ABSTRACT

Directional drilling machine which can be used based on drilling holes in various location and
movement and easily operation done with high accuracy. Productivity can be improved by reducing total
machining time and reduced human effort and reduced manufacturing cycle time. In this present age the
application of micromachining operations continues to grow. These operations are required to fabricate
the products required for sectors like medical science, automobile industries and electronics
manufacturing etc. which deals with miniature trends. Drilling process is one of the machining processes
which is used to drill micro holes not only in micro products but also in relatively larger work pieces
which require ultra-small features which can be accomplished only by drilling process

Key words: Drilling machine, Performance, Movement, Material, Operation etc.

 CONTENTS

CETIFICATE

DECLARATION

ACKNOWLEDGEMENT

INTRODUCTION

GENERAL ASPECTS OF DRILLING MACHINE

DRILLING PROCESS

LITARATURE SURVEY

DEVELOPMENT OF DRILLING MACHINE

MOVEMENTS IN FLEXIBLE DRILLING MACHINE

SETUP PROCEDURE

WORKING PROCEDURE
METHODOLOGY

COMPONENT & SPECIFICATION

FUTURE SCOPE

CONCLUSION & SUMMARY

INTRODUCTION

Around 35,000 BCE, Homo sapiens discovered the benefits of the application of rotary tools. This
would have rudimentarily consisted of a pointed rock being spun between the hands to bore a hole
through another material. This led to the hand drill, a smooth stick that was sometimes attached to flint
point, and was rubbed between the palms. This was used by many ancient civilizations around the world
including the Mayans. The earliest perforated artifacts such as bone, ivory, shells and antlers found, are
from the Upper Paleolithic era. Bow drill (strap-drills) are the first machine drills, as they convert a
back-and forth motion to a rotary motion, and they can be traced back to around 10,000 years ago. It was
discovered that tying a cord around a stick, and then attaching the ends of the string to the ends of a
stick(a bow), allowed a user to drill quicker and more efficiently. Mainly used to create fire, bow-drills
were also used in ancient woodwork, stonework and dentistry. Archeologist discovered a Neolithic grave
yard in Mehrgrath, Pakistan dating from the time of the Harappans, around 7,500-9,000 years ago,
containing 9 adult bodies with a total of 11 teeth that had been drilled. There are hieroglyphs depicting
Egyptian carpenters and bead makers in a tomb at Thebes using bow-drills. The earliest evidence of
these tools being used in Egypt dates back to around 2500 BCE. The usage of bow-drills was widely
spread through Europe, Africa, Asia and North America, during ancient times and is still used today.
Over the years many slight variations of bow and strap drills have developed for the various uses of
either boring through materials or lighting fires. We had chosen the user defined project (UDP) for our
final year project. We are decided our topic to develop the automatic multi-operational portable machine
say like tapping, drilling, grinding, reaming, and other relative operation. This will make use of
compressed air (pneumatic mechanism) for its operation. We will trying to develop the portable machine
which will easily handle and cover a maximum working area from one station and make it more flexible
to working easily. As a small industries the machine and operation method use for drilling, tapping and
other similar process is not economically and eco friendly. As we know that drilling machine use the
electricity as there power source these machine have many limitation like it is not flexible and not
moveable, consume more floor area and main problem is that it need continuous electricity which
increase the cost of production. The tapping operations are performed by use of convention tap or hand
tap. during operation it is necessary with a hand tap to periodically reverse rotation to break the chip
formed during the cutting process, thus preventing effect called crowding that may cause defect. In
convention method, main problem causes during the tapping operation for big job industries and
complex job these causes are created defect on tap tool, increasing operational lead time, inaccuracy of
thread geometry, more production cost and more labour cost.
1.1 General Aspects of Drilling Machine:

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. It is the simplest and accurate
machine used in production shop. The work piece is held stationary i.e. Clamped in position and
the drill rotates to make a hole. Drilling machine is kind of machine rotating cutting tool which
direction the drill feeds only on the machine axis(workmanship perforation). Drilling is operating
while producing round holes in the piece work by using a rotating cutter called DRILL. A Drill is
a tool fitted with a cutting tool attachment or driving tool attachment, usually a drill bit or driver
bit, used for boring holes in various materials or fastening various materials together with the use
of fasteners. The attachment is gripped by a chuck at one end of the drill and rotated while
pressed against the target material. The tip, and sometimes edges, of the cutting tool does the
work of cutting into the target material. This may be slicing off thin shavings grinding off small
particles crushing and removing pieces of the work piece, countersinking, counter boring, or
other operations. Drills are commonly used in woodworking, metalworking, construction and do-
it-yourself projects. Drills are available with a wide variety of performance characteristics, such
as power and capacity. Drill machines have been the heart of every industry. Drilling holes in
parts, sheets and structures is a regular industrial work. Perfect and well aligned drilling needs
fixed and strong drills. Some parts cannot be drilled using fixed drills due to low space between
drill bit and drill bed. We need to use hand drills in such cases but hand drills have alignment
problems while drilling. So here we propose a 360 degree flexible drill that can be mounted on a
table or wall and can be used to drill holes horizontally, vertically or even upside down. So this
makes it possible for easy drilling in even complicated parts and surfaces. Thus we use rotating
hinges and connectors with motor mount and supporting structure to design and fabricate a mini
360 degree drill for easy drilling operations.
 2 DRILLING PROCESS

Drilling is the method of making holes in a work piece with metal cutting tools. Drilling is
associated with machining operations such as trepanning, counter boring, reaming and boring. A
main rotating movement is common to all these processes combined with a linear feed. There is a
clear distinction between short hole and deep hole drilling. The drilling process can in some respects
be compared with turning and milling but the demands on chip breaking and the evacuation of chips
is critical in drilling. Machining is restricted by the hole dimensions, the greater the hole depth, the
more demanding it is to control the process and to remove the chips. Short holes occur frequently on
many components and high material removal rate is a growing priority along with quality and
reliability.

Solid drilling is the most common drilling method, where the hole is drilled in solid
material to a predetermined diameter and in a single operation.

Trepanning is principally used for larger hole diameters since this method is not so power-
consuming as solid drilling. The trepanning never machines the whole diameter, only a ring at the
periphery. Instead of all the material being removed in the form of chips, a core is left round the
center of the hole.

Counter boring is the enlargement of an existing hole with a specifically designed tool. This
machines away a substantial amount of material at the periphery of the hole.

Reaming is the finishing of an existing hole. This method involves small working allowances to
achieve high surface finish and close tolerances. The cutting speed, or surface speed (vc) in for
drilling is determined by the periphery speed and can be calculated from the spindle speed (n)
which is expressed in number of revolutions per minute. During one revolution, the periphery of
the drill will describe a circle with a circumference of π x Dc, where Dc is the tool diameter. The
cutting speed also varies depending upon which cutting edge across the drill-face is being
considered. A machining challenge for drilling tools is that from the periphery to the center of the
drill, the cutting speed declines in value, to be zero at the center. Recommended cutting speeds
are for the highest speed at the periphery The feed per revolution (ƒn) in mm/rev expresses the
axial movement of the tool during one revolution and is used to calculate the penetration rate and
 to express the feed capability of the drill. The penetration rate or feed speed (vf) in mm/min is the
feed of the tool in relation to the work piece expressed in length per unit time. This is known as
the machine feed or table feed. The product of feed per revolution and spindle speed gives the
rate at which the drill penetrates the work piece. The hole depth (L) is an important factor in
drilling as is the radial cutting depth (ap) and feed per tooth (fz) for calculations.

Machining holes
Holes are either made or finish machined. Most work pieces have at least one hole and depending
upon the function of the hole, it needs machining to various limitations

The main factors that characterize

A hole from the machining view point are:

 diameter

 depth

 quality

 material

 conditions

 reliability

 productivity
3 LITERATURE REVIEW

Micromachining operations play an important role in precision production industries. Out of the
various machining processes, micro-drilling is used to produce micro holes in fuel injectors,
printed circuit board, aerospace materials etc. So in order to achieve the optimum working
conditions various research were conducted by different researchers from across the globe. This
report reviews some of the journal published by them regarding optimization processes.
Yogendra Tyagi,Vadansh Chaturvedi and Jyoti Vimal have conducted an experiment on drilling
of mild steel, and applied the taguchi methods for determining the optimum parameters condition
for the machining process using the taguchi methods and analysis of variance. The work piece
used is mild steel (100mm×76mm×12mm) and the tool used is HSS with a point angle of 118°
and diameter of 10 mm. Taguchi L9 orthogonal arrays is used here in order to plan the
experiment. The input parameters are feed rate, depth of cut and spindle speed whereas the output
responses are surface roughness and metal removal rate (MRR).In case of signal to noise ratio
calculation, larger the better characteristics is used for calculation of S/N ratio for metal removal
rate and nominal and small the better characteristics is used for the calculation of S/N ratio for
surface roughness. After the analysis of the data obtained it is found that MRR is affected mostly
by feed. Confirmation experiment was conducted using the data obtained from S/N ratio graphs
and it confirmed with the results of taguchi methodology. In case of surface roughness analysis
same procedure was followed where the significant parameter was found to be the spindle speed.
Here too the confirmation experiment was conducted and this confirms the successful
implementation of taguchi methods. Timur Canel,A. Ugur Kaya,Bekir Celik studied the laser
drilling on PVC material in order to increase the quality of the cavity. Taguchi optimization
methods was used to obtain the optimum parameters. The material used in the experimental setup
is PVC samples with dimensions of 5mm×85mm×4.5mm. Surelite Continuum Laser is used to
form the cavities. The input parameters are wavelength, fluence and frequency and the output
response are aspect ratio, circularity and heat affected zone. Taguchi L9 orthogonal array is used
to find the signal to noise ratio. Smaller the better characteristics is used for HAZ, larger the
better characteristic is used for aspect ratioand nominal the better characteristic is used for
circularity. Variance analysis is performed usingthe calculated S/N ratio to conclude optimum
stage. It is found that most effective parameter for aspect ratio is frequency, second is wavelength
and last is fluence. For circularity it is found that the most effective parameter is wavelength,
fluence and frequency. For HAZ it is found that the most effective parameter is wavelength,
second is frequency and last is fluence. The experimental results are compatible with Taguchi
method with 93% rate. Thiren G. Pokar,Prof. V. D. Patel used grey based taguchi method to
determine the optimum micro drilling process parameters. hivapragash, K.Chandrasekaran,
C.Parthasarathy, M.Samuel have tried to optimize the drilling process involving metal matrix
composites(MMC) in order to minimize the damage done to it during the process by using
taguchi and grey rational analysis. The work piece used is Al-TiBr2(MMCs),with dimension of
100mm × 170mm × 15mm.The tool material is HSS with diameter of 0.6 mm. The input
parameter are spindle speed, depth of cut and feed rate whereas the output parameter are MRR
and surface roughness. For finding out the optimal combination of cutting parameters the results
are converted into S/N ratios and higher the better type characteristics is used for MMR, and
smaller the better characteristics is used for surface roughness. Wen Jialing and Wen Pengfei
used an orthogonal experimental design in order to find out the optimum process parameters for
injection molding of aspheric plastic lens, to reduce volumetric shrinkage and volumetric
shrinkage variation. Six input parameters were taken, each with 5 levels(Fill Time/sec, holding
pressure/Mpa, holding pressure/times, cooling time/s, melt temperature/°C, mold
temperature/°C.L25(56) orthogonal array is used to plan the above experiment. The parameters
affecting both volumetric shrinkage and volumetric shrinkage variation are identified in order.
4 DEVELOPMENT OF DRILLING MACHINE

A. Equipments used for the Experiment as shown:

 Base plate

 Vertical arm

 Hrizontal arm

 Suspension spring

 Rollar bearing

 Motor

 Drill bit

 Copper wire

 Switch board

 Guider
Fig. 1: Experimental Setup Diagram
 5 MOVEMENTS IN FLEXIBLE DRILLING MACHINE

This drilling machine possesses a radial arm which along with the drilling head can swing and
move vertically up and down as can be seen in Fig. The radial, vertical and horizontal arm
movement of the drilling head enables locating the drill spindle at any point within a very large
space required by large and odd shaped jobs. The tubular column on that the radial arm which
moves up and down manually or it can powered movement then the drilling head here this is
called drilling head which holds the drill spindle here in which the drill is mounted and is
subjected to rotation. The entire head is mounted on the radial arm and this can move inward and
outward from the drill axis. Also the horizontal arm can slide linearly on vertical arm. Not only
that, as this along with this radial arm the drilling head moves upward and downward to have
large gap between the to drill and job or there is a stoke length. Not only that further this radial
arm can be rotated about the column rotated about the column, say about 360 degree.

The main movements in the machine are:

 360 degrees rotation of arm joint.

 Up & down movement of the horizontal arm on vertical arm.

 Linear slide movement of horizontal arm.

 5.1 Setup Procedure

1) Base:

The base acts a support for the whole machine. It’s made of a mild steel. 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.

2) Arm:
There are two arms:

 Vertical arm

 Horizontal arm
The primary arm holds the secondary arm and it is with the help of this arm the 360° of rotation
is transferred from the t plate to the secondary arm in order to move the drill head at angles. They
are made up of stainless steel.

3) Cross Slide:
We have used a hand drilling machine to be fixed on the cross slide. Our drilling machine can
drill holes on concrete, wood and metal. The drill bit can be rotated both clockwise and
anticlockwise direction
6 WORKING PROCEDURE

Pneumatic multi-operation machine make use of compressed air obtained from

compressor passes through pressure regulator & then passes through pneumatic gun. In
pneumatic gun air exerts a axial spinning force on the spindle located inside the tool head which
causes the drill tool to rotate inside the work piece with required RPM.

Fig. 2: Concept Design

7 METHODOLOGY

Step 1: Part collection

After some survey from market finally we bought pneumatic gun, pressure regulator, pipes,
wheels for table & adaptor at the reasonable price.
Fig 3: Pneumatic Gun
Fig 4: Pressure Regulator

Fig 5: Connecting pipe

 Step 2: Define Joints

 We defined joints which are used for relative motion of arms & also to rotate gun in 360 degree.

 We designed mainly three types of joints such as ball joints, pin joints & rotational top head.

 We can switch to an automation by using servo motor in the defined joints for future scope.

Fig 6: Joints
 Step 3: Design arms or linkages

 We made arms or linkages having material of mild steel with help of fabricator.

 We can use telescopic arms to extend the work envelope of pneumatic drilling machine for future
scope.

Step 4: Fabrication of table

 We made supporting table to sustain the load of pneumatic drilling machine by mounting it on
the table.

 We provide wheels to the table to provide the portability to the machine

Fig 7: Supporting table

Step 5: Assembling of component

After collection & designing of all parts we go for the final assemble to give the final touch to our
machine. Finally we assembled all the components in the one single unit and made universal
drilling machine to justify our project title “DESIGN & DEVELOPMENT OF UNIVERSAL
PNEUMATIC DRILLNG MACHINE”.

Fig 8: Partial Assembling

Fig 9: Final assembly

 Step 6: Fabrication of table

 We did some experiment by drilling the material as wood, aluminium & cast iron using the
appropriate tool & air pressure.

 The experiments in the image shows the drilling of the workpiece. The other operation such as
tapping, boring, grinding, thread cutting can also Performed by our machine.

Fig 10(a): Experiment 1

 Fig 10(b): Experiment 2

8 COMPONENT & SPECIFICATION

Fig 11: Component & specification (All dimensions are in mm)

9 FUTURE SCOPE

 We can use servo motor in our machine to provide the automation by giving auto feed.

 We can use telescoping arm to increase the working envelope of the machine to reach in any
direction easily.

 We can use hydraulic system or hydraulic lubrication to operate the machine in smooth manner
without including the less fatigue of man power. 
 CONCLUSION & SUMMARY

 Due to the various problems faced by conventional operation processes such as Poor thread
finish, more time consumption, frequent tool breakage and many more. So, we have decided to
design the machine which will make use of compressed air as a power source. 

 Above is the Future model of pneumatic machine on which the tapping, drilling, boring etc
operation is achieved by Pneumatic system and it eliminates all the problem faced by
conventional operation process. 

 This pneumatic multi-operation Machine is to be presented for increasing their productivity as

well as quality of job. It also gives the detailed description of machine mechanism and their
different main parts of machine. In this we are defining different process parameters like spindle
speed (rpm), cutting feed rate, cutting force, torque and power for their efficient working of
operation. 