Centring, Drilling and Counterboring / Countersinking Course:

Techniques for Machining of Material. Instruction Examples for

Practical Vocational Training

Table of Contents
Centring, Drilling and Counterboring / Countersinking Course: Techniques for Machining of
Material. Instruction Examples for Practical Vocational Training................................................................1
Preface...................................................................................................................................................1
Instruction example 3.1.: Shaft...............................................................................................................1
Instruction example 3.2.: Die plate.........................................................................................................3
Instruction example 3.3.: Adapter...........................................................................................................5
Instruction example 3.4.: Drawin bush.................................................................................................7

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Centring, Drilling and Counterboring / Countersinking Course:

Techniques for Machining of Material. Instruction Examples for
Practical Vocational Training
Institut fr berufliche Entwicklung e. V.
Berlin
Original title:
Lehrbeispiele fr die berufspraktische Ausbildung "Zentrieren, Bohren und Senken"
Author: Detlev Krechlok
First edition IBE
Institut fr berufliche Entwicklung e.V.
Parkstrae23
13187 Berlin
Order No.: 90333203/2

Preface
The present booklet contains 4 selected instruction examples which are intended to help practising and
consolidating knowledge and skills acquired in the working techniques "centring, drilling,
counterboring/countersinking".
In order to facilitate the preparation and execution of the work, the necessary materials, cutting and operating
tools, measuring and testing tools and accessories are stated for each training example.
For the instruction examples 1 and 3 the steel is specified according to the value of its tensile strength in the
unit "Megapascal" (MPa).
We also recommend knowledge required in addition to knowledge of centring, drilling,
counterboring/countersinking which should be repeated before starting with the work. The specified sequence
of operations gives the steps necessary for the production of the parts. This sequence of operations should be
strictly observed if good quality is to be achieved, For each instruction example a working drawing is attached
showing the required shapes and dimensions of the workpiece. The admissible deviations for sizes with no
indication of tolerances may be taken from the table below.
Nominal size

Admissible deviation in mm

0.5 6

0.1

6 30

0.2

30 120

0.3

120 315

0.5

The admissible surface roughness Rz is specified in m (0.001 mm).

Instruction example 3.1.: Shaft

This example serves to practise centring with the centre drill on rotationally symmetrical parts held in a chuck.

Material
GGL 25 (GG = cast iron, L = flakes, GGL = grey cast iron, 25 = 250 MPa tensile strength)
Dimensions
dia. 60250
Cutting and operating tools
Centre drill B 3.15; key
Measuring and testing tools
Vernier caliper
Accessories
Drill chuck, hard chuck jaws
Required previous knowledge
Reading of drawings, measuring and testing, scribing and prickpunching
Explanations to the working drawing
B 3.15:

B = centre hole type B

3.15 = nominal size of the centre drill (d)

Surface finish: unmachined Rz 80, centre hole Rz 20

Sequence of operations

Remarks

1. Dimensional inspection
2. Clamping of workpiece

Type of clamping: "chucking" in hard chuck jaws. Clamp short. Consider

spindle capacity. For longer parts use spindle support.

3. Clamping of tool

Chuck centre drill in drill chuck. If necessary, have drill chuck held in tailstock
spindle using taper sleeves.

4. Setting of cutting values

Select speed rate as high as possible. Feed manually.

5. Positioning of tailstock

Move tailstock in working position and lock it.

6. Switching on lathe
7. Tool to take first cut

Ensure that tool is in central position when taking first cut. Adjust tailstock, if
necessary.

8. Centring

Finish centring. Consider size specified.

9. Returning of tool carrier

(tailstock)

Leave sufficient space for unloading.

10. Switch off machine

11. Measuring
12. Rechucking

Turn part by 180 around its longitudinal axis and clamp it short.

For machining of the second side repeat operations 5. to 11. Operation 7. is not necessary since central
position of the centring tool has already been aligned.

Instruction example 3.2.: Die plate

This example serves to practise centring with the turning tool on rotationally symmetrical parts held in a chuck

Material
100 Cr 6 (100 = 1 % carbon; Cr 6 = 1.5 % chromium)
Dimensions
dia. 3247
Cutting and operating tools
Inside turning tool for corner work, key
Measuring and testing tools
Vernier caliper, dial gauge, protractor
Accessories
Stepped chuck jaws which can be turned out, supporting plates, coolant, Vee (for round cross section of
turning tool shaft)
Required previous knowledge
Reading of drawings, measuring and testing, scribing and prickpunching
Explanations to the working drawing
(0.04) = admissible truerunning error of 0.04 mm not to be exceeded.
Surface finish: finished Rz 20
Sequence of operations

Remarks

1. Dimensional inspection
2. Clamping of workpiece

Type of clamping: "chucking" in stepped chuck jaws which can be turned out.
Chuck on dia. 30, measure on dia. 20, maintain admissible deviation. Check
for true running. If necessary, turn out chuck jaws. Interrupted cut! Wear safety
goggles I

3. Clamping of tool

Clamp short. See to necessary clearance angle. Swivel top slide by 30

degrees.

4. Setting of cutting values

5. Tool to take first cut

Set end stop. Let tool take first cut at interedge between end face and surface
of hole by means of top slide adjustment.

6. Centring

Adjust cross slide to the left. Manually finishturn centre hole by top slide
adjustment. Use coolant for tools without carbide tips.

7. Dimensional and surface

inspection
8. Unloading

Instruction example 3.3.: Adapter

This example serves to practise drilling with the drill and boring with the boring tool on rotationally symmetrical
parts held in a chuck.

Material
St 602 (St = steel, 60 = 600 MPa tensile strength, 2 = grade)
Dimensions
dia. 5570

Cutting and operating tools

Drill dia. 20. internal roughing tool, centre drill A 3.15, righthand sidecutting tool, key.
Measuring and testing tools
Vernier caliper, depth gauge, dial gauge
Accessories
Drill chuck, taper sleeves, supporting plates, coolant, block gauge 25 mm, chuck jaws which can be turned out
Required previous knowledge
Reading of drawings, measuring and testing, scribing and prickpunching, drilling and
counterboring/countersinking
Explanations to the working drawing
320.1 means:
toleranced size

upper deviation

32.00

lower deviation

31.90

Surface finish: finished Rz 20

Sequence of
operations

Remarks

1. Dimensional
inspection
2. Clamping of
workpiece

Type of clamping: "chucking" in chuck jaws which can be turned out. Clamp short.

3. Centring
4. Longitudinal
turning and facing

Set live centre.

5. Clamping of tool

Drill to be held in tailstock. Ensure firm fit of taper.

Clamp short considering blind hole length. (Use vee, if necessary).

6. Drilling 20

Drill through hole dia. 20 by manual adjustment of tailstock sleeve. Use sleeve
scale.

7. Boring 320.1

Make sure the drill edge is sufficiently cooled. Set end stop. Insert block gauge 25
mm. Tool nose to take first cut on transition between end face and inner surface of
the workpiece. Remove block gauge. Set feed
Finishbore 320.1
Utilize "0" position of crossslide.

8. Deburring

Use primary cutting edge.

9. Rechucking
10. Facing to 60 mm
length
11. Deburring

Thoroughly deburr inner and outer edges.

For batch production repeat sequence of operations until operation 3, rechuck, centre and continue with
operation 4. Operation 8 is then deleted (earlier operation).

Instruction example 3.4.: Drawin bush

This example serves to practise countersinking with the countersink and turning tool (boring tool) of hollow
cylindrical parts.

Material
15 Cr 6 (15 = 0.15 % carbon. Cr 6 = 1.5 % chromium) casehardening steel
Dimensions
dia. 5282
(premachined dia. 5080, hole dia. 20)

Cutting and operating tools

Countersink 60, inside turning (boring) tool for corner work, chuck key
Measuring and testing tools
Depth gauge, protractor, dial gauge
Accessories
Chuck jaws which can be turned out, taper sleeves, supporting plates, coolant
Required previous knowledge
Reading of drawings, measuring and testing, scribing and prickpunching, drilling and
counterboring/countersinking
Explanations to the working drawing
20 H 7:

diameter, 20 nominal size,

H disposition of the tolerance
zone
7 quality

0.02 admissible truerunning error 0.02 mm surface: finished Rz 20, Rz 6.3 finefinished.
Sequence of operations

Remarks

1. Dimensional inspection
2. Clamping of workpiece

Type of clamping: "chucking" in stepped chuck jaws which can be turned

out. Chuck on dia. 50 (surface and end face premachined as per sketch
1). Check for true running (Turn out chuck jaws, if necessary).

3. Clamping of tool

Locate tool in tailstock.

Ensure firm fit of taper.

4. Countersinking 260

Countersink 260 by means of manual sleeve adjustment. Select low

cutting speed.
Use coolant. Use sleeve scale. Visual inspection of size and surface finish.

5. Rechucking

Type of clamping: "Chucking". Check for true running (radial and axial
runout).

6. Clamping of tool

Clamp inside turning tool short on top slide. Ensure clearance angle.
Swivel top slide by 45.

7. Countersinking 1045

Set end stop. Take first cut on transition between inner surface and end
face. Set cross slide to "0". Set feed. Finish turning with several chips by
means of manual top slide adjustment. Use coolant for turning tool without
carbide tip.
Visual inspection of surface finish.

8. Dimensional and surface

inspection.
9. Unloading.

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