SHOP THEORY-Drilling Processes
SHOP THEORY-Drilling Processes
SHOP THEORY-Drilling Processes
V-BELT--........_ -DRIVEN
PULLEY
- -START-STOP ' GUARD
SWITCH DRIVE
MOTOR-- PULLEY--
- FEED - DEPTH
HANDLE SWITCH--- STOP
DRILL
HEAD CLAMP .••, '-CHUCK
-FEED
DRILL / HANDLE
HEAD BRACKET
CLAMP
MOTOR-'
-SLOTTED RACK-"
TABLE
--COLUMN
-T-SLOTTED
/ BASE
fig. 7-2. Dench model sensitive drill press. (Cin-
cinnati lathe & loo! Co.)
2. What skills are necessary to operate a sensitive 3. What is a standard upright drilling machine?
drill press correctly? A standard upright drilling machine is a larger and
A skilled operator is one who has developed a heavier machine than a sensitive drill press (Fig.
"sense of feel" when feeding a drill into the work- 7-3). It is a general-purpose machine used for all
piece. He can feel the cutting action of the drill or types of drilling, reaming, countersinking, counter-
other cutting tool such as a counterbore or counter- boring, tapping, and lapping. It can machine large
sink and knows just how much pressure to apply holes. The spindle-drive unit· usually consists of a
to keep the tools cutting properly. This sense of feel variable-speed transmission. The drill head cdn be
is important because too heavy a feed may break raised or lowered on a machined column and
the drill or damage the workpiece. Too little feed clamped in positior:. The work table, which may
may result in chatter, too much heat, dulling of the be square, rectangular, or round, is raised or lowered
cutting tools, and rapid wear of the drill margins, by means of an elevating screw. Larger machines
which ruins the drill. Another important skill is usually have T-slotted tables so that large work-
the ability to sense that the drill is beginning to pieces can be clamped directly to the table usir.g
break through the work. The skilled operator will T bolts and strap clamps. Small workpieces are
reduce his pressure on the down-feed as the drill held in a vise.
begins to break through, thus permitti11g the drill
to cut its way freely and smoothly through the hole. 4. Describe a heavy-duty drilling machine.
144 Unless this is done, the drill is apt to grab or dig, A heavy-duty drilling machine is a larger, heav:er
FEED
!)RIVE SHAFT
TABLE CLAM
BASE ANO -.
Fig. 7-3. Upright drill press. LOWER TABLE"
machine than the sensitive or the standard upright Fig. 7-4. Principal parts of a heavy-duty drilling
drill press. It has a gear-train drive and power machine. (Cincinnati Bickfof'd Tool Co.)
feeds. It is a powerful machine for drilling, tapping,
and machining large holes. The gear drive permits
a wide range of spindle speeds, which vary from fig. 7-5. Gang drilling machine.
60 to 1,000 revolutions per minute. The slower
speeds and resultant increase in power are necessary
for large-diameter cutting tools. Figure 7-4 gives
the names of the principal parts of this machine.
The spindle end has a large Morse taper bore, which
receives taper-shank cutting tools or drill chucks
equipped with Morse taper arbors. The spindle
can be reversed so that holes can be threaded
with taps.
J [_____]
c-
0 K
-
or di1• in.
A B C D E F
17. ,:an holes other than round holes be drilled · Fig. 7-24. End view of drill for making square
bi r,1tary motion? holes. (Watts Bros. Tool Works.) 151
19. Describe the tools necessary for drilling angular
holes.
The basic tools used for drilling anguiar holes
consist of the Watts full-floating chuck, which is
patented (Fig. 7-25), angular drills (Fig. 7-26),
guide plates (Fig. 7-27), and slip bushings (Fig.
7-28)
The Watts full-floating chuck takes up the driv-
ing and floating motion, which permits the drill to
operate as freely as a standard twist drill. Guide
plates are necessary for each different size and type
of angular drill because they control the path of the
drill when it starts into the metal. The guide plate
must be clamped directly onto the workpiece.
The stepped guide plate can be used in a drill jig.
Watts angular drills for square holes have three
flutes and cutting lips, whereas the drill for producing DRILL FOR DRILL FOR
a hexagonal hole has five flutes and cutting lips. Sizes SQUARE HEXAGONAL
HOLE HOLE
of angular drills vary by sixteenths of an inch, from
V4 to 2 in. All of the cutting is done on the end of Fig. 7-26. Watts drills for drilling square and hexa-
the drill. gonal holes. (Watts Bros. Tool Works.)
To obtain good results, angular drills require equal
cutting surfaces on all sides. The float of the chuck
Fig. 7-27. Guide plates for square and hexagonal
must be central with the angular hole so that the
drills. (Watts Bros. Tool Works.)
drill can float freely into the various corners. The
lead hole also must be in the center of the angular
hole to ensure equal cutting surfaces for the angular
drill.
Slip bushings are fitted into the guide plates so as
to eliminate the need for laying out the lead liole and
save time when setting up the tools. The use of slip
SLIP BUSHING
-+--FULL-FLOATING
CHUCK
SQUARE HEXAGON
Fig. 7-25. A Watts full-floating chuck. (Watts Bros. Fig. 7-28. Slip bushings for square and hexagonal
152 Tool Works.) drills. (Watts Bros. Tool Works.)
,ushings insures that the lead hole is automatically ground away or relieved just back of the cutting. lip
)Cated in the center of the drill press spindle and of the drill.
1at the float of the chuck will be equally distributed.
25. What is the margin of a drill?
0. Name the principal parts of a standard twist The margin is the narrow strip shown ii) Fig. 7-30.
lri/J. It is the full diameter of the drill and extends the
he names of the principal parts of a standard twist · entire length of the flute. Its surface is part of a
'rill are given in Fig. 7-29. The body is the cutting cylinder, which is interrupted by the flutes and by
nit, and the shank is the part held in the drilling what is known as body clearance. The diameter of
1achine ~or driving or rotating the drill. the margin at the shank end of the drill is 0.0005
to 0.002 in. smaller than the diameter at the point.
1. Describe the point of a drill. This allows the drill to revol~e without binding when
he point of the drill should __l)ot be confused drilling deep holes.
1ith the dead center. The point is the entire cone-
naped surface at the cutting end of the drill (Fig. 26. What is the body clearance of a drill?
-30). The portion of the drill body from the margin in
Fig. 7-30 is smaller in diameter than the margin.
2. What is the dead center of a drill? This reduction in size, called body clearance, re-
he dead center is the sharp edge at the extreme tip duces the friction between the drill and the walls
nd of the drill (see Fig. 7-30). Formed by the of the hole being drilled; the margin ensures that
1tersection of the cone-shaped surfaces of the point, the hole will be of accurate size.
1e dead center should always be in the exact
enter of the axis of the drill.
4. . what is the lip clearance of a drill? Fig. 7-30. The point of a twist drill. (Morse Twist
ne lip clearance is the surface of the point that is Drill & Machine Co.)
FLUTES
OVERALL LENGTH
LAND
g. 7-29. Principal parts of a twist drill. (Morse Twist Drill & Machine Co.) · 153
27. What is the web of a drill?
The web is the metal column, which runs the entire
length of the drill between the flutes (Fig. 7-31). It
is the supporting sectio!) of the drill-the drill's
backbone, in fact. The web gradually increases in
thickness toward the shank (Fig. 7-32). This thicken-
ing gives additional rigidity to the drill.
Fig. 7-32. Drill section at the left shows web thick- 29. What is the tang of a drill?
ness near point of drill; section at right shows web
A tang is found only on tapered-shank tools (Fig.
thickness near shank end of drill. (Cleveland Twist
7-29). It is designed to fit into a !'lot in the socket or
Drill Co.)
spindle of a machine. It may bear a portion of the
driving strain, but its principal use is to make it easy
to remove the drill from the spindle socket with the
aid of a drill drift (Fig. 7-35). A safety drill drift,
which is used without a hammer, is shown in Fig.
7-36.
A B C D
MORE.
THAN
8°TOl2°
I
G. WOOD
F. MAGNESIUM ALLOYS
48. Fxplain the wire gage or number series. 51. How are drill diameters measured or gaged?
The wire gage or number series (Fig. 7-57), consists To determine the correct diameter, a micrometer
of drills numbered from 1 to 80. The No. 1 drill is shou!d be used to measure across the margins of the
the largest, with a 0.228-in. diameter, and the No. drill. A drill size gage (Fig. 7-59) may also be used.
80 is the smallest, with a 0.0135-in. diameter. Such gages are made for fractional-size drills up to
There is no uniform variation in the drill diameters Vi in., for number drills (Fig. 7-60), and for letter-
from number to number. To find the decimal size drills (Fig. 7-61).
equivalent of a number drill, consult a drill size
chart or handbook. 52. How should a job be laid out for drilling?
The laying out of the holes to be drilled is done
from a sketch or blueprint. The surface of the
material to be drilled is first coated with layout
dye. The center lines of the holes are then scribed
on the surface according to the dimensions.specified
on the blueprint. The intersection of the lines is
marked with a prick punch. To help the machinist
see that the hole is being drilled on center, a circle
the same size as the hole is scribed with dividers
(Fig. 7-62). The circle itself is then identified
by making small indentations on it with a prick
punch at short intervals (Fig. 7-63).
No. 80 .0135 No. 49 .0730 4,10 mm .1614 6.80mm .2677 27/64 .4219
.35mm .0138 1.90mm .0748 4:20mm .1654 6.90mm .2717 11.00mm .4331
No. 79 .0145 No.48 .0760 No.19 .1660 I .2720 7/16 .4375
1/64 .0156 1.95mm .0768 4,25mm .1673 7.00mm .2756 11.50mm .4528
.40mm .0158 5/64 .0781 4.30mm .1693 I .2770 29/64 .4531
No. 78 .0160 No.47 .0785 No.18 .1695 7,10mm .2795 15/32 .4688
.45mm ,0177 2.00mm .0787 11/64 .1719 K .2810 12.00mm .4724
No. 77 ,0180 2.05mm ,0807 No.17 .1730 9/32 .2812 31/64 .4844
.50mm .0197 No.46 .0810 4,40mm ,1732 7.20mm ,2835 12.50mm .4921
No. 76 .0200 No.45 .0820 No.16 ,1770 7.25mm .2854 1/2 .5000
No. 75 .0210 2.10mm .0827 4.50mm .1772 7.30mm .2874 13.0mm .5118
.55mm ,0217 2.15mm ,0846 No.15 .1800 l .2900 33/64 .5156
No. 74 ,0225 No. 44 ,0860 4.60mrr. .1811 7.40mm .2913 17/32 .5312
.60mm ,0236 2.20mm .0866 No, 14 .1820 M .2950 13.5mm .5315
2.25mm .0886 No.13 .1850 7.50mm .2953 35/64 .5469
No. 73 ,:0240 No.43 .0890 4.70mm .1850 19/64 .2969 14.0mm .5512
No. 72 \0250 2.30mm ,0906 4,75mm .1870 7.60mm .2992 9/16 .5625
.65mm ,,0256 2.35mm ,0925 3/16 .1875 N .3020 14.5mm .5709
No. 71 .0260 No. 42 ,0935 4,80mm .1890 7.70mm .3031 37/64 .5761
70mm .0276 3/32 .0938 No.12 .18)0 7.75mm .3051 15.0mm .590&
No. 70 .0280 2.40mm .0945 No.11 .1910 7.80mm .3071 19/32 .5938
No. 69 .0292 No. 41 .0960 4.90mm .1929 7.90mm ,3110 39/64 .6094
.75mm .0295 2.45mm .0965 No.10 .1935 5/16 .3125 15.5mm .6102
No. 68 ,0310 No.40 ,0980 No.9 .191.iO 8.00mm .3150 5/8 .6250
1/32 .0312 2.50mm ,0984 5,00mm .1968 0 .3160 16.0mm .6299
,80mm .OJ15 No. 39 ,0995 No.a .1990 8.10mm .3189 41/64 .6406
No.67 ,0320 No. 38 .1015 5.10mm ,2008 8,20mm .3228 16.5mm .6496
No.66 ,0330 2.60mm .1024 No. 7 .2010 p .3230 21/32 .6562
.85mm ,0335 No. 37 .1040 13/64 ,2031 6.25mm .3248 17.0mm .6693
No. 65 ,0350 2.70mm .1063 No.6 .2040 8.30mm .3268 43/64 .6719
.90mm ,0354 No. 36 .1065 5,20mm ,2047 21/64 ,3281 11/16 .6875
No."64 .0360 2.75mm .1063 No.5 ,2055 8.40mm .3307 17.5mm .6890
No.63 .0370 7/64 .1094 5.25mm .2067 Q .3320 45/64 .7031
.95mm .0374 No.JS .1100 5.30mm .2087 6.50mm .3346 18.0mm .7087
No. 62 .0380 2.80mm ,1102 No.4 .2090 8.60mm .3386 23/32 .7188
No. 61 .0390
1.00mm .0394 No. 34 .1110 5,40mm .2126 R .•3390 16.Smm .7283
No.60 ,0400 No. 33 .1130 No. 3 .2130 8.70mm .3425 47/64 .7344
No. 59 .0410 2.90mm .1142 5.50mm .2165 11/32 .3438 19.0mm .7480
1.05mm .0413 No. 32 ,1160 7/32 .2188 8.75mm .3445 3/4 .7500
No. 58 .0420 3.00mm .1181 5,60mm ,2205 8.80mm .3465 49/64 .7656
No.57 .0430 No.31 .1200 No.2 .2210 s .3480 19.5mm .7677
1.10mm ,0433 3.10mm .1220 5.70mm .2244 8.90mm .3504 25/32 .7182
1.1smm .0453 1/8 ,1250 5,75mm ,2264 9.00mm .3543 20.0mm .7874
No.56 .0465 3.20mm ,1260 No.1 .2280 T ,3580 51/64 .7969
3/64 ,0469 3.25mm .1280 5,80mm .2283 9.10mm ,3583 20.5mm .6071
1.20mm .0472 No.JO .1285 5.90mm .2323 23/64 .3594 13/16 .8125
1.25mm .0492 3.30mm .1299 A ,2340 9.20mm .3622 21.0mm .8268
1.30mm .0512 3.40mm ,1339 15/64 ,2344 9,25mm .3642 53/64 .8281
No.55 .0520 No. 29 ,1360 6,00mm .2362 9.30mm .3661 27/32 .8438
1.35mm .0531 3.50mm .1378 B .2380 u ,3680 21.5mm .8465
No.54 .0550 No. 28 .1405 6.10mm .2402 9.40mm ,3701 55/64 .8594
1.40mm ,0551 9/64 .1406 C .2420 9.50mm .3740 22.0mm .6661
1,45mm .0571 3.60mm .1417 6,20mm ,2441 3/8 .3750 7/8 .8750
1.50mm .0591 No, 27 .1440 D .2460 V .3770 22.5mm .8658
3.70mm ,1457 6,25mm .2461 9.60mm .3780 57/64 .8906
No. 53 .0595 No. 26 .1470 6.30mm .2480 9.70mm ,3819 23.0mm .9055
1.55mm .0610 3,75mm .1476 1/4 .2500 9.75mm .3639 29/32 .9062
1/16 .0625 No. 25 .1495 E .2500 9.80mm .3858 59/64 .9219
1.60mm ,0630 3.80mm .1496 6,40mm .2520 w .3860 23.5mm .9252
No. 52 .0635 No. 24 .1520 6.50mm ,2559 9.90mm .3898 15/16 .9375
1.65mm ,0650 3.90mm .1535 ,2570 25/64 .3906 24.0mm .9449
1.70mm .0669 No. 23 .1540 6.60mm .2598 10.00mm .3937 61/64 .9531
No. 51 .0670 5/32 .1562 G ,2610 X ,3970 24.5mm .9646
1.75mm .0689 No. 22 .1570 6.70mm .2638 y .4040 31/32 .9688
No.SO .0700 4.00mm .1575 17/64 .2656 13/32 .4062 25.0mm .9843
1.80mm .0709 No. 21 .1590 6,75mm .2657 z .4130 63/64 .964·1
1.85mm .0728 No. 20 .1610 H ,2660 10.50mm .4134 1 1.0000
Fig. 7-61. letter-size. drill
gage. (L S. Starrett Co.)
59. What is a combined drill and countersink and Reamers commonly used in drilling machines are
for what. purpose is it used? (a) fluted chucking reamers, (b) rose chucking
A combined drill and countersink (Fig. 7-67), more reamers, (c) shell reamers, (d) chucking expansion
commonly referred to in the shop as a center drill, reamers, (e) Jobber's reamers, and (f) taper-pin
is used to produce both a short drilled hole and a chucking reamers. The rose and expansion types
countersunk hole in one operation. The angle on have straight flutes, whereas the other types are
these drills is always a 60° included angle. It is made with straight or spiral flutes, as shown in
used largely for drilling center holes in work to be Fig. 7-69.
turned between centers in the lathe and for starting A fluted chucking reamer (Fig. 7-70) is used to
holes in the correct location on a drilling machine. finish holes accurately and smoothly. This is a pre-
cision reamer designed to remove from 0.005 to
60. Describe the operation of reaming. 0.010 in. of material. Each tooth is ground with a
Reaming (Fig. 7-68) is the operation of finishing a clearan~e angle back of the cutting edge for the full
drilled hole. A finished hole has the specified diam- length of the land. The ends of each tooth are cham-
eter size, is perfectly round, the diameter is the same fered slightly for end cutting.
size from end to end, and it has a smoothly finished A rose reamer (Fig. 7-71) is designed to cut on the
surface. A drilled hole is seldom accurate enough in ends of the teeth only. It has no clearance or cutting
size or sufficiently smooth to be called a precision edges on the periphery. The flutes provide a means
hole. When greater accuracy is required, the hole for chips to escape and for coolant to reach the end
must be drilled undersize by a certain amount and cutting edges. The diameter near the shank end is
finished by reaming. slightly smaller than at the front to provide clearance.
This,reamer is considered a roughing reamer; it will
61. Name and describe several types of standard remove a considerable amount of material but will
reamers used in drilling machines. not produce a smooth, accurate hole. 165
J
I
I
....., , ......
I
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reversing. The driving mechanism is constructed to
revolve the tap clockwise (into the work) when the
feed handle of the drill press is moved downward.
When the handle is moved upward, the tap is
re,ersed to remove it from the hole. I~ is possible,
Fig. 7-76. Counterbore and counterbored hole. with practice, to control the forward and reverse
movements of the tap by skillfully manipulating the
feed handle. A tapping attachment is a time~saving
device when a large number of identical holes are
to be tapped.
.
Cutting Speed =21 X 722 X 12
1
X 600 = 78 fpm.
Lapping is a slow, tedious job. Usually only a few Cutting Speed= { x drill diameter x rpm.
thousandths of an inch are removed by this method.
It is a common practice to lap small holes-those In this problem, using the simpler formula, the cut-
less than% in. in diameter-after the material has ting speed would be calculated as follows:
been hardened. Before hardening, small holes that
are to be lapped are reamed with a lapping reamer. Cutting Speed ={ X; X600 = 75 fpm
Lappingreamers are one or two thousandths of-an
168 inch smaller than ~tandard-sized reamers. The difference i$ so small as to be negligible.
68. When the cutting speed is known, how can you mended when drills made of high-speed steel are
calculate the rpm? used. For drills made of carbon tool steel, the cutting
When the cutting speed is known, the rpm may be speeds should be about one-half less.
calculated by using either of two formulas:
Aluminum 200-300 fpm
Cutting speed x 4 Brass-soft 200-300 fpm
rpm=
Drill diameter Cast iron - soft 100- 15 0 fpm
Copper 200fpm
_ Cutting speed
rpm - 1/4 X Drill diameter Machine steel 80-100 fpm
Mone! metal 40-60 fpm
Stainless steel 30-50 fpm
Applying the formula to the problem in Question 67,
Tool steel alloys 50-60 fpm
the rpm would be
75 X 4 300 70. If a toolmaker wanted to drill a Yi-in. hole in -a
- - - = - . = 600 rpm
Yi Y2 piece of machine steel at the recommended speed of
80 fpm, at what speed in rpm should he operate
thedri/1 press?
69. What cutting speeds are recommended for While the answer may be calculated mathematically,
drilling some of the more commonly used metals? it is more practical to use a cutting-speed table
The following average cutting speeds are recom- similar to Fig. 7-82. By locating the diameter of the
fig. 7-82. Cutting speeds for high-speed steelfraction-size drills. (Cleveland Twist Drill Co.)
170