 = Web Diameter @ Chisel

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 Web Thinning
Conventional Split Point Gash (Notch)Type

Stock is removed Two secondary back-off Grinding two

in such a way grinds, adjacent to half-round
as to follow the chisel and almost gashes near the
the flute contour. to center center of the drill

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Web Thickness Guidelines
Drill Size, Number and Web Thickness Percent of
Fractional, Millimeters Drill Diameter

Nos. 97 to 66 (o.15 - 0.85) 30

Nos. 65 to 56 (0.89 - 1.18) 25
No 55 to 3/16 (0.0520 - 0.1) 20
3/16 to ¼ (4.76 - 6.35) 17
¼ to 5/8 (6.35 - 15.875) 15
5/8 to 1 3/8 (15.875 - 34.925) 13
1 3/8 to 2 3/8 (34.925 – 60.325) 12
Over 2 3/8 (60.325) 11

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 Web (Core) Types
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Parallel Increased Parallel

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Increased Increased Parallel

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Negative Negative Parallel

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 Core Thickness
Short & Regular Long All TX, and
Length SE Length SE 4-Margin SE(SE256)

Tapered to Parallel Constant Parallel

to Tapered Taper

+
+Point Strength Bulk Strength Chip Evacuation+
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 Web (Core) Effects

• Directly influences overall torsional &

compressive strength of the drill
• Determines chip shape
• Determines chip evacuation

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 Effects of Regrinding
Resharpening a twist drill results in increasing the web thickness and
chisel edge length and decreases the drill diameter.

Section Web
A-A thickness
A A

Chisel edge
length Drill
Diameter

Section Web
B B-B thickness
B

Chisel
edge length
Drill
Diameter
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 Resharpening an SE Drill
Resharpening decreases Web Thickness, Chisel Length and Diameter

Section Web Thickness

A-A
A A

Chisel
Length
Diameter

Section Web Thickness

B B
B-B

Chisel
Length Diameter
Constant Taper
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 Chip Control

• Drill Point
Geometry
• Flute Shape
• Flood Coolant
• Internal Coolant
• Spray Mist
• Compressed Air

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 Useful Drilling Formulae
π ⋅D ⋅N
V = (m/min)
1000
V ⋅ 1000
N = ( rpm )
π ⋅D
Torque
T =
l
(minutes )
C
f ⋅N
π ⋅D ⋅ f ⋅N V ⋅D ⋅ f
Q = = ( cc/min)
4 4
4 ⋅ π ⋅ N ⋅ F Tq
l HP C = ( Horsepower )
4000
F Tq ( Torque ) = 0 . 634 ⋅ f 0 . 8 ⋅ D 1 . 8 (N - M)
F Th ( Thrust ) = 1446 ⋅ f 0 .8
⋅ D 0 . 8 + 4 . 31 ⋅ D 2 (N )

V = Cutting Speed (m/min)

f = Feedrate (Mm / revolution)
Where:
D = Diameter of Drill (mm)
Thrust l = Length of Hole (inches)
N = Revolutions Per Minute
TC = Cut Time (minutes)
Q = Metal Removal Rate (cubic centimetre / minute)
HPC = Cutting Horsepower
FTq = Torque ((N - M)
FTh = Thrust ( N)
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Minimize Run-OUT…..!

.001” TIR or Better

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