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Chapter 23Chapter 23
Drilling and Related Drilling and Related Hole-Making Hole-Making
Processes Processes
EIN 3390 Manufacturing ProcessesEIN 3390 Manufacturing ProcessesSpring, 2011Spring, 2011
23.1 Introduction23.1 IntroductionDrilling is most common single machining
operationDrilling makes up 25% of machiningMost drilling tools have two cutting edges,
or lips. Cutting action takes place inside the
workpieceThe only exit for chips is the hole that is
mostly filled by drillFriction between the margin and the hole wall
produces heat which is additional to that due to chip formation
Nomenclature and Geometry of Nomenclature and Geometry of a Drilla Drill
FIGURE 23-1 Nomenclature andgeometry of conventional twist drill.Shank style depends upon themethod used to hold the drill. Tangsor notches prevent slippage:(a) straight shank with tang,(b) tapered shank with tang,(c) straight shank with whistle notch,(d) straight shank with flat notch.
23.2 Fundamentals of the 23.2 Fundamentals of the Drilling ProcessDrilling ProcessA conventional two-flute drill, with drill of
diameter D, has two principal cutting edges rotating at an rpm rate of N and feeding axially.
The rpm of the drill is established by the selected cutting velocity or cutting speed with V in surface feet per minute and D in inches.
Conventional Drill GeometryConventional Drill Geometry
FIGURE 23-2 Conventionaldrill geometry viewed from thepoint showing how the rakeangle varies from the chisel edgeto the outer corner along the lip.The thrust force increases as theweb is approached.
23.1 Introduction23.1 IntroductionFour actions take place a the drill tip
◦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 holeNew drill-point geometry and TiN coating
have resulted in improved hole accuracy, longer life, increased feed-rate capabilities.
US manufacturing companies consume 250 million twist drills per year.
23.2 Fundamentals of Drilling process23.2 Fundamentals of Drilling processA conventional two-flute drill with diameter D,
has two principal cutting edges rotating at rpm rate of Ns and feed fr. Ns = (12v)/( D)
Where V – cutting speed at the outer cornerof the cutting lip (point X in Fig. 23 -2)in surface, feet per minute, D – diameter of drill in inch.
The depth of cut in drilling is a half of the feed rate, or t = fr/2 (see section A – A in Fig. 23-2), where is in inches per revolution.
23.2 Fundamentals of Drilling process23.2 Fundamentals of Drilling processThe length of cut in drilling equals the depth of the
hole, L, plus an allowance for approach and for the tip of drill, usually A = D/2.
In drilling, the speed and feed depend upon the material of workpiece, the cutting tool material, and the size of drill.
Table 23-1 gives some typical values for V and for carbide indexable insert drills.
The maximum velocity is at the extreme ends of the drill lips. The velocity is very small near the center of the chisel end of the drill.
Cutting time: Tm = (L + A)/(frNs)= (L +A)/fmwhere fm is the feed rate inches per minute.
Material Removal RateMaterial Removal RateThe material removal rate (MRR) for drilling is:
Which reduces to or Where Tm is cutting time, fr is feed rate, and L is
depth of the hole.
/min
23.2 Fundamentals of Drilling process23.2 Fundamentals of Drilling processA cast iron plate is 2” thick, and needs 1”
diameter hole drilled in it. An indexable insert drill has been selected. 1) Select cutting speed and feed; 2) the spindle Ns and feed rate (in/min.); 3) the maximum chip load (depth of cut); 4) MRR; and 5) the total motor horsepower (HPs = 0.33).
Solution:1)From table 23-1, select a cutting speed of 200
fpm, and a feed of 0.005 ipr.2)Ns = (12v)/( D) = (12 x 200)/ (3.14 x 1) = 764
rpm, pick 750 rpm.
23.2 Fundamentals of Drilling process23.2 Fundamentals of Drilling process2) Feed rate fm = fr x Ns = 0.005 x 750 = 3.75 in
/min , and pick fm = 3.5 in/min. 3) the maximum chip load (depth of cut)
t = fr/2 = 0.005/2 = 0.0025 in/rev. 4) MRR = (/4) (D2) fm = (3.14/4) x 12 x 3.5 = 2.75
in3/min.5) HP =HPs x MRR = 0.33 x 2.75 = 0.9
(horsepower)The value would typically represent 80% of the total
motor horsepower needed, so in this case a horsepower motor greater than 1.5 or 2 would be sufficient. HP = 1.6 x 0.9 = 1.5 (horsepower).
23.3 Types of Drills23.3 Types of DrillsThe most common drills are twist drillsTwist drills have three parts
◦Body: consisting of two or more spiral grooves called flutes, separated by lands. Flutes serve as channels through which chips are withdrawn from hole and coolant gets to cutting edges.
◦Point: a wide variety of geometry are used, but typically have a cone angel of 118°, and a rake angle of 24°
◦Shank: a straight or tapered section where the drill is clamped.
Types of Twist DrillsTypes of Twist Drills
FIGURE 23-3 Types of twistdrills and shanks. Bottom to top:1) Straight-shank, three-flute coredrill; 2) taper-shank; 3) straight-shank;4) bit-shank; 5) straight-shank,high-helix angle; 6) straight-shank,straight-flute; 7) taper-shank,subland drill.
Drill WalkingDrill WalkingStandard drills have a straight line chisel
point.This point caused drills to “walk” along
the surfaceThis effect is counter by using centering
techniques◦Center punches◦Pre-drilled guide holes for large holes
Specialized methods of grinding the point address walking
Specialized TipsSpecialized TipsSpecialized tips are used to produce self
centering holes where hole position is critical. ◦Helical tips◦Four-facet tips◦Racon◦Bickford◦Center core, or slot drills
Used in machining centers and high speed automatic NC systems where manual center punching is impractical
Drill Point Drill Point GeometryGeometry
FIGURE 23-4 As the drilladvances, it produces a thrustforce. Variations in the drill-pointgeometry are aimed at reducingthe thrust force.
Center Core DrillCenter Core Drill
FIGURE 23-5 Center core drills cangreatly reduce the thrust force.
Typical Causes of Drilling ProblemsTypical Causes of Drilling Problems
Depth-to-Diameter RatioDepth-to-Diameter RatioStandard drills typically are used to produce
holes with a depth to diameter ratio of 3:1Deeper holes result in drift of the tool
decreasing hole straightnessSpecialized drills called deep-hole drills or
gundrills are used for greater ratiosGundrills are single tipped tools with a coolant
channel delivering coolant to the tip and flushing chips to the surface
Ratios of 100:1 are possible with gundrills
Gundrills GeometryGundrills Geometry
FIGURE 23-7 The gundrillgeometry is very different fromthat of conventional drills.
Boring Trepanning Association Boring Trepanning Association (BTA)(BTA)BTA drills are other forms of deep-boring
drillsBTA drills are also referred to as ejector
drillsDepth of hole is limited to the torsional
rigidity of the drill shankBTA drills have a hollow center where the
chips are carried away from the cutting surface
BTA Drills for BoringBTA Drills for Boring
BTA for Trepanning and BTA for Trepanning and CounterboringCounterboring
BTA for Deep-hole Drilling with BTA for Deep-hole Drilling with Ejector DrillEjector Drill
BTA for Horizontal Deep-drilling BTA for Horizontal Deep-drilling MachineMachine
Steps to High Accuracy Holes Steps to High Accuracy Holes with Conventional Drillswith Conventional Drills
FIGURE 23-10 To obtain ahole that is accurate as to sizeand aligned on center (located),this 4 step sequence ofoperations is usual.
Specialty DrillsSpecialty DrillsHole cutters: used for holes in sheet stockSubland drills: used for multi diameter holesSpade drills: used for holes over 1 inchIndexable drills: used for high speed
shallow holes in solid stockMicro drills (pivot drills): used for holes
0.02 to 0.0001 inch diameter where grain boundaries and inclusion produce non-uniform material properties
Hole Cutters for Used SheetsHole Cutters for Used SheetsWhen cutting large
holes in sheet stock, a hole cutter is used
Hole cutters have a pilot drill in the center used to accurately locate the center
Also called a hole saw
Subland DrillSubland Drill
FIGURE 23-11 Special purpose subland drill (above), and some of the operations possible with other combination drills (below).
Spade DrillsSpade Drills
FIGURE 23-12 (Top) Regularspade drill; (middle) spade drillwith oil holes; (bottom) spadedrill geometry, nomenclature.
Indexable DrillsIndexable Drills
FIGURE 23-13 One- and two lippedindexable insert drills arewidely used for holes over 1 inchin diameter. (Courtesy ofWaukesha.)
Drill Processes ComparedDrill Processes Compared
Recommended Surface Speeds and Feeds for Recommended Surface Speeds and Feeds for HSS Spade Drill for Various MaterialsHSS Spade Drill for Various Materials
Indexable Drilling Troubleshooting GuideIndexable Drilling Troubleshooting Guide
MicrodrillsMicrodrills
FIGURE 23-15 Pivot microdrillfor drilling very-small-diameterholes.
23.4 Tool Holders for Drills23.4 Tool Holders for DrillsStraight-shank drills are typically
held in chucks◦Three-jaw jacobs chucks: used on manual drill
presses, require a key ◦Collet chuck: used with carbide tools where
high bearing thrust is used◦Quick change chucks: used where rapid change
is neededTapered shank drills held in mores taper
of the machine spindle
Drill ChucksDrill Chucks
FIGURE 23-16 Two of the most commonly used types of drill chucks are the 3-jaw Jacobs chuck (above) and the collet chuck with synthetic rubber support for jaws. (Courtesy of Jacobs Manufacturing Company.)
Correct Chucking of Carbide DrillsCorrect Chucking of Carbide Drills
FIGURE 23-17 Here are some suggestions for correct chucking of carbide drills.
23.5 Workholding for Drilling23.5 Workholding for DrillingFor prototype pieces, stock material is
held in simple clamping visesFor high production rates, custom jigs are
usedStock material is never to be held on the
work table by hand
23.6 Machine Tools for Drilling23.6 Machine Tools for DrillingDrilling can be performed on:
◦Lathes◦Vertical mills◦Horizontal mills◦Boring machines◦Machine centers
Specialized machines designed specifically for drilling called “drill presses”
Requirements of a Drill PressRequirements of a Drill PressDrill presses must have sufficient power
and thrust to perform cutDrill presses must be rigid enough to
prevent chatterDrill press consist of a base, a work
table, and a column that supports the powerhead and spindle
Specialized Drill PressesSpecialized Drill PressesGang-drilling machines: independent columns,
each with different drilling operation, work piece slid from one column to next
Turret-type, upright drilling machines: used when numerous drilling operation are required in rapid succession, turret rotates needed tool into position for each operation
Radial drilling machines: used on large workpieces, spindle mounts on radial arm, allowing drilling operations anywhere along the arm lenght
Specialized Drill PressesSpecialized Drill PressesSemiuniversal and universal
machines: On a universal machine the spindle head can be rotated about the horizontal axis to any angle, semiuniversal can be rotated to a limited degree
Multiple-spindle drilling machines: Single powerhead operates multiple spindles enabling multiple holes at one time, each hole can be unique
Deep-hole drilling machines
23.7 Cutting Fluids for Drilling23.7 Cutting Fluids for Drilling
23.8 Counterboring, 23.8 Counterboring, Countersinking, and Spot FacingCountersinking, and Spot FacingCounterboring: Follows a drilling operation, or in
with drilling with a custom tool. Purpose is to produce a flat bottom so that bolt head or nut is below the surface with enough clearance for a tool.
Countersinking: Similar to counterboring, but with a 60°, 82°, or 90° beveled bottom to accommodate flat-head screw or rivet.
Spot facing: Machine minimum depth and diameter around hole to ensure full seating of a bolt head. Used on rough stock surfaces where corrosion or fatigue requirements require full seating
Counterboring and Counterboring and Countersinking ToolsCountersinking Tools
FIGURE 23-21 (a) Surfacesproduced by counterboring,countersinking, and spot facing.(b) Counterboring tools: (bottomto top) interchangeablecounterbore; solid, taper-shankcounterbore with integral pilot;replaceable counterbore andpilot; replaceable counterbore,disassembled. (Courtesy of Ex-Cell-O Corporation and ChicagoLatrobe Twist Drill Works.)
23.9 Reaming23.9 ReamingReams remove small amounts of
material to ensure exact hole size and improve hole surface finish
Reams are either hand operated or machined at slow speed
Ream types◦Shell reams◦Expansion reams◦Adjustable reams◦Tapered reams
Ream GeometryReam Geometry
FIGURE 23-22 Standard nomenclature for hand and chucking reamers.
Types of ReamsTypes of Reams
FIGURE 23-23 Types ofreamers: (top to bottom) Straightflutedrose reamer, straight-flutedchucking reamer, straight-flutedtaper reamer, straight-flutedhand reamer, expansion reamer,shell reamer, adjustable insertbladereamer.
SummarySummaryDrilling is the most common machining
operationDrilling can be performed on a number of
machine tools, drill machines are specialized machine tools for drilling only
Drills come in a wide variety of types and tip geometries depending upon production rate and accuracy needed
Hole geometries can be adjusted through the use of counterboring, countersinking and reaming
HW for Chapter 23 (due date 4/7/2011)HW for Chapter 23 (due date 4/7/2011)Review Questions:1, 2, 10, and 25 (page 653-654, 5 points for
each question )
Problems (page 654):3, 5, 7, 9 (10 points for each)
Plant: US FoundryAddress: 8351 N.W. 93rd. St.
Medley, FL 33166 Date: April 6 (Wednesday), 2011 Time 9:30 am Carpool: by project team
Long pants & closed toe shoes.
Extra credit: 50 points for homework.
Plant Visit to US Foundry Plant Visit to US Foundry