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08 drilling
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- 2. • Drilling coversthe methods of making cylindrical holes in a workpiece with metal cutting tools. • The machine tool is called a drill. • Typical operations: trepanning, counterboring, countersinking, reaming, boring, and tapping,,… • Common to all these processes is a main rotating movement combined with a linear feed. • Demands on chipbreaking and the evacuation of chips is critical in drilling. Drilling- Introduction
- 3. INTRODUCTION Brace (tool), 1420 Bowdrill (strap-drills) 10,000 years ago First table top drilling machine 1838 Pump drill Roman Era, 510 years BC Gimlet, 1750 Auger, 1800
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- 6. 1.Turret Drilling machine MACHINETYPES VIDO Video
- 7. MACHINE TYPES 2. RadialDrilling machine Video
- 8. 3.Pillar Drilling machine MACHINETYPES Video
- 9. 4. CNC Drillingmachine MACHINE TYPES VIDEO Video
- 10. MACHINE TYPES 5.Multi Spindleor Gang Drilling machine Gang-drilling machine Multi spindle machine VIDEO Video
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- 13. Plain vise Plainvise with swivel base Universal vise Angle vise Compound vise WORKHOLDING DEVICES Vise Magnetic vise
- 14. Clamps • Used forbig size or irregular parts. • Part is hold using clamps, t-slot bolts, screws, washers, nuts, parallels, step blocks,… It is important to keep in mind the efforts/deformations produced on the part. WORKHOLDING DEVICES Step block Angle plate Toe mold clamp Cam clamp Washer C clamp V blockSwing clamp T-nut T-slot bolt
- 15. WORKHOLDING DEVICES By hand Usingthe hands (long parts) Using a hand vise (short parts) Special holding devices
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- 17. Drill chuck KEY TYPECHUCK KEYLESS CHUCK TOOL HOLDING DEVICES Morse Taper Shank Straight Shank • It is used to hold cylindrical shank drills.
- 18. Drill sleeve TOOLHOLDING DEVICES •It is used to hold tapered shank drills. • For too SMALL drills for the tapered hole in the spindle. Drill socket • It is used to hold tapered shank drills. • For too LARGE drills for the tapered hole in the spindle.
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- 21. • The lowestprice per hole. • Very versatile tool (capable of drilling, re-drilling, facing). • Bigger diameter than solid carbide drills. MACHINING OPERATIONS DRILLING. Drill types Indexable insert drill Brazed carbide drill • For small diameter holes. • Drilling depths up to 15xD • Tight tolerances. • Alternative to solid carbide drill for large diameters and a high stability Is needed (less sensitive steel body). Solid carbide drill
- 22. MACHINING OPERATIONS • Standarddiameters up to 110mm. • Interesting when machine power is limited (lower power consumption than using conventional driills). • Long diameters up to 72 x D. DRILLING. Drill types • Standard diameters up to 80mm. Trepanning Deep hole drill VIDEO Big diameter drill
- 23. 5xD MACHINING OPERATIONS 10xD Dc 15xD L/Dc Solid carbidedrill Deep hole drilling 10 20 30 40 50 60 70 80 110 Trepanning Small length drill Brazed carbide drill Big diameter drill DRILLING. Drill types
- 24. Counter boring DRILLING. Machiningoperations MACHINING OPERATIONS Reaming Counter sinking TappingCenter drilling Spot facing Tapered drilling Redrilling Step drilling Drilling Deep hole drilling Trepanning
- 25. MACHINING OPERATIONS Countersinking Counterboring Trepanning Video VideoVideo
- 26. MACHINING OPERATIONS Deep holedrilling Reaming Step drilling Tapping Video’s
- 27. It is themost common drilling operation, where a hole is drilled in solid material. Through hole Blind hole SPOT DRILLING • The purpose of spot drilling is to drill a hole that will act as a guide for drilling the final hole. • Used in milling and drilling machines. CENTER DRILLING • The purpose of center drilling is to drill a hole that will act as a center of rotation for possible following operations. • Used in turning machines. VIDEO MACHINING OPERATIONS VIDEO Spot drilling / Center drilling Drilling
- 28. Trepanning MACHINING OPERATIONS • Trepanningis commonly used for creating larger diameter holes (up to 1.000 mm) where a standard drill bit is not feasible or economical. • The trepanning tool does not machine the whole diameter, only a ring at the periphery. • In horizontal set-ups, long and heavy cores may require a core support to prevent the core from falling down (not in vertical). • This method is for through-hole applications. Redrilling or boring • It consists on increasing the hole size. Video
- 29. Counterboring Countersinking MACHINING OPERATIONS The toolis called “counterbore”, and it has a pilot to guide the cutting action. It is commonly used for: • enlarging a hole to make a bolt head fit flush with the surface. • spot facing in workpieces that are forged or casted. IDEO • This process is similar to counterboring, but the step in the hole is cone- shaped. • The tool is called “countersink”. A common use is: • to allow the head of a countersunk bolt or screw, when placed in the hole, • to sit flush with or below the surface of the surrounding material. • to remove the burr left from a previous drilling or tapping operation. • to enhance pin entry. VIDEO VIDEO
- 30. a) Manual reamers:long entry (A) and length (L) Milling reamers: short entry (A) and length (L) Reamer with no shank or separated shank. b) c) VIDEO MACHINING OPERATIONS The reamer never should be spinned counterclockwise. Reaming Straight flute Axial coolant supply For blind holes Spiral flute Lateral coolant supply For through holes RIGHT WRONG • Objective: To achive a good surface roughness and good dimensional tolerances (H7) in a pre-drilled hole. • High penetration rates and small depths of cut. • The tool is called “reamer”.
- 31. Taper drilling MACHINING OPERATIONS •Taper drills were engineered to be used to pre drill the pilot holes for the shank and threaded portion of a wood screw. Step drilling • The tool is called “step drill”. • The transition between this ground diameter and the original diameter is either straight, to form a counterbore, or angled, to form a countersink. • These drills are limited to use on thin material (e.g. sheet-metal work). • Improves production times, reduces number of drills. VIDEO
- 32. • The toolis called “tap”. • It is commonly used for small threads. Used for manual or automatic operations. Straight flute tap Spiral point tap Spiral flute tap Forming tap Tapping MACHINING OPERATIONS 1- Tapping: Rough Intermediate Finish MANUAL OPERATION Hand tap wrench T-handle tap wrench AUTOMATIC OPERATION
- 33. • The toolis called “die”. • It is commonly used for small threads. • Used for manual operations. • a)Within the lathe. b) In a bench vise. Main spindle (chuck) Part Die Stock (handle) VIDEO 2- Die threading: b) a) Die Stock (handle) MACHINING OPERATIONS Die handle Tapping MANUAL OPERATION
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- 35. STACK DRILLING Steel DRILLING APPLICATIONS ROTORBLADE Composite or carbon fiber
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- 38. MACHINING TIME Determine thecutting time needed to drill the steel part of the figure, knowing that a rough operation will be carried out using a twist drill with a tip angle of H=118°. The entry and exit security distance are 3mm. For additional cutting data, please refer to “Cutting parameters” section at the end of this presentation. DRILLING MACHINE WORKPIECE TOOL MATERIAL OPERATION Vc fn MATERIAL (m/min) (mm/rev) DRILLING MACHINE STEEL HIGH SPEED STEEL (HSS) ALUMINIUM HIGH SPEED STEEL (HSS) Spot drilling 18 0.04 – 0.1 Drilling 18 0.04 – 0.1 Counterboring 9 Countersinking 9 Spot drilling 30 – 40 0.04 – 0.1 Drilling 30 – 40 0.04 – 0.1 Counterboring 15 – 20 Countersinking 15 – 20