03‐09‐2018

Drilling Process and Tool Geometry Outline

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• Hole making Processes - Overview

• Drill Point Geometry
• Mechanics of Drilling
Prof. S. S. Pande
• Problems in Drilling
− Special Drill Points
Mechanical Engineering Department
Indian Institute of Technology, Bombay

What is a Hole? Types of Holes

Internal functional Cavity or a Passage • Circular / Noncircular

in a part. • Through/ Blind
Applications
• Plain/ Threaded
• Coolant (Fluid ) Flow
• Compound
• Lubrication passage
− Counter Bore
• Fastener locations for Assembly
• Motion between parts − Counter Sunk

Hole Requirements Hole making Processes

• Based on Diameter • Hole Generation

− Normal range
− Drilling, Punching, EDM, LBM, EBM
− Micro holes -50 -1000 microns
• Hole Enlargement
• Based on L/D ratio
− Core drilling, Counter Bore/ Sunk, WEDM
− Normal range (L/D < 5)
• Hole Finishing
− Extra Long and Deep Holes
− Reaming, Boring, Grinding

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Hole Enlarging Tools Hole Finishing and Forming Tools

Counter Bore

Reamer – Finishing Tool Tap – Thread cutting

Core Drills

Counter Sunk

Micro Hole Applications

Micro Drilling Processes - Comparison

Parameters Laser EDM ECM Electron Ultrasonic

Beam

Hole Size (μm) 50-400 >100 >50 80-200 100-500

Surface
20 6 6 4 10
Roughness(μm)

Dim. Accuracy
0.05-0.2 ±0.025 ±0.025 ±0.025 ±0.025
(μm)

Cooling Turbine Array in Silicon Micro holes in glass Drilling speed

Common <1 >0.05 0.125 <1 N/A
blades Carbide wafers Size: 5 microns (mm/s)
Size: 50 microns

Drilling Twist Drill

N
Primary Process of Hole Production
feed

• Drill Rotates and Feeds into job

• Drill geometry
− Cone Point – machines hole
− Flutes – Chip and coolant flow
− Shank – Holding
Workpiece
• Drill has Two Helical Flutes

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Drill Point Geometry

• Drill – a complex cutting tool

• Two cutting edges (Lips)
• Curved Rake and Relief surfaces
• Complex cone point geometry
• Oblique cutting phenomena
− Severe chip deformations

Elements of a Drill Point

• Cone Point – Roof Top geometry
− Point Angle
• Helix Angle
• Rake Angles
− Axial and Normal
• Chisel Edge
• Web Thickness/ web Taper
• Clearance / Relief angles

Drill Point Angle

• Governs Smoothness of drill entry into part

• Decides cutting edge Lip length for a drill diameter

, Point angle = 2ϱ
ϱ
• Governs relation - Normal and Axial Rake angles
• Point angle depends on work material

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Drill Point Angles Helix and Rake Angles

• Helix angle at drill periphery is

• Axial Rake angle
• Cutting edge Lip has a Curved Rake face
• Axial and Normal Rake angles exist for a lip
• Rake angle varies along the drill Lip
− Reduces towards axis
− Negative at Chisel edge (near axis)

Rake Angle Variation along Lip Drill Helix Angle

-56 -15 + 12
34 – 38 deg

28 – 32 deg

+ 28

12 – 22 deg

Web and Chisel Edge Web Thickness

• Web - Material between Drill Flutes

• Governs Torsional rigidity of drill
• Trade off - Flute area (Volume) and Rigidity
• Web thickness varies in Regrinding
− Web Taper

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Chisel Edge Web Thinning

• Sharp edge
• Intersection of cone point surfaces
• Non cutting action at chisel edge
− Indentation
− Near zero velocity

• Generates Very High Axial Force

− 60-70 % of Thrust Force

Mechanics of Drilling Forces in Drilling

N Drill Feed f N
Feed f
2 Thrust Force F = f (PX)
f/2
D = Drill Dia
Torque M = f (Pz)
Chip Area

.
Chip area per lip =

MRR =

Torque and Thrust Oxford Equation

Thrust Force : F . Thrust F (N)

. .
Torque : M= . 10 x 0.195 0.0022
Torque M (Nm)
Constants - C1 , C2, n1 , n2 , n3 , n4
. .
depend on work material. M 2 10

Experimentally derived empirical equations. HB = Brinell Hardness Number of material

D = Drill diameter in m
F = feed in m/rev

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Machining Time Problems in Drilling

L = Lip Height
• Drill walk and wobble
D f
− Lack of Centering - Location error
H = Hole depth
2 − Oversize holes – Circularity error
O = Overtravel (Thru) L • Axis bending – Straightness error
f = feed mm/rev
• Burr production
N = rpm H
− Material extruded but not cut
Machining Time (t)
O
Primary Cause
L+H+O
t= • Large Axial Thrust force – Chisel Edge
f.N
• Unequal lips –wobble

4 Facet Point - Split Clearance Faces

Special Drill Points

• Split point
− 4 Facet Drill, Crankshaft point

• Spiral Point
− Spiro Helicoidal relief surface
− S shaped chisel edge
− Significant reduction in Thrust force

Spiral Point Geometry

Excellent Self Centering

Burr control