KULLIYYAH OF ENGINEERING, IIUM

MEC1105 WORKSHOP TECHNOLOGY

BENCHWORK & DRILLING

DRILLING

SAFETY
As explained during the Introductory session. For bench-work, do not use a file without a proper handle Clean files using wire brush

INTRODUCTION 1
Introduction Most common machining process One estimate is that 75% of all metal-cutting material removed comes from drilling Holes to take operations. Screws, rivets,
Shafts, etc.

INTRODUCTION 2
Introduction Chips must exit through the flutes to the outside of the tool Cooling passage

Pecking necessary when chips are large & continuous

Drill can wander upon entrance and for deep holes

 Introduction Holes produced normally bigger than the drill diameter

Depending on applications (accuracy), reaming or honing is necessary Large torque Use of wood backing or holed table Use of vise

INTRODUCTION 3

DRILLS 1
The figure below labels the important angles for a typical twist drill bit

Right hand cut or left hand cut

DRILLS 2
The figures below illustrate various drill bits and their cut hole configurations.

DRILLS 3
The figures below illustrate various drill bits and their cut hole configurations.

DRILLS 4
Center drills Short stubby drills For centering work

Drill chucks can be of several types, but are typically three-jaw since three points on the circumference define a circle

DRILLS 5
gun drilling

Indexable insert

trepanning

Coated drill

 Reaming

DRILLS 6

A process to slightly enlarge a pre-existing hole to a tightly toleranced diameter Hand reamer

On machine, speed is 1/2 of drilling speed

DRILL PRESS 1

DRILLING PARAMETERS 1
Drilling parameters Size of drill - governed by diameter over the lands Flutes - 1, 2, 3, or 4 flutes Helix angles - different helix angles for different materials (standard ~ 24o) Main motion - rotary Feed motion - perpendicular to work-piece Point angles - 118o

DRILLING PARAMETERS 2

Helix angle (rake angle)

Lip clearance (clearance angle)

DRILLING PARAMETERS 3
Drilling parameters shank - straight & taper (over 13 mm diameter, for more torque) V 1000 Drill RPM, N rev/min p D
cutting speed, V (m/min) drill diameter, D (mm)

feed rate, f (mm/rev) MRR = (pD2/4)(f)(N) (mm3/min)

DRILLING PARAMETERS 4
Steel Iron Aluminum Lead Cutting speed vs work-piece material

Carbon Steel High Speed Steel Carbide Cutting speed vs Tool material Coolant should be aimed Cooling & lubricating

at the area the tool contacts the work. It should be flooded so that as much fluid as possible reaches the cutting edges (also helps wash the chips out of the

DRILLING PARAMETERS 5
Guidelines for drilled part design. Specify standard drill bit sizes Through holes preferred over blind holes. Do not specify flat-bottomed holes. Do not specify holes smaller than 3.5 mm. Drills tend to break

For large holes, cast preliminary hole & bore out to specification.
Minimize no of drilled hole sizes to minimize tool changes

DRILLING PARAMETERS 5
Guidelines for drilled part design. Minimize no of directions on the part holes must be drilled from Avoid deep holes; use stepped holes Ease of the feed pressure slightly before the drill breaks through

Use spot drill to start a hole

Use several smaller sized drills in order to get the final hole diameter

BENCH WORKING

TOOLS
Two types of tools Hand tools & power tools

Common tools
Hammer, screw-drivers, wrenches (box, open-end, combination, adjustable, pipe, torque), chisels, pliers, pullers, hacksaws, files, punches (centre, prick), drills, taps, dies, rules, etc.

 Layout

LAYING OUT 1

Accurate measuring depends on your needs, attitude & your tools

Accurate location of center for holes & circles

Define boundaries, shapes & other locations Guide in making the part to the given dimensions

Process involves:
surface preparation

tools selection

 process involves:

LAYING OUT 2

reference point/edge (datum)

marking
Involves accurate transfer of measurements from a drawing

Tools needed for your projects:

Metal rule - Scriber Combination square Protractor Vernier height gage - Divider

Hand tap

- Drill bits

LAYING OUT 3
Errors Parallax

Rounding
Accuracy of tools - tool conditions

Marking/scribing method

LAYING OUT 4
Burn-in 1 mm or 1 cm to avoid error

 Files To cut & shape work-piece accurately to achieve smooth finish & to prescribed dimensions Classified into: Width of cut Type of cut - single-cut (finishing & soft materials), double-cut (to cut steel, cast iron, etc.), rasp (wood) Grade ~ 00 (Course for heavy works) - 5~10 (finishing)

BENCH-WORKING 1

 Files File shapes ~ for different applications square, flat, round, half-round, 3square, websaw, cantsaw,knife Clamp work-piece Negative Protect work-piece rake Height of vice angle to Holding of file - nail thumb scrape materials Files are brittle - do not drop them Good filing speed ~ 40 - 50 strokes/min

BENCH-WORKING 2

BENCH-WORKING 3
Files Position of feet - horse stand Movement of file - forward pressure Use slow even filing over the Point entire file length Length Tang Face Handle Heel

Edge

BENCH-WORKING 4
Hacksaws Set up good support like your workbench, allow good clearance for full long stroke of your saw Measure & mark your stock & align blade slightly to the waste side of your mark to allow for the width of saw kerf Make three pull strokes to establish your cuts (only forward strokes cut) Cut your stock (with downward force) Finish with lighter strokes

BENCH-WORKING 5
Taps & Dies Taps cut inside threads Tap wrench holds the tap Dies cut outside threads Die stock holds the die Left or right-hand thread Use cutting oil or lubricant to the surface Every two turn, back off tap or die & apply more oil

BENCH-WORKING 6 Bench vise

Use soft metals to protect part surface Use vise to hold your work-pieces to do filing, hack-sawing, chiseling, & bending light metals Never hammer on your vise Pedestal grinders Do not grind on the side of the wheel Watch out for sparks Do not touch rotating wheels Wear eye protection

THE END
IQ + EQ + SQ = TQ