CH 5 Drilling

Drillin
By S K
Mondal
Drilling
Drilling is a operation that cuts cylindrical holes.
GATE-2015
In a machining operation , if the
generatrix and directrix both are
straight lines, the surface obtained is
a)Cylindrical
b)Helical
c)Plane
d)Surface of revolution
TYPES OF DRILL PRESSES
Vertical or pillar type
Radial Arm type
Gang drill
Multi Spindle drill
Numerical Control drill

Drilling Operations
Chip formation
of a drill
Drill
The twist drill does most of the cutting with the
tip of the bit.
There are
flutes to carry
the chips up
from the
cutting edges
to the top of
the hole where
they are cast
off.
Drill
IES - 2004
Consider the following statements:
The helical flute in a twist drill provides the
necessary
1. Clearance angle for the cutting edge
2. Rake angle for the cutting edge
3. Space for the chip to come out during drilling
4. Guidance for the drill to enter into the
workpiece
Which of the statements given above are correct?
(a) 1 and 2 (b) 2 and 3
(c) 3 and 4 (d) 1 and 4
IES - 2003
The purpose of helical grooves in a twist
drill is to
1. Improve the stiffness
2. Save a tool material
3. Provide space for chip removal
4. Provide rake angle for the cutting edge
Select the correct answer using the codes given
below:
Codes:
(a) 1 and 2(b) 2 and 3
(c) 3 and 4(d) 1 and 4
Drill
Axial rake angle is the angle between the face and the
line parallel to the drill axis. At the periphery of the drill,

it is equivalent to the helix angle.
The lip clearance angle is the angle formed by the
portion of the flank adjacent to the land and a plane at

right angles to the drill axis measured at the periphery of
the drill.
Lead of the helix is the distance measured parallel to the
drill axis, between corresponding point on the leading

edge of the land in one complete revolution.
Drill
Drill sizes are typically measured across the drill
points with a micrometer

Most widely used material is High Speed Steel
The drill blanks are made by forging and then are
twisted to provide the torsional rigidity. Then the

flutes are machined and hardened before the final
grinding of the geometry.
Deep hole drilling requires special precautions to
take care of the removal of large volume of chips.

GATE- 1996
The rake angle in a drill
(a) Increases from centre to periphery
(b) decreases from centre to periphery
(c) Remains constant
(d) Is irrelevant to the drilling operation
IES - 1997
The rake angle in a twist drill
(a) Varies from minimum near the dead centre
to a maximum value at the periphery
(b) Is maximum at the dead centre and zero at
the periphery
(c) Is constant at every point of the cutting
edge
(d) Is a function of the size of the chisel edge.
Point Angle (2)
The point angle is selected to suit the hardness and
brittleness of the material being drilled.
Harder materials have higher point angles, soft materials
have lower point angles.
An increase in the drill point angle leads to an increase in
the thrust force and a decrease in the torque due to
increase of the orthogonal rake angle.
This angle (half) refers to side cutting edge angle of a
single point tool.
Standard Point Angle is 118
It is 116 to 118 for medium hard steel and cast iron
It is 125 for hardened steel
It is 130 to 140 for brass and bronze
It is only 60 for wood and plastics
Helix Angle ()
Helix angle is the angle between the leading
edge of the land and the axis of the drill.
Sometimes it is also called as spiral angle.
The helix results in a positive cutting rake
This angle is equivalent to back rake angle of a
single point cutting tool.
Usual 20 to 35 most common
Large helix : 45 to 60 suitable for deep holes
and softer work materials
Small helix : for harder / stronger materials
Zero helix : spade drills for high production
drilling micro-drilling and hard work materials
IES - 1992
A drill for drilling deep holes in aluminum
should have
(a) High helix angle (b) Taper shank
(c) Small point angle (d) No lip
GATE- 1997
Helix angle of fast helix drill is normally
(a) 35o
(b) 60o
(c) 90o
(d) 5o
IES - 1992
Low helix angle drills are preferred for
drilling holes in
(a) Plastics (b) Copper
(c) Cast steel (d) Carbon steel
IFS-2011
Discuss deep-hole drilling keeping in mind
speed and feed, mentioning the technique of
applying coolant.
[5-marks]
Cutting Speed in Drilling
The cutting speed in drilling is the surface
speed of the twist drill.
DN
V m / min
1000
Drilling Time
Time for drilling the hole
L
T , min
fN
MRR in Drilling
D 2
MRR 3
fN , mm / min
4
Example
A hole with 40-mm diameter and 50-mm
depth is to be drilled in mild steel
component. The cutting speed can be
taken as 65 m/min and the feed rate as
0.25 mm/rev. Calculate the machining time
and the material removal rate.
Some Formulae for Drilling
D
Cone height (h)
2 tan
f
Uncut chip thickness (t ) sin
2
D
Width of cut (b)
2sin
2r / D tan
Orthogonal rake angle ( ) tan 1

sin
GATE- 2002
The time taken to drill a hole through a 25
mm thick plate with the drill rotating at
300 r.p.m. and moving at a feed rate of
0.25 mm/revolution is
(a) 10 sec (b) 20 sec
(c) 60 sec (d) 100 sec
GATE- 2004
Through holes of 10 mm diameter are to
be drilled in a steel plate of 20 mm
thickness. Drill spindle speed is 300 rpm,
feed 0.2 mm/ rev and drill point angle is
120. Assuming drill over travel of 2 mm,
the time for producing a hole will be
(a) 4 seconds (b) 25 seconds

(c) 100 seconds (d) 110 seconds
GATE- 2012
In a single pass drilling operation, a through
hole of 15 mm diameter is to be drilled in a
steel plate of 50 mm thickness. Drill spindle
speed is 500 rpm, feed is 0.2 mm/rev and
drill point angle is 118. Assuming 2 mm
clearance at approach and exit, the total drill
time (in seconds) is
(a) 35.1 (b) 32.4
(c) 31.2 (d) 30.1

IES - 2002
The arm of a radial drilling machine is
being raised at a speed of 3.9 m/min by
single start square threads of 6 mm pitch
and 30 mm diameter. The speed of the
screw
(a) Is 650 rpm
(b) Is 180 rpm
(c) Is 130 rpm
(d) Cannot be determined as the data is
insufficient
IES - 1994
The ratio between two consecutive spindle
speeds for a six-speed drilling machine
using drills of diameter 6.25 to 25 mm size
and at a cutting velocity of 18 m/min is
(a) 1.02 (b) 1.32
(c) 1.62 (d) 1.82
IES - 2009
What is the drilling time for producing a
hole in an MS sheet of 25 mm thickness
using an HSS drill of 20 mm diameter? The
cutting speed and feed for drill are 20
m/min and 0.25 mm/revolution
respectively, Neglect time taken for
setting up, approaching and travelling of
tools.
(a) 0.314 min(b) 0.236 min
(c) 0.438 min(d) 0.443 min
IES - 2002
A 31.8 mm H.S.S. drill is used to drill a
hole in a cast iron block 100 mm thick at a
cutting speed 20 m/min and feed 0.3
mm/rev. If the over travel of drill is 4 mm
and approach 9 mm, the time required to
drill the hole is
(a) 1 min 40 s (b) 1 min 44 s
(c) 1 min 49 s (d) 1 min 53 s
GATE - 2014
A hole of 20 mm diameter is to be drilled in a
steel block of 40 mm thickness. The drilling is
performed at rotational speed of 400 rpm and
feed rate of 0.1 mm/rev. The required approach
and over run of the drill together is equal to the
radius of drill. The drilling time (in minute) is
(a) 1.00 (b) 1.25 (c) 1.50 (d) 1.75

GATE-2014 (PI)
An HSS drill of 20 mm diameter with 5 mm
cone height is used to drill a through hole
in a steel work-piece of 50 mm thickness.
Cutting speed of 10 m/min and feed rate of
0.3 mm/rev are used. The drilling time, in
seconds, neglecting the approach and over
travel, is _______
IAS - 1999
To drill a 10 mm diameter hole through a
20 mm thick M.S. plate with a drill bit
running at 300 rpm and a feed of 0.25 mm
per revolution, time taken will be
(a) 8 s (b) 16 s
(c) 24 s (d) 32 s
GATE 2007 (PI) Linked S-1
Blind holes 10 mm diameter, 50 mm deep
are being drilled in steel block. Drilling
spindle speed is 600 rpm, feed 0.2
mm/rev, point angle of drill is 120o.
Machining time (in minutes) per hole will
be
(a) 0.08 (b) 0.31 (c) 0.44 (d) 0.86
GATE 2007 (PI) Linked S-2
Blind holes 10 mm diameter, 50 mm deep
are being drilled in steel block. Drilling
spindle speed is 600 rpm, feed 0.2
mm/rev, point angle of drill is 120o.
During the above operation, the drill
wears out after producing 200 holes.
Taylors tool life equation is of the form
VT0.3 = C, where V = cutting speed in
m/minute and T = tool life in minutes.
Taylors constant C will be
(a) 15 (b) 72 (c) 93 (d) 490
IAS - 1994
The time (in minutes) for drilling a hole is
given by
Depth of the hole h
t
Feed RPM
where 'h' is the
(a) Length of the drill
(b) Drill diameter
(c) Flute length of the drill
(d) Cone height of the drill.
IES - 1999
Match List-I (Drill bits) with List-II (Applications) and select
the correct answer using the codes given below the Lists:
List-I List-II
A. Core drill 1. To enlarge a hole to a certain depth so as to
accommodate the bolt head of a screw
B. Reamer 2. To drill and enlarge an already existing hole in a
casting
C. Counter bore drill 3. To drill a hole before making internal
thread
D. Tap drill 4. To improve the surface finish and dimensional
accuracy of the already drilled hole
Code:A B C D A B C D
(a) 1 3 2 4 (b) 2 3 1 4
(c) 2 4 1 3 (d) 3 2 4 1

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Drillin

Radial Arm type

Multi Spindle drill

Numerical Control drill

line parallel to the drill axis. At the periphery of the drill,

portion of the flank adjacent to the land and a plane at

drill axis, between corresponding point on the leading

points with a micrometer

The drill blanks are made by forging and then are

twisted to provide the torsional rigidity. Then the

take care of the removal of large volume of chips.

(a) 4 seconds (b) 25 seconds

(a) 35.1 (b) 32.4

(c) 31.2 (d) 30.1

(a) 1.00 (b) 1.25 (c) 1.50 (d) 1.75

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