Lecture slides on drilling and milling

By: Dr H N Dhakal
Lecturer in Mechanical and Marine
Engineering,
School of Engineering,
University of Plymouth

Drilling
Hole making is among the most important operations in
manufacturing, and drilling is a major and common hole-making
process.
In drilling, the surface of interest is the side wall of the hole,
which is burnished by the rubbing action of the twisted flutes of
the drill and the material that escapes outward.

Drilling machine configuration

Drilling is the most common (multi-point) cutting technique
targeted for the production of small-diameter holes: Yet, the
complexity of its tool geometry makes it one of the most
complex operations to model mathematically:
Fixed head
Adjustable head
Spindle
Tool

Column

Worktable

Workpiece

Base

Drilling machines
The types of drilling machine range from simple bench type
drills used to drill small diameter holes to large radial drills
which can accommodate large workpieces. Also three axis CNC
drilling machines has turret that holds as many as eight different
tools, such as drills, taps and reamers
There are various types of drill machines. The most common
machine is the drill press.
The workpiece is placed on the adjustable table, either by
clamping or directly into the slots and holes on the table or by
using a vice which is in turn clamped to the table.

Common types of drills

Figure: Two common types of drills: (a) Chisel-point drill (b) crankshaft drill
Source: S. Kalpakjian, S.R. Schmid: Manufacturing Engineering & Technology,
5th edition, Prentice-Hall International, 2006; pp. 705.

Various types of drills

Reamer, adjustable

drill and counterbore

Various types of drills

The most common drill is the conventional standard-point
twist drill. The geometry of the drill point is such that the
normal rake angle and the velocity of the cutting edge vary with
the distance from the centre of the drill.
The main features of the twist drills are: a. point angle 118135o; b. lip-relief angle 7-15o, c. chisel edge angle 125- 135o; d.
helix angle 15-30o

Various types of drills and operations

Source: S. Kalpakjian, S.R. Schmid: Manufacturing Engineering

& Technology, 5th edition, Prentice-Hall International, 2006; pp.
707.

Various types of drills and operations

A step drill produces holes with two or more different diameters. A
core drill is used to make an existing hole larger.
Counterboring and countershinking drills produce depressions on
the surface to accommodate the heads of screws and bolts below the
workpiece
A centre drill is short and is used to produce a hole at the end of a
piece of stock, so that it may be mounted between centres of the
head stock and tailstock of a lathe . A spot drill is used to spot (to
start) a hole at the desired location on a surface.

Various types of drills and operations

Solid carbide and carbide tipped drills are available for drilling
hard materials such as cast irons, concrete and bricks and composite
materials with abrasive fibre reinforcements.
Gun drilling is used for drilling deep holes and requires a special
drill.

Drilling cutting velocity

Drilling:

N dt
V=
1000

N: spindle speed (rev/min);

dt: (drill) tool diameter (mm);

(mm/min)

MRR in drilling
The material removal rate (MRR) in drilling is the volume of
material removed by per unit time. For a drill with a diameter D,
the cross-sectional area is : 4D
The velocity of the drill perpendicular to the workpiece is the
product of the feed f (the distance of the drill penetrates per unit
revolution), and the rotational speed, N, where N = V/D. Thus,
2

MRR =

D2
4

fN

N: spindle speed (rev/min);

D: (drill) tool diameter (mm);
f: feed distance per revolution (mm/rev, or mm).

MRR in drilling-example
A hole is being drilled in a block of magnesium alloy with a 12 mm
drill bit, at a feed of 0.3 mm/rev, and the spindle running at N= 700
rpm. Calculate the material-removal rate and the torque on the drill.
Solution: The MMR is calculated using equation:

MRR =
MRR =

(3.14)(12) 2
4

D2
4

fN
3

(0.3)(700) = 23738.4 mm / min 395.65mm / s

Taking average unit power of 0.5 W.s/mm3 for magnesium alloy. The
power required then; Power= (396) (0.5)= 198 W
Power is the product of the torque on the drill and the rotational speed,
which in this case is (700) (2)/60 = 73.26 radians per second. (J =
N.m)
T = 198/73.26=2.70 N.m

Design consideration for drilling

Design should allow holes to be drilled on flat surfaces
and perpendicular to the drill motion. Exit surfaces for
drill also should be flat.
Interrupted hole surfaces should be avoided or
minimized for improved dimensional accuracy, drill life
and to avoid vibrations.
Through holes are preferred over blind holes. If holes
with large diameters are required, the w/p should have a
pre-existing hole, preferably made during fabrication of
the part
Blind holes must be drilled deeper than subsequent
reaming or tapping operations that may be performed.

Safety in drilling
Should not wear loose clothing such as tie or jewellery which
could become entangled
Guards should always be in place and suitable face protection
should always be worn
The floor space around the machine should be without
obstructions and slippery substances.
The machine should not be kept running when not in use.
Provide holding clamps or fixtures to secure the work to the
drill press bed.
Use brushes, chip pullers or other tools to remove chips from
table or work; do not allow removal by unprotected hands.

Milling

Milling is a material-removal process for non-rotational objects:
It uses a multi-point tool that rotates about a fixed axis, while the
prismatic workpiece is fed into the tool according to a pre-specified
travel path:
This intermittent-cutting process is commonly classified as
face (or end) milling versus peripheral (or plain, or
slab) milling:
Tool
Workpiece

Tool
Workpiece

Metal cutting - milling

The milling process:
Typically uses a multi-tooth
cutter
Work is fed into the rotating
cutter
Capable of high MRR
Well suited for mass production
applications
Cutting tools for this process are
called milling cutters

Different milling machines

Schematic illustrations of (a) A horizontal-spindle column

and knee type milling machine and (b) vertical spindle
column and knee type milling machine
Source: S. Kalpakjian, S.R. Schmid: Manufacturing Engineering
& Technology, 5th edition, Prentice-Hall International, 2006; pp.
739.

Metal cutting - milling

Source: S. Kalpakjian, S.R. Schmid: Manufacturing Engineering

& Technology, 5th edition, Prentice-Hall International, 2006; pp.
725.

Milling operations

Source: S. Kalpakjian, S.R. Schmid: Manufacturing Engineering

& Technology, 5th edition, Prentice-Hall International, 2006; pp.
734.

MRR in milling

Milling with max MRR

w. a. f m
MRR=
?
, [cm3/min]
w : width of cut (step depth) [mm];
1000
a: depth of cut [mm];
fm: feed rate of the table [mm/min] , fm = ft..N.n .
N: spindle speed [rev/min];
dt: (milling) tool diameter [mm];

fm
a

Feed rates/cutting velocity in milling

In milling, the thickness of material removed is the depth-ofcut (DOC). The feed rate per tooth ft (tabulated, mm/tooth) is
related to the amount of material each tooth removes during a
revolution. It is given as the travel rate of the tool divided by the
number of teeth n. So, the feed rate of the table fm can be
calculated as follows:
fm = ft..N.n , mm/min

The cutting velocity V
is the linear velocity of
the tool tip as it engages
the workpiece.

N d t , m/min
V=
1000

Selecting cutting conditions

The surface finish achieved by cutting is a function of:

cutting speed

depth-of-cut

feed rate

Sequence of cutting:
rough cuts, carried out at high speed and feed rates and
large depths-of-cut and big tool size for a maximum materialremoval rate (MMR),
finish cuts, where RPM can remain the same, but at much
lower values for feeds and depth-of-cut for a better surface
finish and dimensional accuracy.

Cutting time calculation

Calculate the cutting time for skimming 2mm
of the top surface of a 200 mm long
aluminium plate using 4 tooth diam 80 mm
mill.

Tool
Workpiece

Speed = L/T = fm= ft..N.n , mm/min hence: T=L/ft.N.n , min

From the table: feed rate per tooth ft = 0.2 mm/tooth
To find N:

N dt
V=
1000

, m/min

From the table: cutting speed V= 300 m/min

hence: N=1000V/ dt = 1000x300/ x 80=1194~1200 rev/min
Hence: T= 200/(0.2x1200x4)= 0.2 min

References
1. S. Kalpakjian, S.R. Schmid: Manufacturing Engineering &
Technology, 5th edition, Prentice-Hall International, 2006.
2. E. Paul Degarmo, J. R. Black, R. A. Kohser; Materials and
Processes in Manufacturing, 9th edition, John Wiley & Sons,
Inc, 2003.
3. R. L. Timings, S. P. Wilkinson: Manufacturing Technology,
2nd edition, Pearson Education Limited, London, 2000.