Centring, Drilling, Counterboring and Countersinking, Reaming and

Tapping on the Drilling Machines Course: Techniques for Machining

of Material. Instruction Examples for Practical Vocational Training

Table of Contents
Centring, Drilling, Counterboring and Countersinking, Reaming and Tapping on the Drilling
Machines Course: Techniques for Machining of Material. Instruction Examples for Practical
Vocational Training..........................................................................................................................................1
Introduction.............................................................................................................................................1
Instruction example 1.1. Distance piece.................................................................................................2
Instruction example 1.2. Gib...................................................................................................................4
Instruction example 1.3. Cylinder...........................................................................................................6
Instruction example 1.4. Prismatic guideway..........................................................................................9
Instruction example 1.5. Stop...............................................................................................................12

ii

Centring, Drilling, Counterboring and Countersinking, Reaming and

Tapping on the Drilling Machines Course: Techniques for Machining
of Material. Instruction Examples for Practical Vocational Training
Institut fr berufliche Entwicklung e.V.
Berlin
Original title:
Lehrbeispiele fr die berufspraktische Ausbildung
Zentrieren, Bohren, Senken, Reiben und Gewindeschneiden auf der Bohrmaschine
Author: Dieter Frank
First edition IBE
Institut fr berufliche Entwicklung e.V.
Parkstrae 23
13187 Berlin
Order No.: 90333501/2

Introduction
This material contains 5 selected instruction examples which serve the purpose of applying and consolidating
the knowledge of the techniques of centring, drilling, counterboring and countersinking, reaming and tapping
on the drilling machine.
The information given about the necessary materials, tools, measuring and testing means and auxiliaries
serves as a basis for preparing and carrying out the sequence of operations. In instruction example 2 the steel
is characterized by the value of the tensile strength in the unit Megapascal (MPa).
The previous knowledge necessary is mentioned as a recommendation. It should be repeated before starting
work. The specified sequence of operations reflects the order of steps leading to the manufacture of the
corresponding workpiece. In order to reach good quality, it is necessary to follow this order of steps.
Premachining of the workpieces (turning, milling) is in most cases a prerequisite for the sequence of
operations of the abovementioned techniques.
The whole sequence of operations implies the correct choice of cutting values. Hints on this can be taken from
the Trainees handbook of lessons.
Each instruction example is provided with a working drawing from which the required shapes and dimensions
of the workpiece can be taken. It is also possible to choose other pieces for exercise with smaller or larger
dimensions. The admissible deviations of dimensions without tolerance indication can be taken from the
following table.
Nominal size

Admissible deviation in mm

0.5 6

0.1

6 30

0.2

30 120

0.3

120 315

0.5

The allowable surface roughness Rz is given in m (0.001 mm).

Instruction example 1.1. Distance piece

This instruction example describes the manufacture of rotationally symmetrical workpieces with through hole
in the chuck by means of the techniques of centring and drilling. Machining is made on the internal
circumference of the workpiece.

Material
9 S 20 K (9 = 0.09 % carbon, 20 = 0.2 % sulphur content; K = colddrawn)
Dimensions
30 60
Tools
A 2.5 centre drill; twist drill of 16
Measuring and testing deans
Vernier caliper
Auxiliaries
Chuck, drill chuck, taper sleeves, drill drift, coolant or lubricant
Required previous knowledge
Reading of drawings, measuring and testing, choice of cutting values
Sequence of
operations

Remarks

1. Measure rough
dimensions.

In case of length undersize reject workpiece.

2. Clamp workpiece.

Kind of clamping: chucking in hard chuck jaws. Chuck for 30 mm. Clamp the
chuck high in place to make chip removal possible.

3. Clamp tool.

Insert drill chuck into boring sleeve, use taper sleeves, if necessary. Make sure
that the axial positions of workpiece and tool correspond. In case of deviations
align workpiece with chuck (punch marking in the centre of the workpiece
facilitates visual comparison).

4. Set cutting values.

5. Centre.

Note central position, feeding is made by hand.

6. Clamp tool.

Insert taper shank of twist drill into boring sleeve, use taper sleeves, if necessary.

7. Drill 16 mm.

Use coolant, make through hole.

8. Switch off machine.

Before switching off, return tool.

9. Dechuck.

Clean chuck.

10. Make dimensional

inspection and visual
check.

Make surface inspection and dimensional inspection. Pay attention to cylindricity

and surface appearance.
Deburr the bore on both sides with suitable means (counterbore, triangular
scraper). In case of series production centre all workpieces first and then drill.

Distance piece

Instruction example 1.2. Gib

This instruction example describes the manufacture of prismatic workpieces with cylindrical through hole and
counterbore by means of the techniques of centring, drilling and counterboring. Punch marking (determination
of the centre of the hole to be machined by means of the scriber and centre punch) is presupposed.
In case of series production the use of fixtures (positioning of the workpiece in fixed position) is advisable.

Material
GGL 25 (GG cast iron, L lamellar, tensile strength of 25 250 MPa)
Dimensions
160 40 20 (premachined)
Tools
Twist drill of 8.4; piloted counterbore of 8.4 13
Measuring and testing means
Vernier caliper, depth gauge
Auxiliaries
Machine vice, drill chuck, taper sleeves, drill drift, parallels, coolant or lubricant
Required previous knowledge
Reading of drawings, measuring and testing, choice of cutting values
Sequence of operations

Remarks

1. Measure rough dimensions.

In case of undersize in length, width, height and shoulder thickness reject

workpiece.

2. Clamp workpiece.

Kind of clamping: loose vice clamping, insert parallels.

Clamp for size 40 mm.
Note: Dead weight of the vice must be heavy enough to avoid distortions,
otherwise clamp firmly. Clamping width must be at least 100 mm (if
clamping area is smaller, intermediate clamping is necessary).
Parallels must lie freely and not allow spotdrilling (width smaller than 6
mm). Press on firmly and clamp centrally.

3. Clamp tool.

Insert drill chuck into boring sleeve, use taper sleeves, if necessary.

4. Set cutting values.

5. Align.

Align vice with clamped workpiece for first centre punch.

Keep in central position (with left hand).

6. Drill first through hole of

8,4 mm.

Spotdrill and check for centre (centring is not necessary because of

centre punching). Align in case of deviation. Make through hole of 8.4
mm. Drill uniformly with manual feed.

7. Align.

Align for second hole according to working step 5.

8. Drill second through hole of

8.4 mm.

Finish hole according to working step 6.

9. Align.

Align for third hole according to working step 5.

10. Drill third through hole of

8.4 mm,

Finish hole according to working step 6.

11. Clamp tool.

Use drill chuck or taper sleeves (in case of taper shank).

12. Align.

Align vice with clamped workpiece for corresponding axial position

between tool pin and work piece hole of 8.4 mm.
In doing so, insert pin into workpiece hole. Alignment is made by hand at
low speed (approx. 15 r.p.m.).

13. Counterborefirst
counterbore of p 13 mm.

Choose the speed n to be less than 40 r.p.m. (multipleedge tool). Guide

the feed by hand and uniformly. Pay attention to size (counterbore depth
of 8 mm).

14. Align.

Align for second counterbore according to working step 12.

14. Counterboresecond
counterbore of 13 mm.

Finish counterbore according to working step 13.

16. Align.

Align for third counterbore according to working step 12.

17. Counterbore third

counterbore of 13 mm.

Finish counterbore according to working step 13.

18. Deburr, make dimensional

inspection and visual check.

Deburr external contours of the 8.4 mm and 13 mm holes with

suitable means (countersink, triangular scraper, twist drill). Surface
inspection pay attention to centredistance displacement between 8.4
mm and 13 mm holes.

Gib

Instruction example 1.3. Cylinder

This instruction example describes drilling, counterboring, countersinking and reaming of prismatic workpieces
with multiplestep bores and a fitting throughhole (closely tolerated bore) with necessary countersink.
Centring or punch marking is presupposed. In case of series production the use of fixtures is recommended.

Material
Al 99.5 (Al aluminium; 99.5 % pure aluminium; 0.5 % impurities)
Dimensions
70 60 60
Tools
Twist drill of 7 and 28; piloted counterbore of 7 11; spiralflute counterbore of 29.7; 45 included
angle countersink; machine reamer of 30 H7
Measuring and testing means
Vernier caliper, depth gauge, limit glug gauge 30 H7, coolant or lubricant (spirit for reaming)
Required previous knowledge
Reading of drawings, measuring and testing, kinds and applications of tools, clamping equipment and
auxiliary equipment.
Explanations to the working drawing
30 H7: diameter, 30 nominal size, H position in the tolerance zone/basic bore, 7 quality
Auxiliaries
Parallels, clamps, coolants or lubricants (spirit in case of reaming)
Sequence of operations

Remarks

1. Measure rough dimensions.

In case of undersize in length, width and height reject workpiece.

2. Clamp workpieces.

Kind of clamping: loose vice clamping, insert parallels.

Clamp on edge and rectangularly for size 60 mm.

3. Clamp tool.

Insert drill chuck into boring sleeve, use taper sleeves, if necessary.

4. Align.

Align vice with clamped workpiece for first centre punching of 2 7

mm.

5. Drill first through hole of 7

mm.

Spotdrill and check for centre, in case of displacement realign, cool

tool.

6. 11. Align and drill 2nd to 4th

through hole

Align and drill according to working steps 4 and 5.

12. Clamp tool.

Use drill chuck or taper sleeves (in case of taper shank).

13. Align.

Centre vice with clamped workpiece in axial position.

14. Counterbore first

counterbore of 11 mm.

Pay attention to size (counterbore depth 50 mm). Take care to ensure

sufficient chip removal.

15. 20. Counterbore 2nd to 4th

hole of 11 mm.

Align and counterbore according to working steps 13 and 14.

21. Clamp workpiece.

Kind of clamping: firm vice clamping. Mount vice by means of clamp, as

the working pressure will be too high when drilling 28 mm and
distortions are possible.
Align for centre position (centre punching of 30 mm) and fix in
position.

2. Drill 28 mm.

Make through hole, cool tool, do not spotdrill parallels, make sure that
there is sufficient chip removal.

23. Clamp tool.

Use taper sleeves, if necessary.

24. Counterbore 29.7 mm.

Make through counterbore. Choose small speed approx. 40 r.p.m.

Guide feed uniformly and by hand. Pay attention to surface appearance
(formation of tooling marks).
Use spirit for lubrication (only with aluminium).

25. Clamp tool.

Use taper sleeves.

26. Countersink 40 mm.

Guide the feed by hand and uniformly. Choose the speed to be less than
15 r.p.m.

27. Clamp tool.

Further alignment is not necessary, because firm clamping of the work is

applied, use taper sleeves. Check reamer marking, measure cutting
edge size with micrometer, if necessary.

28. Ream 30 H7.

Start the cut and make preliminary check with plug limit gauge. Lubricate
the cutting edges. Choose the speed to be smaller than 30 r.p.m. Note
surface finish, ream uniformly, return reamer with the machine running.

29. Make dimensional inspection

and visual check.

Use plug limit gauge.

Cylinder

Instruction example 1.4. Prismatic guideway

This instruction example describes drilling, countersinking and reaming of prismatic workpieces which have
tapered bores. Centring or punch marking as well as mounting holes are presupposed. The workpieces are
premachined in their outer contours.

Material
15 Cr 3 (0.15 % carbon, 0.6 % chromium)
Dimensions
120 60 20 (premachined)
Tools
Twist drill of 8, taper reamer (1 : 50)
Measuring and testing means
Vernier caliper, taper pin of 8 (1 : 0)
Auxiliaries
Machine vice, drill chuck, taper sleeves, drill drift, parallels, coolant and lubricant
Required previous knowledge
Reading of drawings, measuring and testing, kinds and applications of tools, clamping and auxiliary
equipment, kinds and shapes of tapers
Explanations to the working drawing
(K = 1:50): taper per inch, on 50 mm of length 1 mm of taper
Sequence of operations

Remarks

1. Measure rough dimensions.

In case of undersize reject workpiece.

2. Clamp workpiece.

Kind of clamping: loose vice clamping, insert parallels (be careful

not to drill them). Clamp for size 60 mm.

3. Clamp tool.

Insert drill chuck, use taper sleeves.

4. Align.
5. Drill first through hole of 8 mm.

Spotdrill and check for centre, finish through hole as

preparation for reaming, use coolant.

6. Align.
7. Drill second through hole of 8 mm.

Finish hole according to working step 5.

8. Clamp tool.

Insert reamer into drill chuck or use taper sleeves in case of

taper shank.

9. Align.

10

10. Ream first taper hole.

Finish taper hole, use coolant. Feed by hand and uniformly.

11. Align.
12. Ream second taper hole.

Finish second taper hole according to working step 10.

13. Make dimensional and visual check

inspection.

Deburr the holes with suitable means. In case of series

production finish the hole of 8 mm first and then ream.

Prismatic guideway

11

Instruction example 1.5. Stop

With this instruction example the drilling, countersinking and tapping of prismatic workpieces is practised.
Centring or punch marking is presupposed.

Material
100 Cr 6 (1 % carbon, 1.2 % chromium)
Dimensions
85 30 20 (premachined)
Tools
Twist drill of 6.75 mm; 30 included angle countersink; M8 machine tap
Measuring and testing means
Vernier caliper, M8 thread limit plug gauge
Auxiliaries
Machine vice, drill chuck, tap chuck, taper sleeves, drill drift, parallel, coolant or lubricant
Required previous knowledge
Reading of drawings; measuring and testing; kinds and applications of tools, clamping and auxiliary
equipment; kinds and shapes of thread
Explanations to the working drawing
M8: m metric screw thread, 8 nominal diameter
Sequence of operations

Remarks

1. Measure rough dimensions.

In case of undersize reject workpiece.

2. Clamp workpiece.

Kind of clamping: loose vice clamping. Insert parallels, set up for size
30 mm.

3. Clamp tool.

Insert drill chuck, use taper sleeves.

4. Align.

Pay attention to centre position.

5. Drill first through hole of 6.75

mm.

Spotdrill and check for centre, finish through hole as preparation for
tapping, use coolant.

6. Align.

12

7. Drill second through hole of

6.75 mm.

Finish hole according to working step 5.

8. Clamp tool.

Use taper sleeves.

9. Align.
10. Countersink first hole for 6.75
mm.

Countersink for 8.5 mm, keep cutting values of the multipleedge tool
low (n = 30 r.p.m.)

11. Align.
12. Countersink second hole for
6,75 mm.

Finish countersink according to working step 10.

13. Reset workpiece.

Clamp the workpiece for turnover (180). Clean bearing surfaces

before.

14. Countersink the side turned

over.

Countersink holes for 6.75 mm according to working steps 9 12.

15. Clamp tool.

Use tap chuck and taper sleeves.

16. Tap M8.

Make tapped holes. Align according to working step 4. Consider

runout time and switching phase from clockwise rotation to counter
clockwise rotation (n = 60 r.p.m.).

17. Make dimensional inspection

and visual check.

Make surface check.

13

Stop

14