COURSE: MANUFACTURING TECHNOLOGY/WORKSHOP PRACTICE COURSE CODE: MEE 207 LECTURE NOTE DRILLING Drilling is the operation of producing circular hole in the work-piece by using a rotating cutter called DRILL. "The machine used for drilling is called drilling machine. * The drilling operation can also be accomplished in lathe, in which the drill is held in tailstock and the work is held by the chuck "The most common drill used is the twist drill, Drilling Machine + Itis the simplest and accurate machine used in production shop. * The work piece is held stationary ie. Clamped in position and the drill rotates to make a hole. Types 1) Based on construction: Portable, Sensitive, Radial, up-right, Gang, Multi-spindle 2) Based on Feed: Hand driven Power driven Components of drilling machine Spindle The spindle holds the drill or cutting tools and revolves in a fixed position in a sleeve.Sleeve The sleeve or quill assembly does not revolve but may slide in its bearing in a direction parallel to its axis. When the sleeve carrying the spindle with a cutting tool is lowered, the Cutting tool is fed into the work: and when it’s moved upward, the cutting tool is withdrawn from the work. Feed pressure applied to the sleeve by hand or power causes the revolving drill to cut its way into the work a fraction of an mm per revolution, Column The column is cylindrical in shape and built rugged and solid. The column supports the head and the sleeve or quill assembly. Head The head of the drilling machine is composed of the sleeve, a spindle, an electric motor and feed mechanism. The head is bolted to the column. Worktable The worktable is supported on an atm mounted to the column. The worktable can be adjusted vertically to accommodate different heights of work or it can be swung completely out of the way. It may be tilted up to 90 degree in either direction, to allow long pieces to be end or angle drilled. Base The base of the drilling machine supports the entire machine and when bolted to the floor, provides for vibration-free operation and best machining accuracy. The top of the base is similar to the worktable and may be equipped with t- slot for mounting work too larger for the table. Hand Feed The hand- feed drilling machines are the simplest and most common type of drilling machines in use today. These are light duty machine that are operated by the operator, using a feed handled, so that the operator is able to “feel” the action of the cutting tool as it cuts through the work piece. These drilling machines can be bench or floor mounted, Power feed The power feed drilling machine are usually larger and heavier than the hand feed ones they are equipped with the ability to feed the cutting tool in to the work automatically, at preset depth of cut per revolution of the spindle these machines are used in maintenance for medium duty work or the work that uses large drills that require power feed larger work pieces are usually clamped directly to the table or base using t-bolts and clamps by a small work places are held in a vise. A depth ~stop mechanism is located on the head, near the spindle, to aid in drilling toa precise depth. Sensitive or Bench Drilling Machine© This type of drill machine is used for very light works. Fig.1 illustrates the sketch of sensitive drilling machine. * The vertical column carries a swiveling table the height of which can be adjusted according to the work piece height. * The table can also be swung to any desired position. * At the top of the column there are two pulleys connected by a belt, one pulley is mounted on the motor shaft and other on the machine spindle. Vertical movement to the spindle is given by the feed handle by the operator. Operator senses the cutting action so sensitive drilling machine. * Drill holes from 1.5 to 15mm STEP CONE = 1 PULLEY ~~ BELT Ol L. PEED lqotor| HANDLE OS { SPINDLE Heap ——— spinpie DRILL ————+] TABLE taste —[ES SSS came nS ae BASE Fig.1. Sensitive Drilling Machine Up-Right Drilling Machine © These are medium heavy duty machines © It specifically differs from sensitive drill in its weight, rigidity, application of power feed and wider range of spindle speed. Fig.2 shows the line sketch of up-right drilling machine, * This machine usually has a gear driven mechanism for different spindle speed and an automatic or power feed device. © Table can move vertically and radially. © Drill holes up to 50mmpa HORE Fig.2 Up-Right Drilling Machine Radial Drilling Machine Radial drilling machine belong to power feed type. Fig.3 shows the line sketch of radial drilling machine. Ej | [ }> ee coun —| 2 | ci { | TABLE Fig. 3 Radial Drilling Machine It the largest and most versatile used for drilling medium to large and heavy work pieces. The column and radial drilling machine supports the radial arm, drill head and motor. 1 MOTOR FOR ELEVATING ScREW Moron Fon s see Ea ane | |e ‘The radial arm slides up and down on the column with the help of elevating screw provided on the side of the column, which is driven by a motor.© The drill head is mounted on the radial arm and moves on the guide ways provided the radial arm can also be swiveled around the column. © The drill head is equipped with a separate motor to drive the spindle, which carries the drill bit. A drill head may be moved on the arm manually or by power. © Feed can be either manual or automatic with reversal mechanism. Drill Materials ‘The two most common types are 1. HSS drill - Low cost 2. Carbide- tipped drills ~ high production and in CNC machines Other types are Solid Carbide drill, TiN coated drills, carbide coated masonry drills, parabolie drills, split point drill. Fig.4 shows various types of drills (a) Tose drt (©) Steaighe-fute deh GE? i () swp du (@) Spade dell DET GEE fe) Gun drt (1. Dt ttl erent emetic ti artite ort veay —f€2 Brill with indexable. carbide inserts Gow-allay ~ ae aD arbi haere rig. 4 Various types or aruDrill fixed to the spindle |—Drill ‘Chuck Siot j—Twist Drill Tang Drill Chuck ‘Twist Drill Fig, 5 Drill fixed to a spindle Tool Nomenclature Body Flute Web Shank Margin Cutting Edge Body Lip, clearance Margin Chisel edge HealFig. 6 Nomenclature of twist drill Tool holding devices Fig.7 and Fig.8 shows the different work holding and drill drift device. The different methods used for holding drill in a drill spindle are + By directly fitting in the spindle hole. «By using drill sleeve By using drill socket By using drill chuck (0 ont ence St TES Fig. 8 Dri Ovit Drilling operations Operations that can be performed in a drilling machine are Drilling Reaming Boring Counter boring Countersinking Tapping vvvyvyDrilling: It is an operation by which holes are produced in solid metal by means of revolving tool called ‘Drill’. Fig. 9 shows the various operations on drilling machine, Reaming: Reaming is accurate way of sizing and finishing the pre-existing hole ‘Multi tooth cutting tool. Accuracy of +0.00Smm can be achieved Boring: Boring is a process of enlarging an existing hole by a single point cutting tool. Boring operation iS often preferred because we can correct hole size, or alignment and ean produce smmacth fais achieved, ‘Counter Boring Driling ‘Tapping Boring | Rearing ‘Countersinking Fig. 9 Various operations on drilling machine Counter Bore:- This operation uses a pilot to guide the cutting action to accommodate the heads of bolts, Fig, 10 illustrates the counter boring, countersunk and spot facing processes. Countersink:- Special angled cone shaped enlargement at the end of the hole to accommodate the screws. Cone angles of 60°, 82°, 90°, 100°, 110°, 120°Countersunk hole Counterbored hole Spot faced hole Fig. 10 Counter boring, countersunk and spot facing Tapping: Tapping is the process by which internal threads are formed. It is performed either by hand or by machine. Minor diameter of the thread is drilled and then tapping is done. Fig. 11 show the tapping processes.“TAP WRENCH Intermediate Finisher Hard Tepping using Tap Wrench Hand Taps Fig. 11 Hand taps and tapping process using tap wrench 2 g Pe Fg 2 8 a 8 3 2 Bis id Riccaaylen. gid wre S93 £ £ &€ » 8 2 ge & 8 RoR og So 8 8 k & By —Herpresure Fig. 12 Various operations performed on drilling machine Work Holding Devices 1. Machine Table Vice 10The machine vice is equipped with jaws which clamps the work piece. The vice can be bolted to the drilling table or the tail can be swung around swung around, Fig. 13 shows the standard and swivel vice. The swivel vice is a machine wise that can be swivel through 360° on a horizontal plane. ‘Standard mechire table vie Fig. 13 Machine Table vice. 2. Step Blocks These are built to allow height adjustment for mounting the drilling jobs and are used with strap clamps and long T-slot bolts. Clamps These are small, portable vises , which bears against the work piece and holding devices. Common types of clamps are C-clamp, Parallel clamp, machine strap clamp, U- clamp etc.. Fig. 14 shows the correct and incorrect methods of mounting the work piece. th TOT EO UA Correct method Incorrect method Fig. 14 Correct and incorrect methods of clamping the work piece. Block ARON 14, V-Blocks These are designed to hold round work pieces, 5. Angles Angle plates are made in a 90°angle with slots and bolt holes for securing work to the table. 6. Jigs The jig guides the drill through a bushing to locate and drill holes accurately. 7. T- Slots Bolt ‘These are special bolts which has a T shaped head, which slides into the T slots of drilling machine work table, Definitions 1. Cutting Speed (v):- It's the peripheral speed of the drill.The cutting speed depends upon the properties of the material being drilled, drill material, drill diameter, rate of speed, coolant used etc... v=TII*D*N where D= dia of the drill in m N= Speed of rotation in rpm 2. Feed Rate (f):- It's the movement of drill along the axis (rpm) 3. Depth of Cut (d):- ‘The distance from the machined surface to the drill axis, d=D/2 As the depth of hole increases, the chip ejection becomes more difficult and the fresh cutting fluid is not able to cutting zone. Hence for machining the lengthy hole special type of drill called ‘gun drill is used. 4. Material Removal Rate:- 2It’s the volume of material removed by the drill per unit time MRR=(IID2/4)*f*N mm3/min 5. Machining Time (T) :- It depends upon the length (1) of the hole to be drilled , to the Speed (N) and feed (f) of the drill t=L/fNmin Precautions for Drilling machine Lubrication is important to remove heat and friction. Machines should be cleaned after use Chips should be removed using brush. T-slots, grooves, spindles sleeves, belts, and pulley should be cleaned. Machines should be lightly oiled to prevent from rusting Safety Precautions Do not support the work piece by hand ~ use work holding device. Use brush to clean the chip No adjustments while the machine is operating Ensure for the cutting tools running straight before starting the operation. Never place tools on the drilling table Avoid loose clothing and protect the eyes. Ease the feed if drill breaks inside the work piece. 13WOODWORK WORKSHOP Woodwork workshop is a shop that offers instruction in all aspects of woodworking including furniture design, cabinet making, wood turning and carving. A standard woodwork workshop is equipped with extensive tools and machinery, a finishing room equipped with a spray booth and a studio for matting and framing photos, prints, posters, and drawings. Below are some of the common tools and equipment use in woodwork workshop. SOME COMMON TOOLS AND EQUIPMENT USED IN WOODWORK WORKSHOP NAME DESCRIPTION/USES A cross cut saw usually has smaller teeth than a rip saw (cut at 60°) and is used when cutting across the grain of wood. The blade does flex slightly Cross cut saw A rip saw has large teeth like chisels that cut along the grain and is used for cutting large pieces of wood. The blade does flex slightly, A coping saw cuts when pulled and has a small detachable blade which is easily removed. This saw is ideal for cutting round curves, A tenon saw is a small saw with a brass back which keeps the blade very straight. Ideal for cutting small pieces of wood in a straight line, Most saws cut when they are pushed away from the user. Tenon saw 14‘Compass saw Ithas a narrow, longer and stronger tapering blade, which is used for heavy works (Fig. 1.13). It is mostly used in radius cutting. The blade of this saw is fitted with an open type wooden handle, Itis the most commonly used general purpose plane. It is about 35 em long. The cutting iron (blade) should have a cutting edge of slight curvature. It is used for quick removal of material on rough work and is also used in oblique planning, A block (jack) plane is used for planning the end grain of @ piece of wood Smoothing plane ‘A smoothing plane is used to get a smooth finish on timber before abrasive paper is used for the final smooth finish. It is used for finishing work and hence, the blade should have a straight cutting edge. It is about 20 to 25 em long. Being short, it can follow even the slight depressions in the stock, better than the jack plane, It is used after using the jack plane. Rebate plane tis used for making a rebate. A rebate is a recess along the edge of a piece of wood, which is generally used for positioning glass in frames and doors. 15Itis used to cut grooves, which are used to fix panels in a door. Spoke shave ‘A spoke shave is used to smooth curved edges A bevel edges chisel can be used to cut and trim would where the Mortise chisel Mortise chisels are strong with straight sides made from steel. It is used for cutting mortises and chipping (chopping) inside holes in timber (eg slots for mortise joints). The cross-section of the mortise chisel is proportioned to withstand heavy blows during mortising. Further, the cross-section is made stronger near the shank 16‘A gouge chisel has a curved blade for carving Firmer chisel The word ‘firmer’ means ‘stronger’ and hence firmer chisel is stronger than other chisels. It is a general purpose chisel and is used either by hand pressure or by a mallet. The blade of a firmer chisel is Flat. Ithas a blade with a beveled back, as shown in Figure, due to which it can enter sharp comers for finishing, as in dovetail joints. 7Woodworking vice A hand held saw is also used for cutting timber in straight lines, but has the advantage of portable which is very useful for site work. Hand held sander Hand held sanders are used for finishing timber to a smooth finish prior to applying ‘wood stain or varnish. Marking Guage Ttis a tool used to mark lines parallel to the edge of a wooden piece. It consists of a square wooden stem with a sliding wooden stock (head) on it. On the stem is fitted a marking pin, made of steel. Carpenter brace ‘Carpenter's brace Itis used for rotating auger bits, twist drills, etc., to produce holes in wood. In some designs, braces are made with ratchet device. With ‘this, holes may be made in a corner where complete revolution of the handle cannot be made. The size of a brace is determined by its sweep. 18tis the most common tool used for making holes in wood. During drilling, the lead sctew of the bit guides into the wood, necessitating only moderate pressure on the brace. The helical flutes on the surface carty the chips to the outer surface. Auger bit Carpenter's brace is used to make relatively large size holes; whereas hand drill is used for drilling small holes. A straight shank drill is used with this tool. It is small, light in weight and may be conveniently used than the brace. The drill bit is clamped in the chuck at its end and is rotated by a handle attached to gear and pinion arrangement Ithas cutting edges like a twist drill. tis used for drilling large diameter holes with the hand pressure. Gimlet 19‘Wood turning lathe and it uses Wood turning lathe Woodturning is a form of woodworking that is used to create wooden objects on a lathe, Woodturning differs from most other forms of woodworking in that the wood is moving while a stationary tool is used to cut and shape it. Many intricate shapes and designs can be made by turning wood. 20BASIC WOODWORK JOINT There are many different joints that the carpenter and joiner may use. This chapter is concerned mainly with those made by hand. Joints generally fall into three categories and carry out the following functions: S/No CATEGORY JOINT FUNCTION T Lengthening Lap Joint End Butt Joint Scarf Joint Laminated Joint Finger Joint Half-lap & Sloping halving Joints To increase the effective length of timber. Widening Edge glue Joint Edge Butt Joint Dowelled Joint Tongued Joints Loose Tongued Joint Slot-Screwed. Joint To increase the width of timber or board material. Framing ‘Housing Joint Angle “Halving Joint Mortise and Tenon Joint Bridle Joint Dowelled Joint ‘Notched and Cogged Joint Dove Tail Joint Mitre and Scribe Joint To terminate or to change direction 21