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revolve on a finished surface and confine the direction of travel. Fig. 1829 shows the design of
various types of deep hole tools. The various tools are
______________________
A. Single lipped rifle drill.its cutting edge is ground to lead in the bole and machine in
clockwise rotation. It opens up holes from the solids and also sizes accuratelv in one operation.
It is used for drilling (f)) holes upto 25 mm.
B. Two lip drills. It drills holes of size 25 mm to 75 nun in the solid material. Coolant
circulation to drill is permitted (pr) by provision of clearance
between shank and machined hole. The drill body between flutes is relieved to bring the coolant
to the cutting tip where it flushes the chips back through the flute and into the centre hole of the
drill and shank,
Figure 19.26 Types of boring tools.
A, Light boring tool with bent shank. B, Forged boring tools. C,
Heavy boring tool.
D, Double-ended cutter or boring tool. E, Counterboring tool with
pilot. F, Multiple-cutter boring tool.
6 Determining cutting variables
6.1 Feeds and Speeds. The speed at which a drill, boring tool, or reamer
should be run depends upon the same considerations as for other tools, as
explained in Chap. In general , the proper peripheral cutting speed of a drill is
about the same as for a sing1epoint tool under comparable circumstances.
The feed of a drill is the distance it advances in one revolution. Feeds depend
mostly upon what the drill will stand, determined by its size and the work
material. As a general guide, the Cleveland Twist Drill Co. recommends “a
feed of 0.001 to 0 . 002 in . /rev for drills * to . 0 . 004 to 0 . 007 for drills to
in . , 0 . 007 to 0 . 0 1 5 ccv: thUis. 4 to 1 in. , and 0.015 to 0.025 for drills
larger than 1 in.” This corresponds. to 0.025 to 0.05 mm/rev for drills 3 to 7
mm, O.Th to 2O frr tiWis 3 ic 13 c to 0.40 for drills 13 to 25 mm, and 0.40 to
0.65 for drills over 25 mm in diameter. Alloy and hard steel should generally
be drilled at a lighter feed than given above, while cast iron, brass, and
aluminum may usually be drilled with a heavier feed than given above.
Boring and similar tools are run at about the same speeds and feeds as drills,
sometimes slightly less. As a rule, reaming must be done at low speeds and
high feeds for best results. Speeds of 50 to 75% of drilling speeds and feeds of
200 to 300% of drilling feeds for rose reamers and 300 to 500% for fluted
reamers are recommended.
6.2 Cutting Forces, Power, and Time. The two components of force in
drilling and boring operations are the thrust T in kN (ib) in the axial direction
of the tool and the torque or moment M in Nm (lb-in . ) . Investigations have
shown that these depend upon the feedfin mm/rev (ipr), the drill diameter d in
mm (in.), the chisel edge length C, the material, and the number of teeth.
Simplified formulas for two flute drills with a normal c/d ratio of 0. 18 have
been given by Oxford as
T 2Kf°8d°8 + Ld2 and M = Kf°8d’8 (22-1)
The factor K is 0.6035 (24,000) for 200 Bhn steel, 0.7795 (3 1 ,000) for 300
Bhn steel, 0.8549 (34,000) for 400 Bhn steel, 0. 1760 (7000) for aluminum
and leaded brass,
0. 1006 (4000) for most magnesium alloys, and 0.3520 (14,000) for most
brasses. The value of L is 4. 309 X 1O(625). The factors for SI units are given
first, and those for English units are in parentheses. Similar expressions are
given in reference books and handbooks for hole-enlarging tools.
The horsepower for a drilling operation may be estimated on the basis of P =
MR/63,025, where R is the drill speed in rpm. The power in kW is
MR19549,with M in Nm. An insignificant portion of the power is related to the thrust because the
feed is slow compared to the speed. Power may also be estimated on the basis of the rate of stock
removal as explained for Table 17-3.
The basic relationship that cutting time is equal to the distance the tool is fed in mm (in.) divided by the
rate of feed in mm/mm (ipm) applies to drilling and boring. This may be illustrated by an example. A
hole 25 mm (1 in.) in diameter is drilled through a cast-iron piece 76 mm (3 in.) thick by a H.S.S. drill
with a surface speed of 15 rn/mm (50 fpm). The drill rotates at 190 rpm. With an advance of 0.4
mm/rev (0.016 ipr), the rate of feed is 0.4 X 190 = 76 mm/mm (0.0 16 X 190 = 3 ipm). The distance the
drill is fed in this case is 76 mm (3 in.) plus an assumed overtravel of 3 mm ( in.) plus an approach of
6.5 mm ( in.) (one-fourth of the diameter of a standard drill). Thus the total travel is 85.5mm (3 in.).
The time for the cut is 85.5/76 = 1.13 minutes (3.375/3 = 1.13 minutes).
6.3 Machining Time in Boring with examples
Machining time in boring operation is calculated by the same.
formula as for calculating the machining time in turning operation,
Length of cut minutes.
Time required=: r.p.m. X Feed/rev ‘
.
the lengh of cut in this case is the depth of hole to be bored. Cutting
speeds and feeds for boring are same as for turning. Example 4.
A 10 mm (trilled hole in a casting of 10 mm thickness is to be
brought in alignment by boring. Calculate (lie time taken in
boring operation, assuming cutting speed 30 meters/minute
and feed 0.13 nun/rev.
Solution. R.P.M. ‘N’ = 1000 x Cutting speed —
1000x30 =955r.p.m.
π X Diameter - π x
10
—
Length of cut 10
Time taken in boring= - r.p.m XFeed/rev.
- 255 x
0.13 minutes.
10 x 60
- 955x0.13
=4.83 seconds
7 BORING OPERATIONS
accuracy of a hole involves both size and location. Accuracy ‘n the tools and the way they are
used. Under average 9racticaI drilling tolerances range from 50 to 0.25 mm (0.01 in.) for 25 to
50 mm ( appreciably better results. A multiblade .imber of holes within 25 to 50 m (0.001 toA
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