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CHAPTER 4
Cutting Tools for Hole Machining
Design of Drills
During drilling rotary motion about the axis of the tool and straight line feed
motion along the tool axis are required (both of these motions are
imparted to the drill).
The drill is clamped in the spindle which rotates it and feeds it downward
into the workpiece clamped stationary on the table.
Drill is a more complex tool than a SPT. The machining process goes in
complex conditions:
1. Flow of chip and the cutting fluid;
2. Friction due to the flow of the chip and rubbing of the tool with the
generated hole;
57
3. Cutting speed varies from max. to zero along the cutting edge;
4. The rake and clearance (relief) angles vary along the cutting edge of
a twist drill.
These factors make the chip formation process in drilling and drill more
severe (complex).
Point - The cutting end of a drill, made up of the ends of the lands and
the web. In form it resembles a cone.
Point angle The angle included between the cutting lips projected
upon a plane parallel to the drill axis and parallel to the
two cutting lips.
58
Chisel edge The edge at the end of the web that connects the
cutting lips.
Chisel edge angle The angle included between the chisel edge and
the cutting lip.
Face The surface on which the chip impinges and along which it
flows as it is separated from the workpiece.
Lip relief surfaces (flanks) The surfaces of the tool facing the
workpiece.
Web The central portion of the body that joints the lands. The
extreme end of the web forms the chisel edge on a two-flute
drill.
Web thickness The thickness of the web at the point, unless
another location is indicated.
Land width- The distance between the leading edge and the heel of
the land.
59
Drill diameter The diameter over the margins of the drill measured
at the point.
Helix angle The angle made by the leading edge of the land with a
Neck The section of reduced diameter between the body and the
shank.
60
Twist drills,
Straight-flute drills,
Flat drills,
Deep-hole drills,
Trepanning drills,
Gun drills,
Tapered drills,
Centre drills and
Special-purpose combination drilling tools.
Each of the enumerated types can be further divided into many design
versions.
61
The diameter of the drill should always be slightly smaller than the
diameter of the hole to be drilled, since drills always cut oversize.
To reduce friction between the drill and the machining surface, the
diameter of the drill over the margins at the body of the drill (finishing
section) is slightly tapered back towards the shank.
The back taper is to provide longitudinal clearance.
The recommended back taper can be selected from the tables 4.1
and 4.2).
Table 4.1: recommended value of the back taper.
Drill diameter, mm
1 to 6
Over 6 to 18
Over 18
0.03 to 0.07
0.04 to 0.08
0.05 to 0.10
Drill dia.
mm
Helix
angle,
Web
thickness,
W
Back
taper in
100 mm
0.25-0.35
18o
0.3D
0.015
0.40-0.45
0.5-0.70
0.75-0.95
1.0-1.9
2.0-2.9
3.0-3.4
3.5-4.4
4.5-6.4
6.5-8.4
8.5-9.9
10-18
Over 18
0.3D
0.3D
0.3D
0.27D
0.27D
0.27D
0.27D
0.27D
0.25D
0.20D
0.16D
0.13D
0.015
0.02
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.10
0.10
2
3
4
5
6
7
8
9
10
11
12
13
19
20o
21o
22o
23o
24o
25o
26o
27o
28o
30o
30o
Cylindrical land
(Margin)
Width,
f
Height,
h
0.2
0.3
0.4
0.6
0.7
0.8
1.0
0.07D
0.1
0.1
0.1
0.15
0.2
0.3
0.5
0.03D
Length
Flute,
Lf
Over all,
Lo
Refer
Refer
Table
Table
16
16
62
Fig. 4.7
63
edge, therefore the drill cutting ability improves and the chip
disposal facilitates.
Experiences show, that with decreasing the point angle (2) from 140
up to 90, axial cutting force decreases to 40-50%, and torque increases
about 25-30%.
Point angles smaller than 118 are preferred for many cast irons,
copper, fiber aluminum alloys, die castings, and abrasive materials.
Point angles greater than 118 are used for hard steels and other
difficult materials.
64
Table 4.3: The recommended values of rake angle and point angle 2 of drills tipped
with cemented carbides.
Workpiece material
, degree
2, degree
0-4
-3
0
-3
-3
6
0
4-6
4-6
0-2
116-118
116-118
116-118
116-118
130-135
116-118
116-118
116-18
140
60-100
Hardness, BHN
(Rockwell
values in
parentheses)
Point
Angle, deg.
LP relief
angle, deg.
Chisel Edge
angle, deg.
Helix
Angle,
deg.
Point
Grind*
100-225
225-325
325-425
RC45-52
118
118
118-135
118-135
12-15
10-12
8-10
7-9
125-135
125-135
125-135
125-135
24-32
24-32
24-32
24-32
S
S
C
C
118
8-10
125-135
24-32
118
118
118
118
8-12
10-12
10-12
7-10
125-135
125-135
125-135
125-135
24-32
24-32
24-32
24-32
S
S
S
C
118-135
7-10
120-130
24-32
118
118-135
7-10
9-12
125-135
125-135
24-32
24-32
C
C
170-290
118
7-10
125-135
24-32
80-360
210-360
RC48-52
30-150
500kg
40-90
500kg
RE20-100
80-100
118
8-12
125-135
24-32
118
7-10
125-135
24-32
90-140
12-15
125-135
24-48
70-118
12-15
120-135
10-30
118
118
12-15
12-15
125-135
120-135
10-30
24-32
S
S
175-425
RC45-52
110-225
225-400
135-200
200-325
325-425
RC48-52
110-440
140-400
180-320
65
Table 4.5 lists the recommended values of the point angle 2 and
flute helix angle for drilling various materials.
66
The web thickness depends on the tool material and the diameter of
the drill as given in table 4.2, 4.6:
In twist drills with milled flutes, the web thickness increases by (1.4 to
1.8 mm per 100 mm) toward the shank.
- This raises the strength and rigidity of the drill.
Table 4.5: Recommended Values of and 2 for Drilling Various Work Metals with Drills of Tool
Steels*
Flute helix
Workpiece material
angle,
Point angle,
2
Workpiece material
Flute helix
angle,
Point angle,
2
Steel, t up to 50
kgf/mm2
35
116
marble
80-90
Steel, t from 50
up to 70 kgf/mm2
30
1160-118
Copper castings
and brass
25-30
130
Steel, t from 70 To
100 kgf/mm2
25
120
Bronze,
HB 100 and harder
15-20
135
20
125
Soft bronze,
HB <100
8-12
125
Stainless steel
25
120
35- 45
130-140
25 -30
116-120
Copper
35 - 45
125
8-12
60-100
Aluminum
alloys
Plastics, ebonite,
laminate fabric base
* The data of this table refer to drills of a diameter beginning with 10 mm and up. Other angles should be
used for smaller drills. These data are for drills of high-speed, carbon and alloy tool steels, but not for
those of, or tipped with, cemented carbides.
__________________________________________________________________________________
Table 4.6: Web thickness of twist drill.
Tool material
Carbon steel and HSS
Carbide tipped
Drill dia., D, mm
Web thickness, mm
6 to10
Over 10
6 to 10 mm
over 10
(0.20 to 0.25) D
(O.13 to 0.16) D
(0.27 to 0.30) D
(0.20 to 0.26) D
67
NOTE: Carbide-tipped drills are made with webs comparatively thick because the drill body is weakened
by the slot for the tip.
Usually, the land width is taken equal to the flute width, i.e. to
one fourth of the drill circumference in two-flute drills.
Table 4.7 shows the proportion of the land width (b) with respect to the
drill diameter (D) for high-speed steel drills:
Table 4.7: The values of the land width b with respect to the drill diameter D.
Drill diameter, mm
Land width b, mm
3 to 8
0.62D
8 to 20
over 20
0.59D
0.58D
The width of the margin (f) and the height (h) are given by:
f = (0.06 0.07) D
4.1
h = (0.02 0.03) D
4.2
68
The lip, or cutting edge, of a twist drill is the line formed by the
intersection of the face and lip relief surface, and in most cases is
straight.
- However, investigations have shown that a more constant rake
angle () can be obtained with a curvilinear (convex) lip.
The shape of the flute cross section is not specified in drawings of twist
drills but another element is indicated:
The tooth profile of the fluting cutter (for drills with milled
flutes)
Or the profile of the rolled drill blank (for twisted drills).
The profile of the fluting cutter (its shape is shown in Figure 4.9) can
be determined by two methods:
By the graphical method in which the profile of the cutter is
constructed from the given flute profile,
And analytically method, with the curves making up the profile
being calculated by analytical formulas.
All the elements of the profile of the fluting cutter (radii Ro and Rf
and width B) can be determined by a simplified analytical method.
The approximate formula for determining radius Ro of the cutter
profile for a drill of diameter D is:
Ro = CR Cr Cfc D
4.3
69
Rf = Cf D
4.7
Cf = 0.015 0.75
4.8
70
Fig. 4.10: Principle of hot forge rolling and twisting of drill blanks: (a) rolling the flutes: (b)
twisting the blank
Several techniques are used for rolling drill blanks (hot forge
rolling; cross, or transverse rolling; longitudinal helical rolling,
etc.).
71
The overall length (Lo) and the flute length (lf) affect the rigidity of
the drill.
A. Flute length (lf):
A longer fluted length permits for larger number of sharpening
along the length of the lip.
The flute length should be shorter for carbide-tipped drills (15 - 45
mm) than for high-speed steel (HSS) drills because it is sharpened
a limited number of times.
B. Overall length (Lo):
The tang and other dimensions are made to the standard. That means:
3Mrc = Mfr
4.11
72
The friction torque between the shank and taper sleeve is:
Standard
Lf,
Lo,
mm
mm
Extra length
Lf,
Lo,
mm
mm
2.7
3
33
67
66
100
3.2
36
73
69
106
3.5
39
78
73
112
3.8
4.0
4.2
43
84
78
119
4.5
47
91
82
126
4.8
5.0
52
97
87
132
shank
9.6
10.6
10.7
11.8
12.0
13.2
Str.
D, mm
13.3
14
14.2
15.0
15.2
16.0
Standerd
Lf,
Lo,
mm
mm
Extra length
Lf,
Lo,
mm
mm
shank
87
150
121
184
Str.
94
161
128
195
Str.
101
172
134
205
MT1
108
189
140
221
MT1
114
212
144
242
MT2
120
218
149
247
MT2
73
5.3
5.5
6.0
57
105
91
139
16.2
17.0
125
223
154
252
MT2
6.2
6.5
63
114
97
148
18.25
19
135
233
158
256
MT3
6.8
7.5
69
123
102
156
19.2
20.0
140
238
166
264
MT3
7.6
8.5
75
131
109
165
20.2
21.0
145
243
171
269
MT3
8.6
9.5
81
141
115
175
21.2
22.3
150
248
176
274
MT3
22.5
23.0
155
253
180
278
MT3
Table 4.9: Coefficients CF and Exponents of the Formulas for Calculating the Cutting Forces and
torque in drilling, boring and coring.
Metal Being
Machined
Machining
operation
Structural and
Carbon Steel b
=75 kgf/mm2
Drilling
High Temper-re
Steel
HB 141
2.0
0.8
68
1.0
0.7
0.09
1.0
0.9
0.8
67
1.2
0.65
Drilling
0.041
2.0
0.7
143
1.0
0.7
Boring and
Coring
0.106
1.0
0.9
0.8
140
1.2
0.65
0.012
2.2
0.8
42
1.2
0.75
0.196
0.85
0.8
0.7
46
1.0
0.4
0.021
2.0
0.8
42.7
1.0
0.8
0.085
.075
0.8
23.5
1.2
0.4
0.021
2.0
0.8
43.3
1.0
0.8
0.01
2.2
0.8
32.8
1.2
0.75
0.17
0.875
0.8
0.7
38
1.0
0.4
0.012
2.0
0.8
31.5
1.0
0.8
0.031
0.85
0.8
17.2
1.0
0.4
0.005
2.0
0.8
9.8
1.0
0.7
Boring and
Coring
Boring and
Coring
Copper
Heterogeneous
Alloys
, HB 120
HSS
Cemented
carbide
Drilling
Boring and
Coring
Malleable cast
iron
HB 150
Cm
0.0345
Drilling
Cast Iron HB
190
Cutting
tool
material
HSS
Drilling
Boring and
Coring
Cemented
carbide
Drilling
Boring and
Coring
Alum-m and
Silumin
Drilling
HSS
74
Or
After determining (dm), from table 10 select the nearest lager taper, i.e.
Morse taper and all other dimensions.
75
K M F and K M - (
M
Morse tapers
Designation
of taper
diameter
dm
D1
d2
d3max
l3max
l4max
a
bh13
c
emax
R
R1
v
Angles of taper
1:19.212
=0.05205
1:20.047
=0.04988
1:20.020
=0.04995
1:19.922
=0.05020
1:19.254
=0.05194
1:19.002
=0.05263
1:19.180
=0.05214
9.045
9.2
6.1
6.0
56.5
59.5
3.0
3.9
6.5
10.5
4.0
1.0
0.06
12.065
12.2
9.0
8.7
62.0
65.5
3.5
5.2
8.5
13.5
5.0
1.2
1.06
17.780
18.0
14.0
13.5
75.0
80.0
5.0
6.3
10.0
16.0
6.0
1.6
0.065
23.825
24.1
19.1
18.5
94.0
99.0
5.0
7.9
13.0
20.0
7.0
2.0
0.065
31.267
31.6
25.2
24.5
117.5
124.0
6.5
11.9
16.0
24.0
8.0
2.5
0.07
44.399
44.7
36.5
35.7
149.5
156.0
6.5
15.9
19.0
29.0
10.0
3.0
0.07
63.348
63.8
52.4
51.0
210.0
218.0
8.0
19.0
27.0
40.0
13.0
4.0
0.07
76
steel
HB < 160
0.09-0.13
0.13-0.19
0.19-0.26
0.26-0.32
0.32-0.36
0.36-0.43
0.43-0.49
0.49-0.58
0.58-0.62
0.62-0.78
0.78-0.89
HB 160-240
0.08-0.10
0.10-0.15
0.15-0.20
0.20-0.25
0.25-0.28
0.28-0.33
0.33-0.38
0.38-0.43
0.43-0.48
0.48-0.58
0.58-0.66
HB 240-300
0.06-0.07
0.07-0.11
0.11-0.14
0.14-0.17
0.17-0.20
0.20-0.23
0.23-0.27
0.27-0.32
0.32-0.35
0.35-0.42
0.42-0.48
HB >300
0.04-0.06
0.06-0.09
0.09-0.12
0.12-0.15
0.15-0.17
0.17-0.20
0.20-0.23
0.23-0.26
0.26-0.29
0.29-0.35
0.35-0.40
Table 4.12: Correction factor K for Steel and Cast Iron, taking into account the effect
of the metal being machined on the cutting Forces.
Metal Being
Machined
Formula For
Calculation
Structural and
Carbon Steel b,
kgf/mm2
60
60
K b
75
HB
K
190
Cast Iron
HB
K
150
Force Fz When
Machining With
SPT
Value Exponent n
Torque Mt and
Axial Force Fx for
Drilling, Boring
and Core Drilling
Fz for Milling
0.75/0.35
0.75/0.75
0.75/0.75
0.75/0.75
0.3/0.3
0.3/0.3
0.4/0.55
0.6/0.6
1.0/0.55
0.4/0.55
0.6/0.6
1.0/0.55
Not: nominator value of n for cemented carbide, denominator value of n for HSS.
Table 4.13: Types of Drill Points.
Drill diameter,
mm
Type of point
Designation
0.25 to 12**
Ordinary (standard)
Sketch
Materials drilled
77
ST
DT
DTM
Double- angle,
thinned web and
notched point
DT-2
12 to 80
** An ordinary (standard) point is used for drills over 12 mm in size if the same drill is
used for various work materials in operation on a foundry skin or with the skin
removed, as is often the case in small-lot production.
At the present time, all the main types of drills have been standardized:
a. Carbon and high-speed steel drills with straight and tapered shanks
and of various lengths (short, standard, long, etc.);
b. Carbide-tipped drills with straight and tapered shanks;
c. Centre drills; etc.
These drills:
1. used for drilling cast iron, hardened steel, plastics, glass,
nonferrous metals, marble, granite and other nonferrous
materials;
2. rarely use for drilling the workpieces of steels, because of the
instability of work (possibility of breakdown, crumbling-off and an
78
In order to increase the rigidity and strength of the cemented carbidetipped drills (for increasing their successful work), it is necessary to
increase their web thickness (core diameter) to (0.25 diameter drills0.25D) compared with the high-speed steel drills.
Drills of small diameters (used for drilling the holes in the hard materials)
their web thickness (core diameter) can be increased to (0.32-0.35
diameters of drill 0.32-0.35D) with the simultaneous decreasing
the length of the cutting part (cutting and finishing parts) of the drill.
79
Fastening (settingup) and accurate fixation of the tip on the drill body
produced by screw (2) with a cone head.
After the cutting edge becomes blunt, the insert (1) (see Figure 4.14) is
indexed to bring a new edge of the insert in operation.
After all the edges of the insert are worn out, the insert can be
replaced quickly without removing the U drill from machine. Thus
re-sharpening is completely eliminated.
80
Indexable insert face has chip-breaking grooves to get small length chip,
which easily disposed away from the tool grooves.
As one of the inserts overlaps the center, U drill can be also used for
central cutting after starting a hole with a center drill.
Many point geometries which can be ground on a twist drill are not
available on spade and indexable drills.
81
82
Each diameter has its own flute and land as shown in (Figure 4.16),
this results in a complex flute geometry, which is necessary for
what is effectively two or more tools sharing a common axis and
core.
2. Concentricity guaranteed.
Fig. 4.17
83
The advantages of the Subland drill over the step drill are the
preservation of the geometry for all diameters after regrinding and
therefore the lager number of regrinds possible.
Investigation Procedure
Sharpening required here
Because you have individual flutes for each diameter. All you have to do
is end grind each diameter maintaining the same step length
dimension. You will never have to grind the tool "diameter".
84
Performance:
85
86
The two-flute assembled twist drill shown in Figure 4.19, b, has four
margins (instead of two) which form channels in the lands for the
cutting fluid.
- Chips are ejected along the flutes and then through inclined holes
into a central hole from where they pass through the driving tube at
the end of which the drill is held.
- Cutting fluid at a pressure of 10 to 20 atm is fed into the annular
space between the driving tube and the drilled hole.
- Drilling is done in a special machine equipped with a pumping station
for feeding the cutting fluid.
The two-flute twist drill with external chip ejection, shown in Figure 4.19,
Deep holes can also be drilled by using high flute helix angle (figure 4.
20).
- These high-helix drills are intended for drilling holes of a depth over
10 diameters in cast iron, steel, light alloys and wood.
87
88
These drills are also of the single-flute type with a one-sided cutting
arrangement.
89
Fig. 4.22: Gun drill: (a) Construction; (b) diagram of the acting cutting forces.
90
92
Instead of standard cone and chisel edge, drill point can be ground to a
variety of shapes according to the material being drilled and other
requirements.
93
94
Fig. 4.25: Chip breaker grooves on twist drills: (a) on faces; (b) on lip relief surfaces.
Two methods of grinding drill points on machines of the first type are
illustrated in Figure 4.26, a and b.
They differ only in the location of the axis of the imaginary cone in
reference to the drill.
The drill holder which locates the drill during the sharpening operation
is designed so that the apex of the cone along whose the surface of
the point is ground is located at a definite distance from the drill axis.
This distance equals (1.16 D) for the first method (Figure 4.26, a)
(and 1.9 D) for the second (Figure 4.26, b).
Moreover, the axis of the grinding cone is offset from the drill axis "by
an amount (K) equal to from 1/13 to 1/10 of the drill diameter.
The different locations of the imaginary cone axis in relation to the
drill axis lead to different kinds of variation of the relief angle along
the lips.
It is better if the relief angle is greater at the periphery than at the
center of the drill.
95
This requirement has made the second method more popular because
it grinds a drill point with a relief angle sharply increasing toward the
center of the drill.
This increase is much less on drill points ground by the first method.
96
Flat drill point grinding (Figure 4.27) is suitable for small drills (up to 3
mm in diameter) and is seldom used for larger drills.
Large drills are usually ground by a two-plane method.
- The first plane provides the required relief angle behind the lip
and the second plane, ground at a much larger angle, eliminates
interference of the heel on the land with the work surface during
drilling.
Double plane
Plane I
Plane
Plane II
97