CNC DRILLING MACHINE

ABSTRACT

The aim of DESIGN AND FABRICATION OF CNC DRILLING

MACHINE project is to drill many number of holes in a work piece, by

using same power.

Any industrys has its own desire to maintain their ability to provide

safe and secure drilling of their customers materials. Addressing these

challenges is an important task and the efficient delivery of their cargo, play

a vital role in the economy of the country.

This project provides less power consumption and through the

multiple spindle system. The drilling machine drills not only in particular

position, but in several positions.

By means of this project, we can do many drilling operations in a

single machine.
 NEED OF THE PROJECT

To achieve high safety

To reduce man power

To increase the efficiency of the work

To reduce the work load

To reduce the fatigue of worker

To reduce time consumption

Less Maintenance cost

To reduce power
 1.INTRODUCTION

1.1 MACHINE TOOL

A machine tool is a powered mechanical device, typically used to

fabricate metal components of machines by machining, which is the

selective removal of metal. The term machine tool is usually reserved for

tools that used a power source other than human movement, but they can be

powered by people if appropriately set up. Many historians of technology

consider that the true machine tools were born when direct human

involvement was removed from the shaping or stamping process of the

different kinds of tools. The earliest lathe with direct mechanical control of

the cutting tool was a screw-cutting lathe dating to about 1483. This lathe

"produced screw threads out of wood and employed a true compound slide

rest".
 2. LITERATURE SURVEY

Machines that a modern perspective might call machine tools have

existed for millennia (for example, lathes and bow drills existed in ancient

Egypt), but it was not until the later Middle Ages and the Age of

Enlightenment that the modern concept of a machine toola class of

machines used as tools in the making of other machinesbegan to evolve.

Clock makers of the middle ages and renaissance men such as Leonardo da

Vinci helped expand humans' technological milieu toward the preconditions

for industrial machine tools. During the 18th and 19th centuries, and even in

many cases in the 20th, the builders of machine tools tended to be the same

people who would then use them to produce the end products (manufactured

goods). However, from these roots also evolved an industry of machine tool

builders as we define them today, meaning people who specialize in building

machine tools for sale to others. The first machine tools offered for sale (i.e.,

commercially available) were constructed by Matthew Murray in England

around 1800. Others, such as Henry Maudslay, James Nasmyth, and Joseph

Whitworth, soon followed the path of expanding their entrepreneurship from

manufactured end products and millwright work into the realm of building

machine tools for sale.

Machine tools can be powered from a variety of sources. Human and animal

power are options, as is energy captured through the use of waterwheels.

However, modern machine tools began to develop only after the

development of the steam engine, which led to the Industrial Revolution.

Today, most machine tools are powered by electricity.

Machine tools can be operated manually, or under automatic control. Early

machines used flywheels to stabilize their motion and had complex systems

of gears and levers to control the machine and the piece being worked on.

Soon after World War II, the numerical control (NC) machine was

developed. NC machines used a series of numbers punched on paper tape or

punched cards to control their motion. In the 1960s, computers were added

to give even more flexibility to the process. Such machines became known

as computerized numerical control (CNC) machines. NC and CNC machines

could precisely repeat sequences over and over, and could produce much

more complex pieces than even the most skilled tool operators.

Before long, the machines could automatically change the specific cutting

and shaping tools that were being used. For example, a drill machine might

contain a magazine with a variety of drill bits for producing holes of various

sizes. Previously, either machine operators would usually have to manually

change the bit or move the work piece to another station to perform these

different operations. The next logical step was to combine several different

machine tools together, all under computer control. These are known as

machining centers, and have dramatically changed the way parts are made.

From the simplest to the most complex, most machine tools are capable of at

least partial self-replication, and produce machine parts as their primary

function. A drilling system and method are provided. The drilling system

comprising a tool body, a drill bit, a mechanism for applying weight to the

drill bit (WOB), and a control system for controlling the rate of rotation of

the drill bit (RPM) and the weight applied to the bit during drilling. The

control system is configurable to a first mode in which RPM and WOB are

controlled to maintain power on the drill bit at a predetermined maximum,

and a second mode in which RPM and WOB are controlled to maintain a

predetermined depth of cut (DOC). In use, the control system is adapted to

switch between the first and second modes depending on drilling conditions.
Botek Type 43A drill head. This is a BTA solid drill head with indexable

inserts and guide pads. It is available in diameters from 150 to 350 mm

(about 6" to 14").

Youre probably accustomed to drilling holes with depths up to, say, five

times their diameter, or maybe, with the latest special drills, up to 15 or even

20 times diameter. But what if you have a customer who gives you a print

for a foot-long part with a quarter-inch hole all the way through 48

diameters. Then youre getting into deep-hole drilling.

A deep hole has a depth-to-diameter ratio of more than 20. It could be 1 mm

in diameter and 2 deep, or a 6 hole thats 35 feet deep. One hundred times

diameter is commonly done. Depths of 200 to 300 diameters are achievable,

Though many consider it a mysterious process, deephole drilling is still

metal cutting. But it poses unique challenges. It requires special tools and in

many cases, special, dedicated machines.

2.1 GUN DRILLING

For a smaller diameter hole like a quarter-inch hole a foot deep, you should

use a gun drill.

A common type of gun drill consists of a shaft with a V-shaped groove, or

flute. The cutting oil or fluid is fed through the tool to the cutting edge and

exits through the V-groove, carrying the chips with it. Gun drilling is

commonly used for holes in the range of 0.5 mm (about 0.020) to two

inches diameter. To help keep the drill straight, you would use a drill

bushing to guide it into the part, or provide a pilot hole.

Gun drilling was invented more than a hundred years ago to provide straight,

precise gun barrels. It is suitable for holes from about half a millimeter

(about 0.02) to 2 in diameter. Hole depths can be 100 diameters or more.

A gun drill, by its geometry, limits the area available for cutting fluid flow

and chip evacuation. Typically the cutting fluid passes through one or two

holes in the shaft of the drill. It exits through the V-groove, which is usually

20 28 percent of the cross-sectional area of the drill, says Tom Swansiger,

vice president, Technidrill Systems Inc., Kent, Ohio, manufacturer of deep

drilling machines. You might need 1 horsepower (hp) for cutting, but

perhaps 5 hp to pump the fluid at pressures in the range of 300 psi to 2000

psi.

Dedicated gun drilling machines are available, but gun drills can also be

used on conventional machines, as long as the cutting fluid pressure and

flow rate are sufficient. For example, Swiss type automatic screw machines

can easily incorporate gun drilling. Typical applications include hydraulic

system components and medical devices, such as bone screws, said George

Bursac, general manager, Star CNC Machine Tool Corp., Roslyn Heights,

N.Y., manufacturer of CNC Swiss type automatic lathes. Though gun

drilling tends to be a slow process, a Swiss machine can perform other

operations while the gun drilling is going on.

Gun drilling is perfect for some applications, but to handle larger diameter

holes and provide faster cutting speeds, youll need a different type of

drilling system.
Star 12-axis Swiss type automatic lathe, with three turrets, allowing three

tools to cut simultaneously.

2.2 BTA or Single Tube System

In the 1930s in Germany, a new technology was developed for deep-hold

drilling to handle larger sized holes, called a single tube system (STS) or

BTA system (for Boring and Trepanning Associationsee also

trepanning, below).

The BTA drill consists of a drill head, a drill tube, a fluid induction unit and

associated fittings and supports. The drill head has cutting edges (often

indexable inserts) and passages for the cutting fluid to flow through. In

addition, the head has guide pads, which ride on the newly cut ID of the hole

and help keep the drill going straight. The drill head is mounted to a drill
tube, which acts as both the shaft of the drill and a return conduit for the

cutting fluid and chips.

Deep drilling machine with covers retracted to show workpiece. To make

oval-shaped holes, fi rst one hole is drilled, then it is filled with a piece of

bar stock and the second hole is drilled. This allows an uninterrupted cut on

the second hole.

In a BTA system, cutting fluid comes in through a fluid induction unit that

seals against the face of the part. This unit also functions as a drill bushing to

support and align the drill. The fluid flows in through the space between drill

tube and the ID of the hole. In the cutting area the fluid picks up the chips

and then flows back out through openings in the face of the drill, exiting

through the inside of the drill tube.

BTA drills are used on dedicated deep-hole-drilling machines, which provide

the necessary spindle horsepower and high-pressure/high-volume fluid flow.

BTA systems are typically used to drill deep holes from about 5/8 to about

20 in diameter,.This type of system will drill five to six times faster than

gun drilling, said Mark Sollich, president, BTA Heller Inc., Troy, Mich., a

tool manufacturer.

COMPUTER NUMERICAL CONTROL

A CNC turning center

Numerical control (NC) is the automation of machine tools that are operated

by precisely programmed commands encoded on a storage medium, as

opposed to controlled manually via hand wheels or levers, or mechanically

automated via cams alone. Most NC today is computer numerical control

(CNC), in which computers play an integral part of the control.

In modern CNC systems, end-to-end component design is highly automated

using computer-aided design (CAD) and computer-aided manufacturing

(CAM) programs. The programs produce a computer file that is interpreted

to extract the commands needed to operate a particular machine via a post

processor, and then loaded into the CNC machines for production. Since any

particular component might require the use of a number of different tools

drills, saws, etc., modern machines often combine multiple tools into a

single "cell". In other installations, a number of different machines are used

with an external controller and human or robotic operators that move the

component from machine to machine. In either case, the series of steps

needed to produce any part is highly automated and produces a part that

closely matches the original CAD design..

History of numerical control

The first NC machines were built in the 1940s and 1950s, based on existing

tools that were modified with motors that moved the controls to follow

points fed into the system on punched tape. These early servomechanisms

were rapidly augmented with analog and digital computers, creating the

modern CNC machine tools that have revolutionized the machining

processes.

Description

Modern CNC mills differ little in concept from the original model built at

MIT in 1952. Mills typically consist of a table that moves in the X and Y

axes, and a tool spindle that moves in the Z (depth). The position of the tool

is driven by motors through a series of step-down gears in order to provide

highly accurate movements, or in modern designs, direct-drive stepper motor

or servo motors. Open-loop control works as long as the forces are kept

small enough and speeds are not too great. On commercial metalworking

machines closed loop controls are standard and required in order to provide

the accuracy, speed, and repeatability demanded.

As the controller hardware evolved, the mills themselves also evolved. One

change has been to enclose the entire mechanism in a large box as a safety

measure, often with additional safety interlocks to ensure the operator is far

enough from the working piece for safe operation. Most new CNC systems

built today are completely electronically controlled.

CNC-like systems are now used for any process that can be described as a

series of movements and operations. These include laser cutting, welding,

friction stir welding, ultrasonic welding, flame and plasma cutting, bending,

spinning, hole-punching, pinning, gluing, fabric cutting, sewing, tape and

fiber placement, routing, picking and placing (PnP), and sawing.

Examples of CNC machines

Mills

CNC mills use computer controls to cut different materials. They are able to

translate programs consisting of specific number and letters to move the

spindle to various locations and depths. Many use G-code, which is a

standardized programming language that many CNC machines understand,

while others use proprietary languages created by their manufacturers. These

proprietary languages while often simpler than G-code are not transferable

to other machines.

Lathes

Lathes are machines that cut spinning pieces of metal. CNC lathes are able

to make fast, precision cuts using indexable tools and drills with complicated

programs for parts that normally cannot be cut on manual lathes. These

machines often include 12 tool holders and coolant pumps to cut down on

tool wear. CNC lathes have similar control specifications to CNC mills and

can often read G-code as well as the manufacturer's proprietary

programming language.

Plasma cutters

CNC plasma cutting

Plasma cutting involves cutting a material using a plasma torch. It is

commonly used to cut steel and other metals, but can be used on a variety of

materials. In this process, gas (such as compressed air) is blown at high

speed out of a nozzle; at the same time an electrical arc is formed through
that gas from the nozzle to the surface being cut, turning some of that gas to

plasma. The plasma is sufficiently hot to melt the material being cut and

moves sufficiently fast to blow molten metal away from the cut.

Electric discharge machining

Electric discharge machining (EDM), sometimes colloquially also referred

to as spark machining, spark eroding, burning, die sinking, or wire erosion,

is a manufacturing process in which a desired shape is obtained using

electrical discharges (sparks). Material is removed from the workpiece by a

series of rapidly recurring current discharges between two electrodes,

separated by a dielectric fluid and subject to an electric voltage. One of the

electrodes is called the tool-electrode, or simply the "tool" or "electrode,"

while the other is called the workpiece-electrode, or "workpiece."

When the distance between the two electrodes is reduced, the intensity of the

electric field in the space between the electrodes becomes greater than the

strength of the dielectric (at least in some point(s)), which breaks, allowing

current to flow between the two electrodes. This phenomenon is the same as

the breakdown of a capacitor. As a result, material is removed from both the

electrodes. Once the current flow stops (or it is stopped depending on the

type of generator), new liquid dielectric is usually conveyed into the inter-
electrode volume enabling the solid particles (debris) to be carried away and

the insulating proprieties of the dielectric to be restored. Adding new liquid

dielectric in the inter-electrode volume is commonly referred to as flushing.

Also, after a current flow, a difference of potential between the two

electrodes is restored to what it was before the breakdown, so that a new

liquid dielectric breakdown can occur.

Wire EDM

Also known as wire cutting EDM, wire burning EDM, or traveling wire

EDM, this process uses spark erosion to machine or remove material with a

traveling wire electrode from any electrically conductive material. The wire

electrode usually consists of brass or zinc-coated brass material.

Sinker EDM

Sinker EDM, also called cavity type EDM or volume EDM, consists of an

electrode and workpiece submerged in an insulating liquidoften oil but

sometimes other dielectric fluids. The electrode and workpiece are

connected to a suitable power supply, which generates an electrical potential

between the two parts. As the electrode approaches the workpiece, dielectric

breakdown occurs in the fluid forming a plasma channel) and a small spark

jumps.
Water jet cutters

A water jet cutter, also known as a waterjet, is a tool capable of slicing into

metal or other materials (such as granite) by using a jet of water at high

velocity and pressure, or a mixture of water and an abrasive substance, such

as sand. It is often used during fabrication or manufacture of parts for

machinery and other devices. Waterjet is the preferred method when the

materials being cut are sensitive to the high temperatures generated by other

methods. It has found applications in a diverse number of industries from

mining to aerospace where it is used for operations such as cutting, shaping,

carving, and reaming.

Other CNC tools

Many other tools have CNC variants, including:

Drills

EDMs

Embroidery machines

Lathes

Milling machines

Wood routers
Sheet metal works (Turret punch)

Wire bending machines

Hot-wire foam cutters

Plasma cutters

Water jet cutters

Laser cutting

Oxy-fuel

Surface grinders

Cylindrical grinders

3D Printing

Induction hardening machines[citation needed]

submerged welding

knife cutting

glass cutting

Tool / machine crashing

In CNC, a "crash" occurs when the machine moves in such a way that is

harmful to the machine, tools, or parts being machined, sometimes resulting

in bending or breakage of cutting tools, accessory clamps, vises, and

fixtures, or causing damage to the machine itself by bending guide rails,

breaking drive screws, or causing structural components to crack or deform

under strain. A mild crash may not damage the machine or tools, but may

damage the part being machined so that it must be scrapped.

Many CNC tools have no inherent sense of the absolute position of the table

or tools when turned on. They must be manually "homed" or "zeroed" to

have any reference to work from, and these limits are just for figuring out

the location of the part to work with it, and aren't really any sort of hard

motion limit on the mechanism. It is often possible to drive the machine

outside the physical bounds of its drive mechanism, resulting in a collision

with itself or damage to the drive mechanism. Many machines implement

control parameters limiting axis motion past a certain limit in addition to

physical limit switches. However, these parameters can often be changed by

the operator.

Many CNC tools also don't know anything about their working environment.

Machines may have load sensing systems on spindle and axis drives, but

some do not. They blindly follow the machining code provided and it is up

to an operator to detect if a crash is either occurring or about to occur, and

for the operator to manually abort the cutting process. Machines equipped

with load sensors can stop axis or spindle movement in response to an

overload condition, but this does not prevent a crash from occurring. It may
only limit the damage resulting from the crash. Some crashes may not ever

overload any axis or spindle drives.

If the drive system is weaker than the machine structural integrity, then the

drive system simply pushes against the obstruction and the drive motors

"slip in place". The machine tool may not detect the collision or the slipping,

so for example the tool should now be at 210mm on the X axis but is in fact

at 32mm where it hit the obstruction and kept slipping. All of the next tool

motions will be off by 178mm on the X axis, and all future motions are

now invalid, which may result in further collisions with clamps, vises, or the

machine itself. This is common in open loop stepper systems, but is not

possible in closed loop systems unless mechanical slippage between the

motor and drive mechanism has occurred. Instead, in a closed loop system,

the machine will continue to attempt to move against the load until either the

drive motor goes into an overcurrent condition or a servo following error

alarm is generated.

Collision detection and avoidance is possible, through the use of absolute

position sensors (optical encoder strips or disks) to verify that motion

occurred, or torque sensors or power-draw sensors on the drive system to

detect abnormal strain when the machine should just be moving and not

cutting, but these are not a common component of most hobby CNC tools.

Instead, most hobby CNC tools simply rely on the assumed accuracy of

stepper motors that rotate a specific number of degrees in response to

magnetic field changes. It is often assumed the stepper is perfectly accurate

and never mis-steps, so tool position monitoring simply involves counting

the number of pulses sent to the stepper over time. An alternate means of

stepper position monitoring is usually not available, so crash or slip

detection is not possible.

Commercial CNC metalworking machines use closed loop feedback controls

for axis movement. In a closed loop system, the control is aware of the

actual position of the axis at all times. With proper control programming,

this will reduce the possibility of a crash, but it is still up to the operator and

tool path programmer to ensure that the machine is operated in a safe

manner. However, during the 2000s and 2010s, the software for machining

simulation has been maturing rapidly, and it is no longer uncommon for the

entire machine tool envelope (including all axes, spindles, chucks, turrets,

toolholders, tailstocks, fixtures, clamps, and stock) to be modeled accurately

with 3D solid models, which allows the simulation software to predict fairly
accurately whether a cycle will involve a crash. Although such simulation is

not new, its accuracy and market penetration are changing considerably

because of computing advancements.

Numerical precision vs equipment backlash

Within the numerical systems of CNC programming it is possible for the

code generator to assume that the controlled mechanism is always perfectly

accurate, or that precision tolerances are identical for all cutting or

movement directions. This is not always a true condition of CNC tools. CNC

tools with a large amount of mechanical backlash can still be highly precise

if the drive or cutting mechanism is only driven so as to apply cutting force

from one direction, and all driving systems are pressed tight together in that

one cutting direction. However a CNC device with high backlash and a dull

cutting tool can lead to cutter chatter and possible workpiece gouging.

Backlash also affects precision of some operations involving axis movement

reversals during cutting, such as the milling of a circle, where axis motion is

sinusoidal. However, this can be compensated for if the amount of backlash

is precisely known by linear encoders or manual measurement.

The high backlash mechanism itself is not necessarily relied on to be

repeatedly precise for the cutting process, but some other reference object or
precision surface may be used to zero the mechanism, by tightly applying

pressure against the reference and setting that as the zero reference for all

following CNC-encoded motions. This is similar to the manual machine tool

method of clamping a micrometer onto a reference beam and adjusting the

Vernier dial to zero using that object as the reference.

3. TYPES OF MACHINE TOOLS

Broaching machine

Drill press

Gear shaper

Hobbing machine

Hone

Lathe

Screw machines

Milling machine
Shaper

Saws

Planer

Stewart platform mills

Grinding machines

Other special machines are:

Electrical discharge machining

Grinding (abrasive cutting)

Multiple edge cutting tools

Single edge cutting tools

4. BASIC CONCEPTS IN MACHINING

Material removal by either hard cutting tools or

energy beams takes place at the interface of the material and the

machining tool. With hard cutting tools such as drills, milling

cutters, etc., the interface is more easily identifiable. With energy

beams, the interface is often more difficult to identify because

energy beams will have some non-uniform energy distribution with

respect to spatial dimensions.

A machine tool is a robot, a kinematic

manipulator with various degrees of freedom and dexterity, which

carries both the cutting tool(s) and the material(s) to be machined.

From a kinematic viewpoint, there is only one function of a

machine tool and that is to accurately and repeatedly control the

point of contact between the cutting tool and the uncut material,

known as the machining interface. This interface is normally better

defined with hard cutting tools than with energy beams, but can

still be unknown due a variety of factors which will be discussed

later. All other functions and structure of the machine tool serve the

purpose of maintaining this interface.

The structure of the machine tool which aids

in maintaining the contact point is termed the structural loop.

Unknown or uncontrollable changes in the structural loop are the

primary source of kinematic errors in machining.

 The structural loop of the machine includes the

cutting tool edge(s), the tool holder, the slides and stages used to

move the tool and/or the work piece, the spindle holding the work

piece or the tool, the chuck, and fixtures, and internal vibration,

eccentricities, and other dynamic effects. Influences outside of the

structural loop, which still influence the loop and cause errors,

include floor vibration, temperature changes, and cutting fluids, for

example.

The attitude wherein all errors are identifiable

and can be quantified is termed determinism. One may not have

the time and/or resources to identify and quantify all errors, but the

attitude of determinism will lead the precision engineer to the

solution of many of the sources of error, rather quickly in many

cases. This is not to say that statistical analysis is not good, but the

reliance on or substitution of statistics for determining the cause of

errors will not eliminate or reduce the influence of those errors.

There are many sources of errors in machining. An

error will be defined as any influence which detracts from

machining the perfect part. A perfect part is an abstraction and has

the attributes of exacting dimensions (to as many decimal places as

can be imagined), an atomically smooth surface, a geometric shape

which is mathematically accurate, and a material which behaves as

desired under all possible applications. There is, of course, no such

thing as the perfect part. Instead, we are satisfied with acceptable

parts where tolerances are within some acceptable range,

roughness which does not exceed some allowable limit set by the

application, a shape which satisfies the application, and a material

with properties which are at least predictable within some range of

uncertainty. Machining errors help contribute to all of these non-

ideal attributes of a part.

The demand for smaller parts also places more

demands on the deviations from the perfect part, especially in

terms of tolerances. One definition of precision is that the tolerance

on a characteristic dimension does not exceed one part in ten-

thousand of that characteristic dimension. As parts become smaller,

and the need for precision in terms of absolute numbers becomes

more demanding, thermal errors become dominant. However,

errors due to temperature variations manifest themselves in a

variety of ways. As kinematic and material errors are introduced,

keep in mind how thermal growth can also influence these error

sources.

5. MACHINING OPERATIONS

Most machining operations can be divided into those that remove

metal from an item, and those that form metal in an item..

Often an unfinished workpiece will need to have

some parts removed or scraped away in order to create a finished

product. For example, a lathe is a machine tool that generates

circular sections by rotating a metal workpiece, so that a cutting

tool can peel metal off, creating a smooth, round surface. A drill or

punch press can be used to remove metal in the shape of a hole.

Other tools that may be used for various types of metal removal are

milling machines, saws, and grinding tools. Many of these same

techniques are used in woodworking.

Metal can be formed into a desired shape much

more easily than materials such as wood or stone, especially when

the metal is heated. A machinist may use a forging machine to

hammer or mold a hot metal workpiece into a desired shape. Dies

or molds may be used if the metal is soft enough, or under high

pressures. A press is used to flatten a piece of metal into a desired

shape.

As a commercial venture, machining is generally

performed in a machine shop, which consists of one or more

workrooms containing major machine tools. Although a machine

shop can be a standalone operation, many businesses maintain

internal machine shops which support specialized needs of the

business.

The inferior finish found on the machined surface

of a workpiece may be caused by insufficent clamping, cutting

conditions or perhaps an incorrectly adjusted machine. It is evident

by an undulating or irregular finish, and the appearance of waves

on the surface.

6.DRILLING

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.
 The most common drill used is the twist drill.

Drilling Machine

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.

Types

1) Based on construction:

Portable,

Sensitive,

Radial,

up-right,

Gang,

Multi-spindle

2) Based on Feed:

Hand driven

Power driven
 7.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.

Power feed

The power feed drilling machine are usually larger and heavier than

the hand feed ones they are equipped with the ability to feed the cutting tool

in to the work automatically, at preset depth of cut per revolution of the

spindle these machines are used in maintenance for medium duty work or

the work that uses large drills that require power feed larger work pieces are
usually clamped directly to the table or base using t bolts and clamps by a

small work places are held in a vise. A depth stop mechanism is located on

the head, near the spindle, to aid in drilling to a precise depth.

8.FACTORS AFFECTING DRILLING

8.1 FEEDBACK VARIABLES

To know the position, and therefore the velocity and

acceleration, of the machine tool it is necessary for the machine to be under

closed-loop control. This requires feedback information. The basic tenet of

precision machining and precision engineering is if the position of a specific

point is required to be known, then measure the location of that point! This

may seem overly simple, but is most often overlooked or is not possible.

Referring back to the previous statement regarding the location of the

machining interface, the point of contact between the tool and the workpiece

is where the feedback device should be located. Needless to say, that is

normally not possible. At the other end of the spectrum, a feedback device

may often be placed on the actuation mechanism causing the desired, or at

least commanded, motion. An example of this is an encoder attached to a

drive motor which provides information on a change in angular position of

the motor. Simply put, this feedback strategy will only provide information

about the angular change in the lead-screw drive mechanism and not about

the lead-screw or the linear position of the stage. The motor could be

slipping on the lead-screw or the lead-screw may have non-linearities. In

either case, false information could be returned.

8.2 LEAD-SCREW NON-LINEARITY

When a lead-screw is used with a ball-nut to provide linear

motion from a rotational actuator, such as a motor, it is often assumed the

pitch (threads per linear distance) is precisely known. Generally, this

information is provided by the manufacturer and is used as a conversion

from rotary displacement to linear displacement. This assumes the pitch is

constant at every location along the lead-screw. Because leads-screws are

machined on machine tools with inaccuracies, the pitch of the lead-screw

will not be constant. The pitch may be larger in some regions of the lead-

screw and less in other regions. This will give an error in the linear location

of the ball-nut and the stage and workpiece attached to it. One bright side to

lead-screw non-linearity is that it is built into the mechanism and all other

things being constant, can be measured and compensated in software

8.3 TOOL WEAR

Again, the wear of the cutting tool is normally not a directly

measured variable but can result in an inaccurate machining condition akin

to a feedback error. Because the tool edge is not where it is thought to be due

to wear, and its location can not be readily measured in use, this results in

the same type error as not measuring the location of interest. If the tool edge

is assumed to have a constant spatial coordinate or a constant length from

some other known point on the tool holder, typically the tool slide at the

base of the tool holder sensed by a linear encoder, then any change in that

information will result in an error. As the tool edge wears, it is shortened and

will result in a larger than commanded workpiece dimension. If the

operation is turning, the shaft will be larger in diameter.

8.4 AXIS ORTHOGONALITY

 Traditional (orthogonal) machine tools (opposed to spatial

free-form machine tools based on Stewart platforms, for example) are

composed of kinematic links ideally situated at right angles to each other. It

is assumed the right angles are present and are maintained throughout all

operational procedures. Because the axis motions are kinematically coupled,

as opposed to physically coupled, errors will result if the axes are not

"perfectly" orthogonal. A motion of only the x-axis, which carries the y-axis

stage, will result in some amount of y motion due to the axes not being at

right angles. A y-motion however would not manifest itself as an x-error. A

non-orthogonal z-axis motion could result in motion components in x and y

if the non-orthogonality is two dimensional. As most fixed errors, if these

angular errors are known, they can be compensated.

8.5 MACHINE TOOL VARIABLES

As mentioned previously, a machine tool is a spatial

manipulator. All manipulators have joints (revolute joints such as a spindle

or prismatic joints such as a linear slide), structural elements or links

connecting the joints, actuators, and positional feedback sensors. Because

machine tools experience forces generated by machining and the weight of

the structural elements themselves, all machine tools are subject to errors

called machine tool variables. The following variables are not all inclusive

but do include many of the more prominent sources of these errors.

8.6 ACCURACY, RESOLUTION, REPEATABILITY

Each of these variables was defined previously and are summarized

as a group. Machined parts are made by commanding the machine tool to

move the tool and/or workpiece to locations within a three-dimensional

volume, called the work volume or work envelope. The locations to move to

are computed by CAD/CAM software or by the machine controller based on

user commands. This implies that each move of the tool or workpiece is to a

location the machine has not previously visited (memorized or been taught)

and a certain set of feedback (encoder) parameters is unknown. The ability

of the machine tool to locate the desired point(s) for the machining operation

will affect the accuracy.

Accuracy will be affected by resolution, for example. All moves are integer

multiples of the minimum, or worst, machine resolution. A linear motor with

high resolution, fed by low resolution encoder feedback, can have high

resolution moves but low resolution of known position, and therefore low

accuracy. The machine can not interpolate between the least counts of the

resolution, and therefore will stop as soon as the commanded position is met.
This can cause repeatability errors depending from which direction the

commanded point is approached.

The previous statements are not meant to imply that feedback sensors can

not be interpolated. For example, a laser interferometer may use interference

fringes where the dark-to-dark fringe pattern can be interpolated in a "gray-

scale" manner. Most oftern, a heterodyne interferometer is used where the

Doppler shift in a two-beam beat frequency is integrated over time to

determine changes in position. Incremental encoders utilizing quadrature

techniques are capable of interpolating between encoder slits to improve

resolution and even detect rotation direction. The point is, the least count of

resolution will affect both accuracy and repeatability, but high resolution is

subsequently easy to accomplish so the actual affect on accuracy and

repeatability is generally small. Overall machine tool accuracy and

repeatability is also closely coupled with many of the other error sources

described

8.7 STIFFNESS

Machine tools are generally massive. Historically, this

is because high structural stiffness is desired to reduce deformation under the

influence of machining forces and the static weight of the machine structure

itself. Deflection will cause the structural loop to deform resulting in

uncertainty and error in the interface point between the tool edge and the

work piece.

Machine tool stiffness tends to have several other

influences. Stiff structures tend to transmit vibration at higher frequencies

than compliant (un-stiff) structures. Machining causes vibration, period. Stiff

machines, with low internal or external damping, will transmit this vibration

throughout the structure. This vibration will cause time-varying deflections

of the structure which, if the vibrations are near a fundamental frequency of

the machine, can be amplified in the machined part. Therefore, a very stiff

machine tool is not necessarily an ideal solution to deformations. One could

argue the best way to compensate for a deflection, especially a time-varying

deflection which may be difficult to predict, is to continually sense the

deflection and compensate for it with the machine motions. This may require

high frequency measurements and motions which are impossible to attain,

however it demonstrates the attitude of determinism where it may be

possible to sense at high frequency, filter to low frequency, and perform the

required compensation.

Associated with stiffness, is the ability of the

machine to dampen vibrations created or transmitted by high stiffness.

Different materials have different internal damping characteristics and so the

material from which the machine and the structural loop are made also
impacts the performance of the machine. The damping characteristic of steel

is different from cast iron and from granite, for example. Additional

damping can be realized in granite, for example, by casting the shapes from

a mix of granite particles and elastomers in a matrix material. Different

materials may also have non-linear damping characteristics whereby one

material may dampen the vibration very well during the first few

milliseconds but then "ring" for a relatively long time. Other materials may

lower the vibration more gradually at first but at a more constant rate so the

vibration dies out faster than the material that rings. One needs to investigate

these phenomena if machine stiffness is to be fully quantified

8.8 SPINDLE VIBRATION

Because the work piece or cutting tool is rotated in a

spindle, vibration of the spindle has two primary effects. First, the spindle

vibration can permeate throughout the structural loop exciting the machine

structure. Generally, spindle vibration will have a relatively high frequency.

Depending on the dynamic characteristics of the machine, the spindle can

excite modes of vibration within the structural loop. Damping in the

structural loop is important to help reduce the amplitude level. The natural

frequency of the structural loop, relative to the spindle frequency, is also

important because the displacement transmissibility will asymptotically

approach zero for input frequencies well above the natural frequency. The
effect is more pronounced for larger values of damping between the natural

frequency and approximately 1.4 times the natural frequency and less at an

input frequency ratio greater than 1.4. This reiterates the fact that the

machine and the process must be well understood and quantified

(fundamental of a deterministic viewpoint) to be made precise.

While calculating the natural frequency of the

machine elements can be difficult, it is one way to estimate which spindle

speeds should be avoided. Easier methods require some level of

instrumentation, but not beyond what is normally available. Mapping the

vibration signature of the basic machine requires some time, but is well

worth the investment. A few accelerometers placed around the structural

loop, particularly one at the tool tip and one at the workpiece will yield a

great deal of information. By electronically taking the difference of the

vibration signatures at these two points, as a function of spindle speed for

example, can give a good predictor for vibration induced errors. If the two

signals are in phase and of the same amplitude, there is essentially rigid

body motion and no relative motion between the tool tip and the workpiece.

As a first order approximation, this is a desired condition. If however, there

are vast differences in the amplitude and/or phase of the motions, there will

undoubtedly be larger levels of imprecision in the cutting operation. This

approach can also be used under actual machining conditions as another

approximation of vibration errors.

Other relatively simple methods to identify

vibration errors reside in the frequency domain of the machine and the

machined part. Surface metrology will be presented in a subsequent section,

but looking at the frequency content of a machined part by analyzing the

power spectral density, for example, will quickly reveal the dominant

frequency components in the machined surface. The two components will be

those which are artifacts of the desired machining condition, and those

which are errors. By knowing the machining conditions, such as feed per

revolution, the desired effects (or at least those which would still be present

under "perfect" conditions) can be identified. All other effects are

undesirable and by knowing their frequency content, one can quickly

identify the physical parameter contributing to that error.

8.9 WORK PIECE VARIABLE

It would seem a foregone conclusion that the material to be

machined must be selected based on the operational requirements of the

finished part. However, several factors associated with the work piece
material and how it is machined can also lead to uncertainty in the finished

results.

8.10 PART FIXTURE

As the requirement for high precision machining becomes more

demanding, more care must be taken when constraining the work piece

against the cutting forces. By its nature, a part fixture induces stresses into

the work piece, and the stresses are particularly high where the fixture

structure contacts the work material. If the contact force is too small, the part

may move during machining so the normal tendency is to apply a large

clamping force. A large force (ie large stress) also induces strain (surface and

internal displacement and stored strain energy) in the work piece. If the

material is then machined to a high precision when clamped, upon

unclamping the work piece the stored strain energy will be released and the

part will change shape. It will relax to a configuration with minimal internal

energy. This change of shape will cause the machined shape to change

resulting in a machining error

8.11 MATERIAL AND HEAT TREATMENT

Different materials will behave differently when

machined and this can influence surface finish, precision, etc. About the only

way to quantify these factors is through experimentation. Materials which

machine at either the large or small scales with one tool material may well

machine differently with another tool material. One such material is 6061-T6

aluminum. Using a steel or carbide tool, this material generally adheres to

the tool leaving a built-up edge and relatively poor surface finish. This is

also generally true with polycrystalline diamond which is a composite

material made of a metallic binder with diamond particles imbedded into it.

Single crystal diamond however, will give relatively good surface finish

although over time aluminum can be seen adhering to the rake face of the

tool. This may take a low power microscope to observe this. Generally, the

built-up aluminum can be removed by a weak hydroxide solution.

Generally, harder materials will give more

precise machining results than softer materials. Reasons include fewer burrs

and shorter chips, which will interfere less with the cutting action. When

properly machined, most ductile materials (aluminum and copper included)

will form long continuous chips. The chips will break only due to high strain

induced by handling, by their own weight, by chip breakers associated with

the tool, or by wrapping around the tool and/or the rotating workpiece.

Except for the use of chip breakers, the methods for reducing continuous

chips are not desirable. It may be necessary to alter the machining

conditions, such as depth of cut or surface speed, to reduce or eliminate long

continuous chips.
 Other methods for increasing the machining precision

is to use a material with some level of heat treatment or solution treating to

reduce the ductility of the material without significantly changing its in-use

properties. Brass may be needed instead of pure copper, for example. This is

of course specific to the application.

Different materials will also wear the tool at different

rates. Focusing on single crystal diamond, ferrous (and a few other)

materials will rapidly wear the diamond because these materials have a high

affinity for carbon. As machining takes place, the temperature at the cutting

interface will increase and the rate of diffusion of the diamond into the work

material will greatly increase. Examples of the wear of diamond on

chromium and copper have been quantified.

8.12 COOLANTS

Associated with material removal is the use of coolants and/or

lubricants. These materials have the functions of reducing the coefficient of

friction between the tool and the work material (before and after the chip is

made), and to help reduce the temperature of the cutting action to increase

tool life and reduce material property changes which can come about by

increased temperature. In micromachining, the ability to reduce the

coefficient of friction might be questionable because of the very light cut.

However, because of a light cut, there is more plastic deformation and

extrusion and the influence of the lubricant is not well understood. However,

the use of a lubricant will, in most cases, give a better surface finish with

most metals such as copper and aluminum. In some micromachining, such

as drilling, the use of a fluid is mandatory to help remove chips from the

drilled hole since microdrills do not have spiral flutes to assist with chip

removal.

While fluids help the basic machining process, it is important to keep

in mind that the fluid (liquid particularly) has a relatively high thermal mass

(specific heat) and therefore if at a different temperature than the work and

tool, can cause thermal expansion/contraction errors. The ideal fluid would

be one which can remove all heat generated by cutting, yet remain at a

constant temperature. This would tend to suggest that phase change cooling

might be an area for further research since phase change is a constant

temperature process.

9. DRILL MATERIALS

The two most common types are

 1. HSS drill

- Low cost

2. Carbide- tipped drills

- high production and in CNC machines

Other types are

Solid Carbide drill, TiN coated drills, carbide coated masonry drills,

parabolic drills, split point drill. Fig.4 shows various types of drills

Various types of drill

Drill fixed to the spindle

10. TOOL NOMENCLATURE
 Nomenclature of twist drill

11. TOOL HOLDING DEVICES

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

12. DRILLING OPERATIONS

 Operations that can be performed in a drilling machine are

Drilling

Reaming

Boring

Counter boring

Countersinking

Tapping

Drilling:

It is an operation by which holes are produced in solid metal by means of

revolving tool called Drill. Fig. 9 shows the various operations on drilling

machine.

Reaming:

Reaming is accurate way of sizing and finishing the pre-existing hole.

Multi tooth cutting tool. Accuracy of 0.005mm can be achieved

Boring:

Boring is a process of enlarging an existing hole by a single point cutting

tool. Boring operation is often preferred because we can correct hole size, or
alignment and can produce smooth finish. Boring tool is held in the boring

bar which has the shank. Accuracy of 0.005mm can be achieved.

Various operations on drilling machine

Counter Bore :-

This operation uses a pilot to guide the cutting action to accommodate

the heads of bolts.

Countersink:-
 Special angled cone shaped enlargement at the end of the hole to

accommodate the screws. Cone angles of 60, 82, 90, 100, 110, 120

Tapping:-

Tapping is the process by which internal threads are formed. It is

performed either by hand or by machine. Minor diameter of the thread is

drilled and then tapping is done

Hand taps and tapping process using tap wrench

Various operations performed on drilling machine
BLOCK DIAGRAM OF MULTIPURPOSE MACHINE

Power supply

Motor Microcontroller

Spindle
program

Drill bit

Drilling operation

workpiece
WORKING PRINCIPLE

The CNC drilling machine consists of an electric motor.

Various parts such as drill bit & rack pinion are attached to the

motor spindle by means of pulley arrangement. When the motor

gets rotated the mechanical power is transmitted to the spindle and

the pulley arrangement and the drilling tool also rotates. Numerical

control (NC) is the automation of machine tools that are operated

by precisely programmed commands encoded on a microcontroller

circuit board. Thus by means of the single power we can perform

automatic drilling operations. The shaft is supported in either and

by bearings.

14. CALCULATION

1. Cutting Speed (v):-

 Its the peripheral speed of the drill.The cutting speed depends upon

the properties of the material being drilled, drill material, drill diameter, rate

of speed, coolant used etc

v = *D*N, where

D = dia of the drill in m

N = Speed of rotation in rpm

2. Feed Rate (f):-

Its the movement of drill along the axis (rpm)

3. Depth of Cut (d):-

The distance from the machined surface to the drill axis.

d=D/2

As the depth of hole increases, the chip ejection becomes more

difficult and the fresh cutting fluid is not able to cutting zone. Hence for

machining the lengthy hole special type of drill called gun drill is used.

4. Material Removal Rate:-

Its the volume of material removed by the drill per unit time
 MRR = ( D2 / 4) * f * N mm3 / min

5. Machining Time (T) :-

It depends upon the length (l) of the hole to be drilled , to the Speed

(N) and feed (f) of the drill

t = L / f N min

15.SAFETY AND PRECAUTIONS

Precautions for Drilling machine

 Lubrication is important to remove heat and friction.

Machines should be cleaned after use

Chips should be removed using brush.

T-slots, grooves, spindles sleeves, belts, and pulley should be

cleaned.

Machines should be lightly oiled to prevent from rusting

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.

16.DESIGN CALCULATION
1. Calculate the speed of the drill bit to drill a hole of dia 20mm where the

cutting speed is 25mts/min.

N [rpm] = ( * D *N)/1000

= (25 * 1000) / ( * 20)

= 397.8rpm

2. The dia of one end of a taper plug is 150mm and dia of the other end is

80mm and the length is 300mm. Calculate its taper.

Taper per mm = (D-d)/L

= (150-80)/ 300

= 0.233mm

3. The dia of one end of a taper plug is 150mm and dia of the other end is

80mm and the length is 300mm. Calculate its taper angle.

Tan /2= (D-d)/2 L

= (150-80)/ 2*300

= 6.65
 17.COST ESTIMATION

S.NO ITEM QUANTITY MATERIAL COST

1. SHAFT & FRAME 1 M.S 1000
2. DRILL BIT & RACK 1 H.S.S 500
3. MOTOR 2 COPPER COIL 2000
MICROCONTROLLER SEMI 4000
4. 1
& CIRCUIT CONDUCTOR
 19.ADVANTAGES

Higher productivity

Less machining time

Less man power

Simple in construction

Less power consumption

APPLICATIONS

Used in all machine shop

 CONCLUSION

The project DESIGN AND FABRICATION OF CNC DRILLING

MACHINE has been successfully designed and tested. It has been

developed by integrating features of all the hardware components used.

Presence of every module has been reasoned out and placed carefully thus

contributing to the best working of the unit.

By means of this simple project, we can do many numbers of

operations using the same system.

Finally we conclude that the project is an emerging field and there is

a huge scope for research and development.

 BIBLIOGRAPHY

Angus, Robert W. THE THEORY OF MACHINES: Drawings,

diagrams, charts. McGraw-Hill 1917. 2nd edition,

Begeman, Myron. MANUFACTURING PROCESSES. Photos,

diagrams, drawings, charts. John Wiley, 1942. 1st edition.

Browne & Sharpe Manufacturing Co. CONSTRUCTION AND USE

OF BROWN & SHARPE AUTOMATIC SCREW MACHINES.

Colvin, Fred H. JIGS AND FIXTURES: A Reference Book.

Diagrams, drawings, plans. McGraw-Hill, 1938. 3rd edition.

Colvin, Fred H. & Frank A. Stanley. DRILLING AND SURFACING

PRACTICE: Drilling, Reaming, Tapping, Planing, Shaping, Slotting,

Milling & Broaching. Photos, drawings, diagrams, charts. McGraw-Hill,

1948. 3rd edition,

Hesse, Herman C. ENGINEERING TOOLS AND PROCESSES: A

Study of Production Technique. Photos, drawings, diagrams. Van Nostrand,

(1941,1952) 11th printing.