Drilling process

Slides of the Drilling manufacturing process.

1. Drilling process Manufacturing technology

2. Manufacturing Manufacturing is the production of products for use or sale using labor and machines, tools, chemical or biological processing or formulation and is the essence of secondary industry. Manufacturing Processes Manufacturing process are the steps through which products are made from raw material. It begins with product design and material specifications, then the materials are modified through manufacturing processes. Types of Manufacturing Processes Casting Forming Moulding Machining Joining Additive Manufacturing Labelling and Painting An industrial worker in KINEX Bearings

3. Drilling Drilling is a process which is used to make circular holes in a solid material. A rotary (multipoint) cutting tool is used for this process which is called a drill bit. This drill bit is pressed against the surface and rotated at high speeds, which removes the chip as the hole is drilled. Process Drilled holes have sharp edge on entrance and burrs on the exit, with helical feed marks inside the hole. Drilling may affect the mechanical properties of the material as the material may become more susceptible to corrosion and crack propagation. So, a finish operation should be done. The type of chips formed is an indicator of the machinability of the material, as long chips suggest good machinability of the material. Cutting fluid is commonly used to cool the drill bit, increase tool life, increase speeds and feeds, increase the surface finish, and aid in ejecting chips.

4. Types of drilling process Spot drilling The purpose of spot drilling is to drill a hole that will act as a guide for the final hole. The hole is drilled only partly in the surface because this is used only as a guide. Center drilling A small 60° countersink, twist drill is used to make centers in a piece of work about to be turned.

5. Deep hole drilling Deep hole drilling is defined as drilling a hole of depth greater than ten times the diameter of the hole. These types of holes require additional equipments for straightness and tolerances. Deep hole drilling can be achieved by following methods. A deep hole, several meters long, drilled in granite Gun Drilling This is used to drill holes of very small diameters, with depth-to-diameter ratio of 300:1. The drills used are self- centering bits and were developed to Drill out gun barrels. Trepanning It is used for creating large diameter holes and it removes the desired diameter by cutting out a solid disc. Eg. Tunnel boring machine

6. Microdrilling Microdrilling refers to drilling of holes less than 0.5mm. It has its own challenges because coolant fed drills cannot be used and high spindle speeds are required. Vibration drilling In this type of drilling, the main principle is to generate axial vibrations along with feed movement of the drill, so that the chips easily breakup and can be easily removed. Orbital drilling Also known as circle interpolating, is based on rotating a cutting tool around its own axis and simultaneously about a centre axis which is off-set from the axis of the cutting tool.

7. Material Drilling in metals For the easy removal of the chips, the drill bit has fluting around it. Sometimes, cutting fluid is used to increase the tool’s life and for lubrication. It is introduced via holes through the drill shank. While cutting aluminium, the cutting fluid ensures a smooth and accurate hole. But in other soft metals, like brass the drill can grab the work piece and leads to chatter. So, a face of 1-2mm is ground on the cutting edge to create an obtuse angle of 91- 93 degrees, which in turn prevents chatter. In CNC machine tools, a process called peck drilling is used which involves plunging the drill partway through the workpiece and then retracting it to the surface. It is done to reduce the chip building. A magnetic base drilling machine allows drilling in a horizontal position and even on a ceiling. It is used when it is not possible to bring the material to the CNC machine. These machines are widely used in construction, fabrication, marine, and oil & gas industries.

8. Drilling in wood It is easier to drill in wood because they are soft, and cutting fluids are not needed. The main challenge in wood drilling is to keep entry and exit holes clean, and to avoid burning. The problem of burning can be solved by using sharp drill bits and the appropriate cutting speed. For boring clean holes, there are several types of drill bits, like forstner bits, brad-point bits and hole saws. Chipping on exit can be minimized by using a piece of wood as backing behind the work piece, and the same technique is sometimes used to keep the hole entry neat.

9. References Manufacturing, wikipedia : https://en.wikipedia.org/wiki/Manufacturing List of manufacturing processes, wikipedia : https://en.wikipedia.org/wiki/List_of_manufacturing_processes Manufacturing processes, engineering articles: http://www.engineeringarticles.org/manufacturing-process-meaning-and-types/ Drilling, wikipedia : https://en.wikipedia.org/wiki/Drilling

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