MANUFACTURING PROCESS

Drilling Process

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DRILLING PROCESS

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 INTRODUCTION

Drilling process is intended as a process

of making round holes using a twist drill.

Drilling (gurdi) process is the

simplest machining process
among other machining
processes.

Drilling Process

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 INTRODUCTION

DIFFERENCE WITH BORING PROCESS

the boring process is the process of expanding

/ enlarging a hole that can be done with a drill
bar (boring bar),
which is not only done on a Gurdi Machine, but can be with a
Lathe, Milling Machine, or Drilling Machine.

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 INTRODUCTION
• Drilling is done with a tool having two cutting edges, or lips.
• Cutting action takes place inside the workpiece.
• The only exit for the chips is the hole that is mostly filled by the drill.
• Friction between the margin and the hole wall produces heat that is
additional to that due to chip formation.
• The counter-flow of the chips in the flutes makes lubrication and
cooling difficult.

There are four major actions taking place at the point of a drill.
1. A small hole is formed by the web—chips are not cut here in the
normal sense.
2. Chips are formed by the rotating lips.
3. Chips are removed from the hole by the screw action of the helical
flutes.
4. The drill is guided by lands or margins that rub against the walls of
the hole.
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 TYPES OF DRILL
Flute

• The most common types of drills are twist drills.

• These have three basic parts: the body, the point (tang), and the shank.
• The body contains two or more spiral or helical grooves, called flutes, separated
by lands.
• The lands terminate in the point, with the leading edge of each land forming a
cutting edge.
• The flutes serve as channels through which the chips are withdrawn from the
hole and coolant gets to the cutting edges

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 TOOL HOLDER FOR DRILLS
• Straight-shank drills must be held in some type of drill chuck .
• Chucks are adjustable over a considerable size range and have radial steel
fingers.
• Conventional holders such as keyless chucks cannot be used because the
gripping strength is limited
• Collet holders should be cleaned periodically with oil to remove small chips
• The entire flute length must protrude from the chuck.
• At maximum hole depth, the length of flute protruding from the hole must be
at least 1 to 1.5 times the drill diameter.

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 WORK HOLDING FOR DRILLS
• Work that is to be drilled is ordinarily held in a vise or in specially designed
workholders called jigs.
• the work should not be held on the table by hand unless adequate leverage is
available the drill has a tendency to catch on the
workpiece and cause it to rotate, especially when the drill exits the workpiece
• Work that is too large to be held in a jig can be clamped directly to the machine
table using suitable bolts and clamps and the slots or holes in the table.
• Jigs and workholding devices on indexing machines must be free from play and
firmly seated

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 MACHINE TOOL FOR DRILLS
• Drilling can be done on a variety of machine
tools such as lathes, horizontal and vertical
milling machines, boring machines, and
machining centers
• The common name for the machine tool used for
drilling is the drill press.
• Drill presses consist of a base, a column that
supports a powerhead, a spindle, and a worktable

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 CUTTING FLUIDS FOR DRILLS
• When the depth of the hole exceeds one diameter, it is desirable to increase
the lubricating quality of the fluid because of the rubbing between the drill
margins and the wall of the hole.
• If the hole depth exceeds two or three diameters, it is usually advantageous
to withdraw the drill each time it has drilled about one diameter of depth, to
clear chips from the hole.
• The effectiveness of a cutting fluid as a coolant is quite variable in
drilling. While the rapid exit of the chips is a primary factor in heat removal,
this action also tends to restrict entry of the cutting fluid

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 FUNDAMENTAL OF DRILLING
the process of drilling creates two chips. A
conventional two-flute drill, with drill of diameter
D, has two principal cutting edges rotating at an
rpm rate of N and feeding axially

12𝑉 Spindel speed (Ns), fpm

𝑁𝑠 =
𝜋𝐷 Diamater (D) ,inch

𝐹𝑟 Feed (Fr), ipr

𝐷𝑂𝐶 = Feed rate (Fm),inch/min
2
𝐹𝑚 = 𝐹𝑟 𝑁𝑠
𝐿+𝐴 𝐿+𝐴
𝑇𝑚 = =
𝐹𝑟 𝑁𝑠 𝐹𝑚
𝑉𝑜𝑙𝑢𝑚𝑒 𝑟𝑒𝑚𝑜𝑣𝑒𝑑
𝑀𝑅𝑅 (𝑀𝑒𝑡𝑎𝑙 𝑅𝑒𝑚𝑜𝑣𝑎𝑙 𝑅𝑎𝑡𝑒) =
𝑇𝑖𝑚𝑒

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 FUNDAMENTAL OF DRILLING
Case A cast iron plate is 2 in. thick and
needs 1-in.-diameter holes drilled
in it. It was selected a cutting
speed of 200 fpm and a feed of
0.005 ipr
1. Determine spindle speed
12𝑉
𝑁𝑠 =
𝜋𝐷
12 ∗ 200 3. Determine max chip load
𝑁𝑠 = = 764 𝑟𝑝𝑚
𝜋1 0.005
𝐷𝑂𝐶 = = 0.0025 𝑖𝑛/𝑟𝑒𝑣
Closest one → 750 rpm 2
2. Determine feed rate

𝐹𝑚 = 𝐹𝑟 𝑁𝑠
𝐹𝑚 = 0.005 ∗ 750 = 3.75 𝑖𝑛/𝑚𝑖𝑛

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FUNDAMENTAL OF DRILLING

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 FUNDAMENTAL OF DRILLING
Case A cast iron plate is 2 in. thick
and needs 1-in.-diameter holes
drilled in it. It was selected a
cutting speed of 200 fpm and a
feed of 0.005 ipr

𝑉𝑜𝑙𝑢𝑚𝑒 𝑟𝑒𝑚𝑜𝑣𝑒𝑑
𝑀𝑅𝑅 (𝑀𝑒𝑡𝑎𝑙 𝑅𝑒𝑚𝑜𝑣𝑎𝑙 𝑅𝑎𝑡𝑒) =
𝑇𝑖𝑚𝑒

𝐷 2
𝜋 ∗𝐿
𝑀𝑅𝑅 (𝑀𝑒𝑡𝑎𝑙 𝑅𝑒𝑚𝑜𝑣𝑎𝑙 𝑅𝑎𝑡𝑒) = 2
𝐿
𝐹𝑚

Teddy Sjafrizal @2015 Page 14

1. What is drilling process? What is the difference with boring
process?
2. What is the most common types of drill? What are the 3 basic
parts?
3. The common name for the machine tool used for drilling? What
are the parts?

CASE

A cast iron plate is 4 in. thick and needs 2-in.-

diameter holes drilled in it. It was selected a
cutting speed of 100 fpm and a feed of 0.001 ipr.

Determine:
1. Spindle Speed
2. Feed Rate
3. Max Chip Load
4. Metal Removal Rate

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