A minor project

on
analysis & measurement of cutting force on
twist drill

Guided by
Prof. Tapan jain
Prof. Sanjay jathar

submitted by
yogesh ladhe

content

Introduction
Problem definition
Mat lab programming
Result and discussion
Conclusion
Future scope
Bibliography

Introduction
Metal cutting is the process of producing work piece by
removing unwanted material from a block of material in
the form of chips . This process is most important since
almost all the product get their final shape & size by
metal removal either directly or in directly.
Following are the some metal cutting process
Turning : turning is a machining operation for generating
external surface.
Boring : boring is the operation of enlarging or finishing
an internal hole which has been previously drilled.
Drilling :drilling is the process of cutting or originating
around hole from solid material.

Importance of drilling
In an manufacturing it is probable that more holes are
produced than any other shape and a large operation of
these are made by drilling so drilling is a very important
process. Although drilling appears to be a relatively
simple process, it is a complex process. Most drilling is
done with a tool having two cutting edge. These edges
are at the end of a relatively flexible tool cutting action
take place inside the work piece. The only exit for the
chips is the hole that is filled by the drill. Friction result in
heat that is additional to that due to chip formation.

Drill machine
Drill machine is one of the simplest moderates and
accurate machine tool used in production shops and tool
room. It consist of a spindle which imparts rotary motion
to the drilling tool. A mechanism for feeding the tool in to
work rest and a frame it considered as a single purpose
machine tool since its chief function is to make holes.

Drill machine

Twist drill
A twist drill consist of a cylindrical piece of steel with
special grooves on one end of the cylinder is pointed and
other end is shaped so that it may be attached to the
drilling machines
The grooves is usually called fluates may cut in to the
cylinder

Drill tool material

Tool steel
Carbon tool steel
Water hardening tool steel
Shock resisting tool steel
Hot work tool steel
High speed steel
Coated high speed steel
Cement carbide

Tool geometry

Part of the twist drill

Three main components are the:

Shank
Body
Point

Shank - This is the portion which is

clamped to provide the drive. Straight
shank for drill up to . Shank is equal to
body diameter. Above , shank can be
tapered or reduced.
Body
Flutes - Helical grooves cut around the
body which form the cutting edges
Allow coolant to flow to the cutting
edge
Allow chips to be withdrawn

Margin- Narrow raised section of the body.

Provides full body to hole support to help keep it
aligned as it drills.
Body clearance - Reduced section of the drill
between the flutes and margin. Used to reduce
friction between drill and work piece
Web- Thin section in the center of the drill which
forms a core for the drill. This feature increases
as it extends to the shank. Forms the chisel edge of
the drill

Point - Chisel edge of the drill.

Lips
Cutting edges
Flat angle point - 135 degrees
Harder metals
Tends to be self centering
friction Three standard point angles include:
Conventional - 118 degrees
General drilling applications
Long angle point - 60-90 degrees
Low helix angle
Non-ferrous materials
Shorter cutting edge with leads to reduced

Force acting on twist drill

The resultant force R required for the plastic deformation
of the layer under drilling can be resolved in to a
tangential component Pz &thrust force Pxy.
Perpendicular to the cutting edge. The force pz is
required for calculating the torque in drilling the force Pxy
can be further be resolved in to a radial component Py &
vertical component Px acting axially along a drill this
force commonly known as thrust in drilling. He effect of
all the force acting on the drill can be represented by
resisting torque & thrust force.

Problem definition
There are several important reason for measuring or
calculating force of twist drill the main force acting on
twist drill is the thrust force and the torque force the
effect of all the force acting on the drill can be
represented by resisting torque and thrust force

Mat lab programming

Mat lab is high performance language for technical
computing . It integrated computational visualization and
programming in an easy to use environment where
problem and solution are expressed in familiar
mathematical notation the typical use include math and
computation, algorithm development ,data acquisition
modeling simulation and prototyping scientific and
engineering graphics .

Element of mat lab programming

The mat lab system consist of five main parts

Mat lab mathematical library
Mat lab language
Graphics
Mat lab application program interface
Mat lab plotting

Program for calculating cutting force

D=input('type the diameter of drill in mm');

f=input('feed in rev.per.mm');
tau=input('shear stress inb n/square mm');
n=input('rpm');
sai=input('helix angle');
mue=input('friction');
k=input('matreial fractor');
bita=[112:120];
r=D/4;
bitar=(pi/180).*(bita)
bitax=(bitar)/2;
sair=(pi/180)*sai;
s=(2*r)/D
l=s*(tan(sair))
c=l./sin(bitax)

alpha=atan(c)
tl=(f/2)*sin(bitax)
y=(D/2)
w=y./sin(bitax)
lamda=atan(mue)
lamdar=((pi)/180)*lamda
q=45*(pi)/180
phi=q+(alpha)-(lamda)
z=(lamda-alpha)
g=(f.*w.*(tau).*cos(z))
h=2*sin(phi)*cos(q)
fc=g./h
ft=(f.*w.*(tau).*sin(z))/2.*sin(phi).*cos(q)
m=((.6).*fc.*D)./1000
F=5.*(ft).*sin(bitax)

%subplot(2,3,1)
figure(1),plot(bitax,F),xlabel('point
angle'),ylabel('thrust')
%subplot(2,3,2)
figure(2),plot(bitax,m),xlabel('point
angle'),ylabel('torque')
%subplot(2,3,3)
figure(3),plot(bitax,fc),xlabel('point
angle'),ylabel('torque force')
% subplot(2,3,4)
figure(4),plot(bitax,ft),xlabel('point
angle'),ylabel('thrust force')

Result
SR
NO

POINT ANGLE
IN DEGREE

POINT ANGLE
IN RADIAN

TORQUE
FORCE IN
NEWTON

THRUST
FORCE IN
NEWTON

TORQUE IN
NEWTON

THRUST IN
NEWTON

112

.97

1.5235

47.6588

18.2825

197.5545

113

.98

1.5183

47.6607

18.2196

198.7180

114

.99

1.5132

47.6574

18.1580

199.8442

115

1.0

1.5081

47.6491

18.0987

200.9342

116

1.01

1.5032

47.6363

18.0383

201.9893

117

1.02

1.4984

47.6193

17.9811

203.0105

118

1.03

1.4984

47.5984

17.9246

203.9991

119

1.04

1.4897

47.5741

17.8694

204.9560

120

1.05

1.4846

47.5465

17.8154

205.8824

Graphs