THIRU SEVEN HILLS POLYTECHNIC COLLEGE MADURAVOYAL, CHENNAI-95.

LEAN AND LEAD 2010-2011 Project report submitted in partial fulfillment of the requirement for the award of DIPLOMA IN MECHANICAL ENGINEERING entitled.

FABRICATION OF UNIVERSAL DRILL LOCATOR

Submitted by NAME: S.RAMADOSS R.VIGNESH M.SATHISH KUMAR A.SASIKUMAR C.SAGAYA MICHAEL DYSAN A.SHEIK ABDUL KAHDER REGISTER NO: 29208493 29208522 29208505 29208502 29208494 29208508

UNDER THE GUIDANCE OF

Mrs. S. VASUDEVAN
HEAD OF THE DEPARTMENT Mr.S.KARTHIKEYAN M.E. Vice principal & HOD of mechanical engineering

THIRU SEVEN HILLS POLYTECHNIC COLLEGE MADURAVOYAL, CHENNAI-95.

LEARN AND LEAD 2010-2011 BONAFIDE CERTIFICATE NAME : REG NO: DEPT: ROLL NO:

Certified that this is the bonafide record of work done by the above student during the year 2010-2011

Signature of the guide

signature of the H.O.D

Submitted for the viva-voice examination held on Internal Examiner External Examiner

ACKNOWLEDGEMENT

We render our profound and heart felt gratitude to our Principal Mrs.R.Premalatha Kanikanan M.E.M.BA., Thiru Seven Hills polytechnic College, for her encouragement and co-operation in accomplishing our project entitled as

FABRICATION OF UNIVERSAL DRILL LOCATOR.

We thank our Head of the Department Mr.S.Karthikeyan M.E., for allowing us to undertake this project. We thank our internal guide S.VASUDEVAN, for his sustained guidance and encouragement. We also reveal our sincere thanks to our department lecturers whose suggestion and teaching brought the comprehension in us to complete this project. We would like to this opportunity to thank our friends for their endurance,patience and support in achieving our ambition. We remain with gratitude to our parents,lecturers,non-teaching staff and management of Sri Muthukumaran Educational Trust.

CONTENTS Chapter no: SYNOPSIS INTRODUCTION TYPES OF DRILLING MACHINE COMPONENTS OF DRILLING MACHINE TYPES OF DRILL BITS

UNIVERSAL DRILL LOCATOR CONSTRUCTION AND WORKINGPRINCIPLE DRILL LOCATOR DIAGRAM ADVANTAGES & DIS ADVANTAGES SAFETY RULES CONCLUSION BIBLIOGRAPHY

SYNOPSIS
UNIVERSAL DRILL LOCATOR: Universal drill locator is basically a holding device for jobs which has to undergo drilling operations. The job which requires more than one drilling operation with different axis with respect to each other could be handled with the help of this universal drilling locator. Universal drill locator facilitates the above requirement in single setting of the particular job and itself can be rotated and clamped at any angle with the help of a handle. Universal drill locator consist of spherical spindle which can be rotated with chuck plate to hold the job. This spherical spindle could be anchored at an angle in between the spindle sphere and spherical adopter by friction. The spherical adopter is attached with base plate for seating purpose.

A cam rod runs into the body of the spherical adopter. In between the cam rod and spherical spindle , a cam follower rests and it can be actuated up or down by the cam rod. During upward travel, the chuck along with spherical spindle gets arrested in between spherical adopter and cam follower. The chuck plate can along with the job can be rotated through 360Deg. On the horizontal plane and also can be rotated 90Deg. On vertical plane. With the help of above referred 2 plane rotation, number of drilling on the job can be drilled at any convenient and required angle with out disturbing the job from the chuck.

DRILLING MACHINE
INTRODUCTION
Drilling is the process of producing circular holes in a work piece. The machine used for this operation is called drilling machine and the tool is called drill or drill bit. The hole is produced by giving axial movement to the rotating drill against the work piece.

TYPES OF DRILLING MACHINE:

The different types of drilling machine are 1. 2. 3. 4. Sensitive drilling machine. Radial drilling machine. Upright drilling machine. Gang drilling machine.

SENSITIVE OR BENCH DRILLING MACHINE:

This type of drill machine is used for very light works. the sketch of sensitive drilling machine.

illustrates

The vertical column carries a swiveling table the height of which can be adjusted according to the work piece height. The table can also be swung to any desired position. At the top of the column there are two pulleys connected by a belt, one pulley is mounted on the motor shaft and other on the machine spindle. Vertical movement to the spindle is given by the feed handle by the operator. Operator senses the cutting action so sensitive drilling machine. Drill holes from 1.5 to 15mm

SENSITIVE DRILLING MACHINE.

RADIAL DRILLING MACHINE

It the largest and most versatile used for drilling medium to large and heavy work pieces. Radial drilling machine belong to power feed type. The column and radial drilling machine supports the radial arm, drill head and motor. Fig.3 shows the line sketch of radial drilling machine.

Radial Drilling Machine

 The radial arm slides up and down on the column with the help of elevating screw provided on the side of the column, which is driven by a motor. The drill head is mounted on the radial arm and moves on the guide ways provided the radial arm can also be swiveled around the column. The drill head is equipped with a separate motor to drive the spindle, which carries the drill bit. A drill head may be moved on the arm manually or by power. Feed can be either manual or automatic with reversal mechanism.

UPRIGHT DRILLING MACHINE

Upright drilling machine is a classification in drilling machines which is used for drilling holes of medium size. These are very similar in construction to sensitive drilling machines but these have a special arrangement for auto feed mechanism. In general the upright drilling machines are classified in to two types

The base is that part of a machine on which the column is mounted. In the belt driven drilling machines both the fast and loose pulley and cone pulley are also mounted on the base. In general the base is of a circular cross section when viewed from top. The base also has T-slots on it facilitating holding of large pieces for machining.

The column is the most important part which is mounted on the base and acts as a support and holding device for all the other parts of an upright drilling machine. It acts as a support for table and all

feed mechanisms. The column should be rigid enough to sustain all the forces produced due to the drilling action of the tool. Based on the shape of the column the upright drilling machines are classified in to two types 1) Round column section upright drilling machine 2) Box column section upright drilling machine Of the above mentioned two the latter one is more efficient and rigid in nature. In some of the drilling machines a rack and pinion are used for facilitating easy movement of the table in vertical direction

Table is the part on which the work piece is mounted. This is held up by fixing it to a column. A table can have rectangular geometry or circular in shape. Slots are provided on the table for holding the work piece very effectively. Three types of movements of the table are provided so as to achieve the centering very easily. The three movements incorporated in the table are 1) Vertical adjustment 2) Radial adjustment around the column 3) Circular adjustment about its own axis

The drill head is the one which holds all the feed mechanisms and spindle drive motion. Drill head is mounted on the column. In some drilling machines provision is made for the movement of the drill head so as the facilitating easy machining over the work piece. In many of the lighter drilling machines the driving motor is mounted at the rear end of the head counter balancing the weight of the spindle

GANG DRILLING MACHINE:

The machine consists of independent columns, heads and spindle mounted rigidly on a common base. The spindles may be driven by power or manually by hand and can be independently or collectively set for the desired speed and depth.

The machine carries a single worktable on which the work pieces can be slid into position for the operation at each spindle. The table may be of stationary type or adjustable type.

Gang drilling machines are designed with drill spindles permanently spaced, or in some machines the position of the columns may be adjusted, so that the space between the spindles may be varied. Gang drilling machines are used in mass production applications, wherein a single operator or more than one operator may be employed to perform various operations.

Components of drilling machine

Spindle
The spindle holds the drill or cutting tools and revolves in a fixed position in a sleeve.

Sleeve
The sleeve or quill assembly does not revolve but may slide in its bearing in a direction parallel to its axis. When the sleeve carrying the spindle with a cutting tool is lowered, the cutting tool is fed into the work: and when its moved upward, the cutting tool is withdrawn from the work. Feed pressure applied to the sleeve by hand or power causes the revolving drill to cut its way into the work a fraction of an mm per revolution.

Column
The column is cylindrical in shape and built rugged and solid. The column supports the head and the sleeve or quill assembly.

Head
The head of the drilling machine is composed of the sleeve, a spindle, an electric motor and feed mechanism. The head is bolted to the column.

Worktable
The worktable is supported on an arm mounted to the column. The worktable can be adjusted vertically to accommodate different heights of work or it can be swung completely out of the way. It may be tilted up to 90 degree in either direction, to allow long pieces to be end or angle drilled.

Base
The base of the drilling machine supports the entire machine and when bolted to the floor, provides for vibration-free operation and best machining accuracy. The top of the base is similar to the worktable and may be equipped with t- slot for mounting work too larger for the table.

Hand Feed
The hand- feed drilling machines are the simplest and most common type of drilling machines in use today. These are light duty machine that are operated by the operator, using a feed handled, so that the operator is able to feel the action of the cutting tool as it cuts through the work piece. These drilling machines can be bench or floor mounted.

Tool holding devices

shows the different work holding and drill drift device. The different methods used for holding drill in a drill spindle are By directly fitting in the spindle hole. By using drill sleeve By using drill socket By using drill chuck

DRILLS BIT:
Drill bits: Drill bits are cutting tools used to create cylindrical holes. Bits are held in a tool called a drill, which rotates them and provides torque and axial force to create the hole. Specialized bits are also available for noncylindrical-shaped holes.

TYPES OF DRILL BITS:

The following are the types of drills used for producing holes.
1. 2. 3. 4. 5. 6.

Twist drill. Oil tube drill. Flat drill. Centre and spotting drill bit. Core drill bit. Left hand bit.

1. TWIST DRILL:
This type of drill is most widely used nowadays. The drill has a cylindrical body on which helical flutes are cut. It has cone shaped cutting edge at the end of the flute . This drill is made up of HSS or carbon steel with various size . Generally twist drill up to 12mm have straight shank and longer size have taper shank.

2. OIL TUBE DRILL:

This is a type of drill having two holes along the flute up to the cutting edge. Coolant passes through this hole for cooling the cutting edge during drilling. Compressed air can also be passed through the holes to remove the chips easily.

3. FLAT DRILL:
It has V-shaped flat cutting edge . The cutting angle varies from 90*120*.the cutting edge is made from a round tool steel by forging. The clearance of 3*-8* is given to the cutting edge . It is generally used for drilling woods,brass and plastic materials.as it can not produce accurate holes,it is mostly used.

4. CENTRE AND SPOTTING DRILL BIT:

Center drill bits are used in metalworking to provide a starting hole for a larger-sized drill bit or to make a conical indentation in the end of a workpiece in which to mount a lathe center. In either use, the name seems appropriate, as the drill is either establishing the center of a hole or making a conical hole for a lathe center.

However, the true purpose of a center drill is the latter task, while the former task is best done with a spotting drill (as explained in detail below). Nevertheless, because of the frequent lumping together of both the terminology and the tool use, suppliers may call center drills combined-drill-and-countersinks in order to make it unambiguously clear what product is being ordered. They are numbered from 00 to 10 (smallest to largest)

5. CORE DRILL BIT:

The core drill bits are similar in appearance to reamers as they have no cutting point or means of starting a hole. They have 3 or 4 flutes which enhances the finish of the hole and ensures the bit cuts evenly. Core drill bits differ from reamers in the amount of material they are intended to remove. A reamer is only intended to enlarge a hole a slight amount which, depending on the reamers size, may be anything from 0.1 millimeter to perhaps a millimeter. A core drill bit may be used to double the size of a hole

6. LEFT HAND BIT:

Left-hand bits are almost always twist bits and are predominantly used in the repetition engineering industry on screw machines or drilling heads. Left-handed drills allow a machining operation to continue where either the spindle cannot be reversed or the design of the machine makes it more efficient to run left-handed. With the increased use of the more versatile CNCmachines their usage is less common than when specialized machines were required for machining tasks.

DRILL NOMENCLATURE:
Axis: The imaginary straight line which forms the longitudinal center line of the drill Back Taper: A slight decrease in diameter from front to back in the body of the drill Body: The portion of the drill extending from the shank or neck to the outer corners of the cutting lips Body Diameter Clearance: That portion of the land that has been cut away so it will not rub against the walls of the hole Built-Up Edge: An adhering deposit of nascent material on the cutting lip or the point of the drill Cam Relief: The relief from the cutting edge to the back of the land, produced by a cam actuated cutting tool or grinding wheel on a relieving machine Chip Breaker: Nicks or Grooves designed to reduce the size of chips; they may be steps or grooves in the cutting lip or in the leading face of

the land at or adjacent to the cutting lips Chip Packing: The failure of chips to pass through the flute during cutting action Chipping: The breakdown of a cutting lip or margin by loss of fragments broken away during the cutting action 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, as viewed from the end of the drill Clearance: The space provided to eliminate undesirable contact between the drill and the work piece Clearance Diameter: The diameter over the cut away portion of the drill lands

Crankshaft or Deep Hole Drills: Drills designed for drilling oil holes in crankshafts, connecting rods and similar deep holes; they are generally made with heavy webs and higher helix angles than normal Cutter Sweep: The section formed by the tool used to generate the flute in leaving the flute Double Margin Drill: A drill whose body diameter clearance is produced to leave more than one margin on each land and is normally made with margins on the leading edge and on the heel of the land Drift: A flat tapered bar for forcing a taper shank out of its socket Drift Slot: A slot through a socket at the small end of the tapered hole to receive a drift for forcing a taper shank out of its socket

Drill Diameter: The diameter over the margins of the drill measured at the point Exposed Length: The distance the large of a shank projects from the

drive socket or large end of the taper ring gage External Center: The conical point on the shank end of the drill, and the point end on some sizes of core drills Flat Drill: A drill whose flutes are produced by two parallel or tapered flats Flat (Spade) Drill: A removable cutting drill tip usually attached to a special holder designed for this purpose; generally used for drilling or enlarging cored holes Flutes: Helical or straight grooves cut or formed in the body of the drill to provide cutting lips, to permit removal of chips, and to allow cutting fluid to reach the cutting lips Flute Length: The length from the outer corners of the cutting lips to the extreme back end of the flutes; it includes the sweep of the tool used to generate the flutes and, therefore, does not indicate the usable length of the flutes Gage Line: The axial position on a taper where the diameter is equal to the basic large end diameter of the specified taper Galling: An adhering deposit of nascent work material on the margin adjacent to the leading edge at and near the point of a drill Guide: A cylindrical portion, following the cutting portion of the flutes, acting as a guide to keep the drill in proper alignment; the guide portion may be fluted, grooved, or solid Gun Drill: Special purpose straight flute drills with one or more flutes used for deep hole drilling; they are usually provided with coolant passages through the body; they may be either solid or tipped Half-Round Drill: A drill with a transverse cross-section of approximately half a circle and having one cutting lip Heel: The trainting edge of the land Helical Flutes: Flutes which are formed in a helical path around the axis Helix Angle: The angle made by the leading edge of the land with a plane containing the axis of the drill Land: The peripheral portion of the body between adjacent flutes Land Width: The distance between the leading edge and the heel of the land measured at a right angle to the leading edge Lead: The axial advance of a leading edge of the land in one turn around the circumference Lips: The cutting edges of a two flute drill extending from the chisel edge to the periphery Lip Relief: The axial relief on the drill point

Lip Relief Angle: The axial relief angle at the outer corner of the lip; it is measured by projection into a plane tangent to the periphery at the outer corner of the lip Margin: The cylindrical portion of the land which is not cut away to provide clearance Multiple-Margin Drill: A drill whose body diameter clearance is produced to leave more than one margin in each land Neck: The section of reduced diameter between the body and the shank of a drill Oil Grooves: Longitudinal straight or helical grooves in the shank, or grooves in the lands of a drill to carry cutting fluid to the cutting lips. Oil Holes or Tubes: Holes through the lands or web of a drill for passage of cutting fluid to the cutting lips Overall Length: The length from the extreme end of the shank to the outer corners of the cutting lips; it does not include the conical shank end often used on straight shank drills, nor does it include the conical cutting point used on both straight and taper shank drills Periphery: The outside circumference of a drill Peripheral Rake Angle: The angle between the leading edge of the land and an axial plane at the drill point Pilot: A cylindrical portion of the drill body preceding the cutting lips; it may be solid, grooved, or fluted Point: The cutting end of a drill, made up of the ends of the lands and the web; in form it resembles a cone, but departs from a true cone to furnish clearance behind the cutting lips. 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 Relative Lip Height: The difference in indicator reading on the cutting lip of the drill; it is measured at a right angle to the cutting lip at a specific distance from the axis of the tool

Relief: The result of the removal of tool material behind or adjacent to the cutting lip and leading edge of the land to provide clearance and

prevent rubbing (heel drag)

Shank: The part of the drill by which it is held and driven Sleeve: A tapered shell designed to fit into a specified socket and to receive a taper shank smaller than the socket Socket: The tapered hole in a spindle, adaptor, or sleeve, designed to receive, hold, and drive a tapered shank Step Drill: A multiple diameter drill with one set of drill lands which are ground to different diameters Straight Flutes: Flutes which form lands lying in an axial plane Sub land Drill: A type of multiple diameter drill which has independent sets of lands in the same body section for each diameter Tang: The flattened end of a taper shank, intended to fit into a driving slot in a socket Tang Drive: Two opposite parallel driving flats on the extreme end of a straight shank Taper Drill: A drill with part or all of its cutting flute length ground with a specific taper to produce tapered holes; they are used for drilling the original hole or enlarging an existing hole Taper Square Shank: A taper shank whose cross section is square Web: The central portion of the body that joins the lands; the extreme end of the web forms the chisel edge on a two-flute drill

Typical Drilling Process

INTRODUCTION OF UNIVERSAL DRILL LOCATOR

Drilling Machine
Drilling is the operation of producing circular hole in the work-piece by using a rotating cutter called DRILL. The machine used for drilling is called drilling machine. The drilling operation can also be accomplished in lathe, in which the drill is held in tailstock and the work is held by the chuck. It is the simplest and accurate machine used in production shop. The work piece is held stationary ie. Clamped in position and the drill rotates to make a hole.

UNIVERSAL DRILL LOCATAR

These are medium heavy duty machines. It specifically differs from sensitive drill in its weight, rigidity, application of power feed and wider range of spindle speed. Fig.2 shows the line sketch of up-right drilling machine. This machine usually has a gear driven mechanism for different spindle speed and an automatic or power feed device. Table can move vertically and radially. Drill holes up to 50mm

CONSTRUCTION AND WORKING PRINCPLE

CONSTRUCTION
Place the base plate parallel on the surface. Now upset the base plate. Insert the spindle into the hollow hole of the base plate. Then insert the cam follower. A hollow hole is drilled in the base plate for insert the cam rod. The cam rod is placed inside the base plate. Washer and split pin are placed in the cam rod. The cam rod is placed for tighting purpose. Then place the chuck plate on the spindle. They are attached by using head screw. The cam lever is placed on the right end of the cam rod. The cam lever is used for tighting the chuck plate in fixed position.

WORKING PRINCPLE
Work piece is placed on the chuck plate. Before the work piece is placed hold the work piece by using suitable nuts. The work piece should never fall from the chuck plate. The work piece is to be tighten by using nuts. The nuts are inserted in the slot ways for tighten the work piece. The chuck plate is to be tighten by using cam lever. We can put desired hole in the work piece. Correct the position of the drill bit and work piece should be in correct position. The marking of the work piece should be placed in correctly position. We can put desired hole in the work piece. Complicated jobs can also be done easily.

PHOTO VIEWS

COMPONENTS OF DRILL LOCATAR

Base Plate Chuck Plate Cam Follower Spindle Cam Rod

DESCRIPTION OF THE EQUIPMENT

The proposed universal drill locator consist of the following comnponent

Base Plate Chuck Plate Cam Follower Spindle Cam rod The materials are Made up of mild steel

ADVANTAGES

The universal drill locator drills when the work piece bed is inclined position or the work piece itself in inclined position. The chuck plate along with job can be rotated through 360 deg. The job can be drilled at any convenient and required angle. Table can move vertically and radially. Drill holes up to 50 mm. The universal drill locator drills when the work piece bed is inclined position or the work piece itself in inclined position. The chuck plate along with job can be rotated 360. The job can be drilled at any convenient and required angle. Complicated jobs can also be drilled.

DISADVANTAGE
Only light duty machine can be done. It is handling very carefully. Skilled labors are required. The assembly of work holding device is difficult.

PRECAUTIONS

Safety Precautions
Do not support the work piece by hand use work holding device. Use brush to clean the chip No adjustments while the machine is operating Ensure for the cutting tools running straight before starting the operation. Never place tools on the drilling table Avoid loose clothing and protect the eyes. Ease the feed if drill breaks inside the work piece.

Safety Rules for Drill Press

All drill press users must know how to operate a drill press properly and safely. Do not operate a drill press if it is damaged and report the damage to the technical staff. The technical staff can provide instructions on the safe and proper operation of the drill press. 3. Certain materials are hazardous to drill. Check the MSDS on your material. Ceramics or refractoriness containing crystalline silica is a designated substance require special handling practices; wet drilling is preferred. 4. Always wear proper eye protection (see McMaster Eye Protection Policy). Keep hands away from the cutting surfaces and all moving parts.

5. Do not wear loose clothing, gloves, neckties, rings, bracelets or other jewelry that can become caught in the drill press. Secure loose clothing and long hair. Do not use rags near moving parts of drill press. 6. The belt guard on the drill press must be locked in place. 7. Use a clamp or vice to hold the work piece in place on the table and prevent work piece from spinning. DO NOT hand hold the work piece when drilling.

8. Ensure that all drill bits are clean and sharp so they can cut freely without being forced. 9. Make sure the drill bit or cutting tool is locked securely in the chuck. REMOVE The chuck key before starting the drill press. Shut off the power before removing the drill bit. 10. Stop the machine before measuring, cleaning or making any adjustments. Ensure that the start/stop switch is within easy reach when the drill press is in use. 11. Adjust the position of the table so that drilling is done into the work piece only and not the table, vice, clamps, etc.

CONCLUSION
We have successfully complete this project work at our institute. The test carried out on UNIVRESAL DRILL LOCATOR gives better finishing this apparatus is reasonable. The experience gained in this project will give safe-confidence to design simple machines and apparatus on similar lines under entrepreneurs scheme of the government. Once again we express our sincere thanks to our staff members.

BIBLIOGRAPHY

Web Search:
WWW.GOOGLE.CAM

Web Site Search:

WWW. UNIVERSAL DRILL MACHINES.CAM

Design:
DRAWINGS ON AUTOCAD.

Safety Precautions
Do not support the work piece by hand use work holding device. Use brush to clean the chip No adjustments while the machine is operating Ensure for the cutting tools running straight before starting the operation. Never place tools on the drilling table Avoid loose clothing and protect the eyes. Ease the feed if drill breaks inside the work piece.

Safety Rules for Drill Press

All drill press users must know how to operate a drill press properly and safely. Do not operate a drill press if it is damaged and report the damage to the technical staff. The technical staff can provide instructions on the safe and proper operation of the drill press. 3. Certain materials are hazardous to drill. Check the MSDS on your material. Ceramics or refractoriness containing crystalline silica is a designated substance require special handling practices; wet drilling is preferred. 4. Always wear proper eye protection (see McMaster Eye Protection Policy). Keep hands away from the cutting surfaces and all moving parts.

5. Do not wear loose clothing, gloves, neckties, rings, bracelets or other jewelry that can become caught in the drill press. Secure loose clothing and long hair. Do not use rags near moving parts of drill press. 6. The belt guard on the drill press must be locked in place. 7. Use a clamp or vice to hold the work piece in place on the table and prevent work piece from spinning. DO NOT hand hold the work piece when drilling.

8. Ensure that all drill bits are clean and sharp so they can cut freely without being forced. 9. Make sure the drill bit or cutting tool is locked securely in the chuck. REMOVE The chuck key before starting the drill press. Shut off the power before removing the drill bit. 10. Stop the machine before measuring, cleaning or making any adjustments. Ensure that the start/stop switch is within easy reach when the drill press is in use. 11. Adjust the position of the table so that drilling is done into the work piece only and not the table, vice, clamps, etc.

CONCLUSION
We have successfully complete this project work at our institute. The test carried out on UNIVRESAL DRILL LOCATOR gives better finishing this apparatus is reasonable. The experience gained in this project will give safe-confidence to design simple machines and apparatus on similar lines under entrepreneurs scheme of the government. Once again we express our sincere thanks to our staff members.

BIBLIOGRAPHY

Web Search:
WWW.GOOGLE.CAM

Web Site Search:

WWW. UNIVERSAL DRILL MACHINES.CAM

Design:
DRAWINGS ON AUTOCAD.