Manual Drilling Machine

WOLLO UNVERSITY
KOMBOLCHA INSTITUTE OF TECHNOLOGY DEPARTMENT OF

MECHANICAL ENGINEERING STREAM (DESIGN)
TITTLE:-DESIGN AND MODELING OF MANUALLY AND ELECTRICALLY

OPERATED DRILLING MACHINE
1. LEMI DEMISSIE
2. AMHA ABAY
3. DAWIT KIROS
4. TADESSE TEFERA
A Thesis Submitted to Department of ‘Mechanical Engineering’ Kombolcha

Institute of Technology in Partial Fulfillment of the Requirements for the Degree
of Bachelor of Science in ‘Design stream’
Bachelor Science Thesis
Wollo University
Kombolcha Institute of Technology
Department of ‘MECHANICAL ENGINEERING’
MED-2015-002BSC
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Bachelor of Science Thesis: MED-2015-002BSC
TITLE:- DESIGN AND MODELING OF MANUALLY AND ELECTRICALLY

OPERATED DRILLING MACHINE
Lemi Demissie
Amha Abay
Dawit Kiros
Tadesse Tefera
Approved: Examiner: Advisor: Mr. Raja
Date: Chairperson: Co-advisor:
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Abstract
The design of drilling machine is dual operated by electrical power and manually pedal
operated system our design is most recommended to the areas which is insufficient amount of
electric power or irregular power supply in rural area. And also it is highly use full for small
scale industries and work shop manually operated drilling machine is used for traditional
agricultural too material oxen ploughing material that are 90% wooden material most materials
joined by drilling materials but they use chisel drilling by using hammer and chisel to drill and
enlarging drilled hole but operating by this machine is reduce operation time and to save human
power this machine also used for all people use wooden material in house and for many
application. The electrically operated machine can able to drill the material made up of
nonferrous metals the manually operated system machine can able to drill the soft material such
as wood PVC, and sheet metal it is simplistic in design easy to operate and handle it. The
machine is operated by single person at a different velocity ratio. The drilling feed rate is
changing according to the different material depending on material we will change the velocity
ratio by using gear shifting mechanism the drill bit is connected to the chuck and it is operated by
rotating linear drill bit operated by cycling the pedal or electrical motor shaft is coupled to
driving shaft. The tip of the cutting tool which is going to make a drill hole on work piece the
simple example for our mechanism is pedal operated bicycle by a single person.
Key word: Non ferrous metals, Velocity ratio, Gear shifting mechanism, Driving shaft, Cutting
tool
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II. Acknowledgement
We would like to express our sincere thanks and appreciations to our instructor Mr Raja next to
God, for their guidance, advice, precious time and constant support all time.
Next to these we would like to thank our instructor Ato Azmaraw for their feedback and sharing
ideas with us and to all those who have helped as, we express our sincere “Thanks!”
Authors Name: - LEMI DEMISSIE, AMHA ABAY, DAWIT KIROS and TADESSE
TEFERA
ID Number: - R/583/03, R/0113/03, R/285/03 and R/848/03
BSc, Mechanical Engineering
Kombolcha Institute of Technology 2015
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Table of Contents
1. CHAPTER ONE...…………………………………………………………………………....1
1.1.Introduction ............................................................................................................................... 1
1.2 Background ............................................................................................................................... 2
1.2.1 The short history of early drilling machines .......................................................................... 2
1.3 Statement of the problem .......................................................................................................... 3
1.4 Objective ................................................................................................................................... 4
1.4.1 General objective ................................................................................................................... 4
1.4.2 Specific objective ................................................................................................................... 4
1.5 Significance of the project ........................................................................................................ 4
1.6 Scope of the project .......................................................................................................... 4
1.7 Methodology .................................................................................................................... 5
2. CHATER TWO………………………………………………………………………………..6
2.1 LITERATURE REVIEW ......................................................................................................... 6
2.1.1 Drilling operation ................................................................................................................... 6
2.1.2 Drilling and drilling allied operations .................................................................................... 7
2.2 Working principle of drill press ................................................................................................ 8
2.3 Drill Chucks .............................................................................................................................. 8
2.4 Twist drills ................................................................................................................................ 9
2.5 Drill bit Nomenclature and Geometry ...................................................................................... 9
2.6 work Materials ........................................................................................................................ 10
2.6.1 Non-ferrous Metals .............................................................................................................. 10
2.7 Cutting Speed, Feed, Depth of Cut, Tool Wear, and Tool Life .............................................. 11
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2.8 Cutting Speed Formulas .......................................................................................................... 11
2.9 Estimating Machining Power .................................................................................................. 12
2.10 Estimating Drilling Thrust, Torque....................................................................................... 13
2.11Tool Wear and Tool Life Relationships................................................................................. 13
2.12 Literature review Discussion ................................................................................................ 13
3. CHAPTER THREE ................................................................................................................. 15
3.1 Geometrical analysis ............................................................................................................... 15
3.2 Given parameters .................................................................................................................... 16
3.2.1 Working principle of drilling machine ................................................................................ 16
3.2.2 Working material identification ........................................................................................... 16
3.2.3 Driving Motor Power ........................................................................................................... 17
3.2.4 Driving speed ....................................................................................................................... 22
3.2.5 Driving Motor Torque.......................................................................................................... 22
3.3 CHAIN DRIVES .................................................................................................................... 22
3.3.1 Advantages of chain drive over belt or rope drive ............................................................... 23
3.3.2 Design Procedure of Chain Drive ........................................................................................ 23
3.3.3 Material for roller chain and sprocket .................................................................................. 23
3.3.4 Gear shift Mechanism .......................................................................................................... 24
3.4 SHAFT .................................................................................................................................... 28
3.4.1 Material Used for Shaft ........................................................................................................ 29
3.4.2 Diameter and length determination ...................................................................................... 30
3.4.3 Standard Sizes of Transmission Shafts the standard sizes of transmission shafts ............... 30
3.4.4 Manufacturing process of Shafts ......................................................................................... 30
3.5 Key and Coupling ................................................................................................................... 31
3.5.1. Types of key........................................................................................................................ 31
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3.5.2 Keys and coupling material ................................................................................................. 31
3.5.4 Types of coupling ................................................................................................................ 32
3.6 BEARING SELECTION ........................................................................................................ 33
3.6.1 Materials and Manufacture of Ball Bearings ....................................................................... 34
3.6.2 Lubrication of Ball Bearings ................................................................................................ 35
3.8 Belt and pulley ........................................................................................................................ 36
3.10.1 Specification of Rack ......................................................................................................... 39
3.11 Frame .................................................................................................................................... 40
3.12 Seat ........................................................................................................................................ 40
3.13 Working principle ................................................................................................................. 42
4.13.1 Basic result ......................................................................................................................... 45
4.13.3 Discussion .......................................................................................................................... 46
4. CHAPTER FOUR ..................................................................................................................... 46
4. Conclusion, Recommendation and Future Research Work ...................................................... 46
4.1 Conclusion...................................................................................................................... 46
4.2 Recommendation ............................................................................................................ 46
4.3 Future work .................................................................................................................... 47
5. REFERENCES ......................................................................................................................... 50
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IV. List of figure page
Figure 1.1 Drill press…………………………………………………………....................3

Figure 2.1 Chuck and chuck key…………………………………………………………...9
Figure 2.2 Tip of drill bit…………………………………………………………………...9
Figure 2.3 tip of drill bit…………………………………………………………………....9
Figure 2.4 Different helix angle…………………………………………………………...10
Figure 3.1 Geometrical analysis…………………………………………………………...15
Figure 3.2 Chain drives……………………………………………………………………22
Figure 3.4 Gear ratio (velocity ratio)……………………………………………………...23
Figure 3.3 Sprocket………………………………………………………………………..24
Figure 3.5 Shaft…………………………………………………………………………...28
Figure 3.7 Gibb head key………………………………………………………………….31
Figure 3.6 Clamp or compression coupling…………………………………………….....32
Figure3.8 Ball bearing……………………………………………………………………..33
Figure 3.9 Wheel ………………………………………………………………………….35
Figure 3.10 Belt drive……………………………………………………………………...36
Figure 3.11 Rack and pinion……………………………………………………………....38
Figure 3.12 Frame for supporting……………………………………………………….....39
Figure 3.13 Frame for housing………………………………………………………….....39
Figure 3.14 chair (seat)………………………………………………………………….....40
Figure 3.15 Pilot feed levers............................................................................................ ...42
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VI. List of table page
Table 3.1 Driving Motor Power ………………………………………………………......17

Table 3.2 Machine Tool Efficiency Factors………………………………………….........18
Table 3.3 Tool Wear Factors W……………………………………………………. …… 18
Table 3.4 Power Constants KP….........................................................................................18
Table 3.5 Formulas for Calculating the Metal Removal Rate, Q……………………....….19
Table 3.6 Recommended values for drilling………………………………………….…...19
Table 3.7 Feed Factors, C, for Power Constants…………………………………............. 20
Table 3.8 Number of teeth at velocity ratio………………………………………..............24
Table 3.9 Characteristics of roller chains according to IS: 2403 — 1991……………......26
Table 3.10 Mechanical properties of steels used for shafts……………………….............29
Table 3.11 Principal dimensions for radial ball bearing………………………………......33
Table 3.12 Dimensions of standard V-belts according to IS: 2494 – 1974……….............36
Table 3.13 Maintenance schedule………………………………………………………….43
Table 3.14 Resource requirement and cost analysis………………………………...…….44
Table 4.1 Results of component dimensions……………………………………………....43
Table 4.2 Main components of drilling machine…………………………………………..49
List of Conversion Factors
1KW = 1000Watts
1HP= 746Watts
1m = 1000mm
1in=2.54cm
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1. CHAPTER ONE
1.1. Introduction
Drilling is a process used extensively by which through or blind holes are originated or
enlarged in a work piece. This process involves feeding a rotating cutting tool along its axis of
rotation into a stationary work piece. The axial feed is usually very small when compared to the
peripheral speed. Drilling is considered a roughing operation and, therefore, the accuracy and
surface finish in drilling are generally not of much concern. If high accuracy and good finish are
required, drilling must be followed by some other operation such as reaming, boring, or grinding.
The most commonly employed drilling tool is the twist drill, which we can drill in diameters
ranging from 3 to 20 mm. Drilling allied or alternative operations such as core drilling, center
drilling, counter boring, countersinking, spot facing, reaming, tapping, and other operations can
also be performed on drilling machines. Accordingly, the main and feed motions are the same as
in drilling; that is, the drill rotates while it is fed into the stationary work piece. In these
processes, the tool shape and geometry depend upon the machining process to be performed. [2]
This drilling machine is fitted with a drill bit used for drilling holes in various material the
drill bit and rotated while cycling the pedal the tip of the cutting tool does the work cutting in to
the target material by using chain and roller chain drives. It is used to drill piece of material
made of, metal wood PVC and etc. The machine is operated by both human and electrical power
therefore can be used in areas were electricity is irregular or insufficient. It is used for small scale
workers who can work in their work shop and simplistic in design operation and handling. [3]
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1.2 Background
1.2.1 The short history of early drilling machines
Development of drilling rotary techniques from ancient ages to modern times is

described in this article. The manual drive was used in first drilling devices. Original drilling
methods were proposed by ancient Egyptians. The recreating of rotary method was connected
with the drilling rig for drilling of the deepest well in the world was described by Leonardo da
Vinci’s. methods and devices for drilling of stones, glasses, metals, jewels and bones were
developed by ancient people (20-10 thousand years ago) in different regions of the world
(Europe, Asia, Egypt, America). An ancient man used primitive methods of drilling to
create working instruments and house tools in pal eolith period (stone’s hummers, jewelry
and so on) Perhaps working instrument was performed as two concentric wood rods filled
with abrasive material (sand, probably diamond). The characteristic feature of these tools was
such that orifice was drilled in the detail. The advantage of relative principle was based on the
creation of great pressure on the working edge of the bit and possibility to damage the whole
bottom. In Ethiopia 46.3% of people are in agricultural sector until now we use traditional
agricultural too material oxen ploughing material are 90% wooden material most materials
joined by drilling materials but they use chisel drilling by using hammer and chisel to drill and
enlarging drilled hole but these time consume operation and not precise one most people use
wooden material in house and for many application.
Today modern a drilling machine comes in many shapes and sizes, from small hand-held power
drills to bench mounted and finally floor-mounted models. They can perform operations other
than drilling, such as counter sinking; counter boring, reaming, and tapping large or small holes.
Because the drilling machines can perform all of these operations, this will also cover the types
of drill bits, took, and shop formulas for setting up each operation. Safety plays a critical part in
any operation involving power equipment. This will cover procedures for servicing, maintaining,
and setting up the work, proper methods of selecting tools, and work holding devices to get the
job done safely without causing damage to the equipment, yourself, or someone nearby. A
drilling machine, called a drill press, is used to cut holes into or through metal, wood, or other
materials Drilling machines use a drilling tool that has cutting edges at its point.
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Figure 1. Drill press
This cutting tool is held in the drill press by a chuck or Morse taper and is rotated and fed into
the work at variable speeds. Drilling machines may be used to perform other operations. They
can perform countersinking, boring, counter boring, spot facing, reaming, and tapping. Drill
press operators must know how to set up the work, set speed and feed, and provide for coolant to
get an acceptable finished product. The size or capacity of the drilling machine is usually
determined by the largest piece of stock that can be center-drilled For instance, a 15-inch drilling
machine can center-drill a 30-inch-diameter piece of stock. Other ways to determine the size of
the drill press are by them largest hole that can be drilled, the distance between the spindle and
column, and the vertical distance between the worktable and spindle.
1.3 Statement of the problem

Drilling without drilling machine is difficult operation in local workshop and in
manufacturing industries drilling machine is not available in all work shop and it is expensive it
needs electric power and operated by skilled person only those problems are cause:
 Drilling is difficult operation
 Cost of the drilling machine is maximum relative to manually drilling machine
 Drill machine must need only electrical power
 In most rural area there is no electric power and drilling without drill machine is difficult
for agricultural tool material, house hold tools and transportation material
 Most of traditional agricultural tool materials are joined by drilling the material in
traditional method, example chisel hammer drilling.
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1.4 Objective
1.4.1 General objective

 The main objective of this project is to design manually and electrically operating
drilling machine.
1.4.2 Specific objective

 To design the machine that available within low cost and simply operate
 To design and model parts,
 To specify human and electric power for safe working condition
 To give awareness about importance and application of this machine for local
people
 To fabricate this machine with minimum cost in local work shop if there is any
sponsor
1.5 Significance of the project

In the age of globalization for local people it is better to use these machines to get better
revenue from drilling operation. From these machines drilling is simple and common operation
for people live in any local area. By using this machine we can get the better drilling operation.
We can drill materials with in required diameter and required standard precision and it also
operated by one person only. Maintenance of all part is put in to scheduled format and applied in
the any operation condition.
1.6 Scope of the project
This design drilling machine was designed based on the material that to be drilled,
drilling diameter, operated by both electric and human power and designed by considering
financial capacity of local people. In such a way it can easily be operated by one person and this
machine can able to drill metal, wood, PVC and this machine is used to grinding tool material
and other sharp material used in house hold and work shop material with attachment of grinding
disc at the shaft of fly wheel and also used as source of electrical power by connecting rotating
shaft with generator shaft and connecting with storage battery to get light at night time for people
in rural area. we can fabricate this machine with minimum cost in local work shop if there is any
sponsor.
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1.7 Methodology
To successfully work on this project different methods of analysis are used. From the methods
used the main ones are listed below as follows
 Data collection through directs observation the current machine working facture
and referring to some books and hand outs related to the study, using journal
reference.
 Select simple mechanism and drilling operation method
 Design by considering operation and machine ergonomics for safe working
condition
 Literature survey and internet browsing in order to carefully analyze the work
 Proper design based on effective design approaches and
 Developing a prototype.
2. CHAPTER TWO
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2.1 LITERATURE REVIEW
Machining is the removal of the unwanted material (machining allowance) from the work
piece (WP), so as to obtain a finished product of the desired size, shape, and surface quality. The
practice of removal of machining allowance through cutting techniques was first adopted using
simple handheld tools made from bone, stick, or stone, which were replaced by bronze or iron
tools. Water, steam, and later electricity were used to drive such tools in power-driven metal
cutting machines (machine tools). The development of new tool materials opened a new era for
the machining industry in which machine tool development took place. Nontraditional
machining techniques offered alternative methods for machining parts of complex shapes in
hard, stronger, and tougher materials that are difficult to cut by traditional methods. Drilling
allied or alternative operations such as core drilling, center drilling, counter boring,
countersinking, spot facing, reaming, tapping, and other operations can also be performed on
drilling machines. Accordingly, the main and feed motions are the same as in drilling; that is, the
drill rotates while it is fed into the stationary work piece. In these processes, the tool shape and
geometry depend upon the machining process to be performed. [2]
The portable drill is a hand-supported, power-driven machine tool that rotates twist drills,
reamers, counter bores, and similar cutting tools. The portable drill may be electrically powered
by means of an internal electric motor power and also human drilling system. Portable drills are
rated by the maximum size hole that can be drilled in steel without overtaxing the motor or drill.
Therefore, a 1/4-inch-capacity drill is capable of drilling a 1/4-inch diameter whole or smaller in
steel. Portable electric and pneumatic drills rated at 1/4 to 1/2-inch maximum capacities are
usually equipped with geared drill chucks for mounting straight, round shank twist drills or other
similar tools by using a chuck key. Heavier portable drills having a 3/4- to 1 1/4-inch capacity
use taper shank chucks to mount drills and other similar tools. [2]
2.1.1 Drilling operation

Operation of the portable electric and pneumatic drills differs from recommended operating
procedures for the upright drilling machine. The portable drill is hand supported for most
operations, and the cutting speed of the drill is fixed or dependent upon the operator to control.
When hand supported, the drill must be carefully aligned with the work piece and this alignment
must be maintained throughout the drilling operation. Care must be taken not to lose control of
the portable drill and allow it to be wrenched from the operator’s hands. The larger portable
drills can be very dangerous if not held firmly by the operator. If the cutting speed is fixed, the
operator must learn to control the feed of the portable drill by applying sufficient pressure for the
drill to cut, but not too much pressure as to cause overheating of the twist drill or stalling of the
portable drill motor. When metal is to be drilled with the portable drill, the work piece must be
prepared by locating the center position of the potential hole and marking the location with a
center punch. When a large drill is to be used, it will be necessary first to drill a pilot hole
slightly larger in diameter than the thickness of the larger drill’s web, which will allow for the
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drag caused by the larger drill’s chisel edge portable pneumatic drills require special attention to
lubricate their internal moving parts. Each drill may be made slightly different, so refer to the
pertinent lubrication order or manufacturer’s instruction manual before drilling. [4]
For drilling by hand, the work piece must be mounted securely. Thin workplaces should be
backed up with a thicker piece of wood or metal to prevent the drill from snagging in the work
piece. Do not attempt to hold any work piece by hand or serious injury could result. Select a
twist drill of the proper size for the hole to be drilled. Ensure that the twist drill selected has the
right type of shank for the type of chuck mounted on the portable drill. Taper shank drills cannot
be mounted in a drill with a geared chuck. Check each twist drill for sharp cutting edges prior to
use. After securing the twist drill in the proper chuck, connect the portable drill to its power
source. Position the portable drill perpendicular to the work piece and center the chisel point of
the drill in the center-punched hole of the work piece. [4]
2.1.2 Drilling and drilling allied operations

A. Core drilling: is usually an intermediate operation between drilling and reaming which is
performed for the purpose of enlarging holes.
B. Counter boring and countersinking are used for machining cylindrical and tapered recesses
in previously drilled holes. Such recesses are used for embedding the heads of screws and bolts,
when these heads must not extend over the surface.
C. Spot facing is the process of finishing the faces of bosses for washers, thrust rings, nuts, and
other pieces.
D. Center drilling is a combined operation of drilling and countersinking. Center drills are used
for making center holes in blanks and shaft.
E. Reaming is a hole-finishing process intended to true up the hole to obtain high dimensional
and form accuracy.
F. Tapping is the process of generating internal threads in a hole using a tap that is basically a
threading tool.
F. Deep-hole drilling where the length-to-diameter ratio of the hole is 10 or more, the work is
rotated by a chuck and supported by a steady rest, while the drill is fed axially.
G. Gun drills for drilling holes up to 25 mm in diameter.
H. Half-round drills for drilling holes over 25 mm in diameter.
I. Trepanning drills for annular drilling of holes over 80 mm in diameter, leaving a core that
enters the drill during operation.
There are three basic types of drilling commonly in use by today’s woodworker and dozens of
different types of drilling bits and accessories available to make your work easier and ensure the
best results. Most beginning woodworkers give very little thought to the drilling of holes. As a
rule, they already have a set of common twist bits and a portable electric drill. Often, they don’t
discover that drilling a clean, smooth hole in a piece of wood can be a real challenge until
they’ve created a sloppy, splintery hole in their first “real” woodworking project. This hole could
be out-of-round, drilled at an incorrect angle or just look bad enough that they wouldn’t want
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anyone to see it. Using the right tool for the job (portable electric drill, vertical drill press or
horizontal boring machine) and choosing the proper bit – can make a big difference in your final
product. In this article, we’re going to take a look at both of these factors plus provide some
valuable tips for setting everything up correctly to achieve the best, most consistent results. [4]
2.2 Working principle of drill press

Successful operation of the drill press requires the operator to be familiar with the machine and
the desired operation. The following are some good observations to follow when drilling a hole:
1. Prior to drilling a hole, locate the hole by drawing two crossing lines. Use a center punch to
make an indentation for the drill point to aid the drill in starting the hole.
2. Select the proper drill bit according to the size needed.
3. Select an appropriate size center drill.
4. Select a cutting fluid.
5. Properly secure the work piece to the table.
6. Select the correct RPM for the drill bit. Take into account: size of bit, material, and depth of
hole to be drilled.
7. Use an interrupted feed, called peck drilling, to break up the chips being produced.
8. Pilot holes should be used on holes larger than 3/8” dia. Holes are to be enlarged in no more
than 1/4” increments.
9. Clean the drill press and surrounding area when finished.
Hard and fast rules are not always practical for every operation performed in a drill press, since
many factors can influence the speed and feed at which a material can be worked. The above
suggestions, combined with knowledge of the tool being used, will provide a reasonable
guideline for the operator using a drill press.
2.3 Drill Chucks

Drill Chucks feature a unique compact design and small head which prevent the drill from
slipping during drilling operations. Keyed chuck is an integral part of all drill chuck technology.
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Figure 2.1 chuck and chuck key
2.4 Twist drills

A twist drill is a pointed cutting tool used for making cylindrical holes in the work piece. It has
helical flutes along its length for clearing chips from the holes. Twist drills are the most common
used today, but there are many other styles with different purposes. A twist drill is composed of
three major parts: a shank, body, and point. The shank is the part of the drill bit held in the
spindle of the drill press. The drill press’ power is transferred through the shank. Shanks are
either one of two styles, straight or tapered. Straight shank drills are held in a friction chuck.
2.5 Drill bit Nomenclature and Geometry

A twist drill is made up of three components:
1. Shank
2. Body
3. Drill point
1 2 3
Figure 2.2 drill bit

The drill points have four main features: 1. Point Angle, 2. Cutting Lips, 3. Chisel Edge, 4. Lip
Relief
Figure 2.3 tip of drill bit

Drill Nomenclature-Web Thickness
Light: Generally 14 to 16 % of the cutting diameter
Found on fast helix general purpose drills
Medium: Typically 17 % to 22% of the cutting diameter Found on all GP drills
Heavy: Generally 25 % to 40% of the cutting diameter Used on cobalt, coolant hole, parabolic,
and other heavy duty drills
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Helix Angle: Angle formed between a line drawn parallel to the axis of the drill and the edge of
the land.
Figure 2.4 helix angle
Margins: The cylindrical portion of the land that is not cut away to provide clearance The
balance of the land is reduced in diameter, known as “cleared diameter” or “body clearance”
Body clearance prevents excessive rubbing and friction
2.6 work Materials

The large numbers of work materials that are commonly machined vary greatly in their basic
structure and the ease with which they can be machined. Yet it is possible to group together
certain materials having similar machining characteristics, for the purpose of recommending the
cutting speed at which they can be cut. Most materials that are machined are metals and it has
been found that the most important single factor influencing the ease with which a metal can be
cut is its microstructure, followed by any cold work that may have been done to the metal, which
increases its hardness. Metals that have a similar, but not necessarily the same microstructure,
will tend to have similar machining characteristics. Thus, the grouping of the metals in the
accompanying tables has been done on the basis of their microstructure.
2.6.1 Non-ferrous Metals

We have already discussed that the non-ferrous metals are those which contain a metal other than
iron as their chief constituent. The non-ferrous metals are usually employed in industry due to
the following characteristics:
1. Ease of fabrication (drilling, casting, rolling, forging, welding and machining),
2. Resistance to corrosion,
3. Electrical and thermal conductivity, and
4. Light in weight.
The various non-ferrous metals used in engineering practice are aluminum, copper, lead, tin,
Non-metallic Materials: - non-metallic materials are used in engineering practice due to their low
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density, low cost, flexibility, resistant to heat and electricity. Though there are many non-
metallic materials, yet the following are important from the subject point of view.
1. Plastics. The plastics are synthetic materials which are molded into shape under pressure with
or without the application of heat. These can also be cast, rolled, extruded, laminated and
machined. Following are the two types of plastics:
(a) Thermosetting plastics, and
(b) Thermoplastic.
2.7 Cutting Speed, Feed, Depth of Cut, Tool Wear, and Tool Life
The cutting conditions that determine the rate of metal removal are the cutting speed, the feed
rate, and the depth of cut. These cutting conditions and the nature of the material to be cut
determine the power required to take the cut. The cutting conditions must be adjusted to stay
within the power available on the machine tool to be used. Power requirements are discussed in
Estimating Machining Power later in this section. The cutting conditions must also be considered
in relation to the tool life. Tool life is defined as the cutting time to reach a predetermined
amount of wear, usually flank wear. Tool life is determined by assessing the time the tool life at
which a given predetermined flank wears is reached (0.01, 0.015, 0.025, 0.03 inches, for
example). This amount of wear is called the tool wear criterion, and its size depends on the tool
grade used. Usually, tougher grade can be used with a bigger flank wear, but for finishing
operations, where close tolerances are required, the wear criterion is relatively small. Other wear
criteria are a predetermined value of the machined surface roughness and the depth of the crater
that develops on the rake face of the tool.
2.8 Cutting Speed Formulas

Most machining operations are conducted on machine tools having a rotating spindle. Cutting
speeds are usually given in feet or meters per minute and these speeds must be converted to
spindle speeds, in revolutions per minute, to operate the machine. Conversion is accomplished by
use of the following formulas:
Where N is the spindle speeds in revolutions per minute (rpm); V is the cutting speed in feet per
minute (fpm) for U.S. units and meters per minute (m/min) for metric units. In turning, D is the
diameter of the work piece; in milling, drilling, reaming, and other operations that use a rotating
tool, D is the cutter diameter in inches for U.S. units and in millimeters for metric units. π=
3.1416
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2.9 Estimating Machining Power
Knowledge of the power required to perform machining operations is useful when planning new
machining operations, for optimizing existing machining operations, and to develop
specifications for new machine tools that are to be acquired. The available power on any
machine tool places a limit on the size of the cut that it can take. When much metal must be
removed from the work piece it inadvisable to estimate the cutting conditions that will utilize the
maximum power on the machine. Many machining operations require only light cuts to be taken
for which the machine obviously has ample power; in this event, estimating the power required is
a wasteful effort. Conditions in different shops may vary and machine tools are not all designed
alike, so some variations between the estimated results and those obtained on the job are to be
expected. However, by using the methods provided in this section a reasonable estimate of the
power required can be made, which will suffice in most practical situations The measure of
power in customary inch units is the horsepower; in SI metric units it is the kilowatt, which is
used for both mechanical and electrical power. The power required to cut a material depends
upon the rate at which the material is being cut and upon an experimentally determined power
constant, KP, which is also called the unit horsepower, unit power, or specific power
consumption. The power constant is equal to the horsepower required to cut a material at a rate
of one cubic inch per minute; in SI metric units the power constant is equal to the power in
kilowatts required to cut a material at a rate of one cubic centimeter per second, or 1000 cubic
millimeters per second (1 cm3= 1000 mm3). Different values of the power constant are required
for inch and for metric units, which are related as follows: to obtain the SI metric power
constant, multiply the inch power constant.
12
2.10 Estimating Drilling Thrust, Torque
The lips of a drill cut metal and produce a chip in the same manner as the cutting edges of other
metal cutting tools; the chisel edge removes the metal by means of a very complex combination
of extrusion and cutting. For this reason a separate method must be used to estimate the power
required for drilling. Also, it is often desirable to know the magnitude of the thrust and the torque
required to drill a hole.
2.11Tool Wear and Tool Life Relationships

Tool wear tool-life is defined as the cutting time to reach a predetermined wear,
called the tool wear criterion. The size of tool wear criterion depends on the grade used;
usually a tougher grade can be used at bigger flank wear. For finishing operations, where
close tolerances are required, the wear criterion is relatively small. Other alternative wear
criteria are a predetermined value of the surface roughness, or a given depth of the crater
which develops on the rake face of the tool. The most appropriate wear criteria depend on
cutting geometry, grade, and materials.
Cutting tool is maintained daily per any operation drill bit is maintained by sharping the tip
of the drill bit by using grinding with in standard helix angle.
2.12 Literature review Discussion

Drilling operation is difficult without drilling machine but it is very simple operation
within drilling machine in rural area agricultural tool material, house hold material and
transportation material are joined by drilling the material in traditional way, chisel drilling is
common in rural area but this type of drilling operation is time consuming and difficult drilling
operation in industries and local work shop the modern drilling machine is available but it is
operating only by electrical motor when electrical power is not available there is no drilling
operation design of manually and electrically drilling machine is starting from working material,
properties of material such as machining power, speed, feed rate, torque and trust load are
studied, searching all above information is our first work we are searching more about
properties of working material then identifying proper working material and the material
properties and all about drilling machine, drilling machine tool material are very important things
generally drilling of material is depend on material properties and indentifying driving power,
speed, feed rate, torque and depth of cut are very important things so we are indentify all things
in this project.
13
The large numbers of work materials that are commonly machined vary greatly in their
basic structure and the ease with which they can be machined. Knowledge of the power, speeds,
torque feed rate, depth of cut and etc are required to perform machining operations is useful
when planning new machining operations, for optimizing existing machining operations, and to
develop specifications for new machine tools that are to be acquired design of drilling machine is
must be depend on working material the material we select to drill is non ferrous material We
have already discussed that the non-ferrous metals are those which contain a metal other than
iron as their chief constituent. The non-ferrous metals are usually employed in industry due to
the following characteristics:
4. Light in weight.
This research is considering rural people and their income to purchase this machine and in any
place at electrical power is not available we are searching all drilling machine and working
material
14
3. CHAPTER THREE
3.1 Geometrical analysis
0.6m
0.5m
1m
0.3m
0.86m
Figure 3.1 Geometrical analysis
15
3.2 Given parameters
Driving power (motor power) 1.25Kw
Driving power (Motor speed) 1850rpm
Driving power for human 280watts
Average cycling for human 60rpm
Overall length of the machine 1.46m
Over all height of the machine 1.8m
Radius of the pedal foot 30cm
Centre distance between two horizontal sprockets 0.86m
Centre distance between two vertical sprockets 1m
Drill diameters ranging from 0.25 to 20 mm.
The standard helix of a twist drill is 30°, which, together with a point angle of 118°, is
suitable for drilling steel and CI. Drills with a helix angle of 20°, known as slow-helix drills, are
available with a point of 118° for cutting brass and bronze, and with a point of 90° for cutting
plastics. Quick helix drills, with a helix angle of 40° and a point of 100°.
3.2.1 Working principle of drilling machine

This drilling machine is dual operated with in both electrical and human power and fitted
with a drill bit used for drilling holes in various materials the drill bit rotated while cycling the
pedal or when electrical motor is attached to driving shaft and the tip of the cutting tool does
work cutting material by using drilling chuck and rotating lever to drilling press work piece in to
the target point of drilling and power is transmitted by using combination of belt and roller chain
drives. It is drill piece of material made of metal, wood, PVC and operated by electrical power to
drill nonferrous metals and when it is operated by human power it is drill some soft material
made of metal, wood, PVC therefore it can be used in areas was electricity is insufficient or
irregular and. It is used for small scale workers who can work in their work shop and simplistic
in design operation and handling.
3.2.2 Working material identification

Non-ferrous Metals:-we have already discussed that the non-ferrous metals are those
which contain a metal other than iron as their chief constituent. The non-ferrous metals are
usually employed in industry due to the following characteristics:
16
4. Light in weight.
1. Plastics. The plastics are synthetic materials which are molded into shape under pressure with
or without the application of heat. These can also be cast, rolled, extruded, laminated and
machined. Following are the two types of plastics:
(a) Thermosetting plastics, and
(b) Thermoplastic.
3.2.3 Driving Motor Power

P=FxV
P=Pedaling power for human
F = Minimum human force is 150N-200N this machine is operating by maximum Human force
200N there is also fly wheel for speed increment when operator lower the cycling
V= maximum cycling speed when pedal cycling by average is N= 80rpm
V= = =1.256m/s
Power=force x velocity
P=200N x 0.93m/s= 251watts
Then this power is sufficient to drill wooden material, soft metals and PVC material the, power
to drill wooden material is less than 251watts
 The power also increase by means of fly wheel it is freely rotating and store energy when
the pedal is cycling more the stored energy is transmitted from fly wheel to chain drive ,
belt drive, spindle and drill bit.
 This power is drill soft material like non ferrous metal, wooden materials, PVC material
and etc [3]
Calculation of driving power and driving speed is starting from identification material, their
property, machining power constant, machining speeds and feed rate. Then this machine to drill
non ferrous material because of operating power of this machine is less than the drilling machine
Nonferrous Metals are many metals that do not have iron as their basic ingredient are known as
nonferrous metals, offer specific chemical properties or combinations of properties that make
them ideal for tasks not suitable for ferrous metals but softer than ferrous metal and easy to
machining. The power to drill non ferrous material is less than the power to dill ferrous material
17
some nonferrous metals are light in weight. They are more expensive than ferrous metals on a
per weight basis and their supply is rather limited. Nonferrous metals are often combined with
ferrous metals in a finished product. Nonferrous metals include the aluminum, zinc, copper, tin,
magnesium, and lead. Aluminum is the most abundant metal and third-most abundant element.
Aluminum is smelted from bauxite ore, and is identified by its toughness, lightweight, and silver-
white color. Pure aluminum is very soft and malleable. Other materials such as silicon,
manganese, and magnesium are added to give aluminum more strength and other qualities.
Special techniques are used to weld aluminum. [5]
Driving Motor Power [5] Table 3.1
Table 3.2 Machine Tool Efficiency Factors E [5]
Type of drive E
Direct and belt drive 0.9
Back gear drive 0.75
Geared head drive 0.70 – 0.80
Oil – hydraulic drive 0.60 -0.90
Where: Pc= power at the cutting tool; HP, or kW

KP= power constant, HP/ in.3/min or kW/ cm3/s
Q = metal removal rate; in.3/min. or cm3/s
C = feed factor for power constant
W = tool wear factor
18
Table 3.3 Tool Wear Factors W [5]
Table 3.4 Power Constants KP [5]
19
Table 3.5 Formulas for Calculating the Metal Removal Rate, Q [5]
Where Q = Removal Rate, VC= cutting speed, d = depth of cut, f = feed rate
Table 3.6 Recommended values for drilling [5]
Table 3.7 Feed Factors, C, for Power Constants
20
Pc [HP] =KP [HP/ in.3/min]×C×Q[in.3/min]×W Pc [kW] = KP [kW/ cm3/s] ×C×Q [cm3/s] ×W
 W= tool wear factor when type of drilling is normal drilling=1.30. From table 3.3
 KP= power constant, HP/ in.3/min or kW/ cm3/s, for Aluminum cast…KP= 0.25 HP/
in.3/min KP= 0.68 kW/ cm3/s, for Aluminum rolled hard= KP= 0.33 HP/ in.3/min, KP=
0.90 kW/ cm3/s. From table 3.4
 Q = metal removal rate; in.3/min. or cm3/s,
For inch units units only For si metric units only

Q = in .3 / min Q = cm3 / s
12 vc f d
Q = Removal Rate, VC= cutting speed, d = depth of cut, f = feed rate
VC=16feet/min, VC=16m/min, f= 0.008in, f=0.2mm d = depth of cut is depend on thickness of

work piece for 20mm for maximum removal rate. From table 3.6
For Inch Units Only Q = 12 VCf d= 12 x 16feet/min x 0.008in x 1.575in= 2.42in.3/min for
minimum cutting speed in feet/min (16feet/min)
For SI Metric Units Only Q = VCf d/60= (1600cm/min x0.02cm x 2cm)/60= 1.06cm3/s for
minimum cutting speed in feet/min (16m/min)
C is feed factors, for Power Constants. From table 3.7 [5]
C is feed factors, for Power Constants=1.08
Driving Motor Power in [HP] and [kW]

Pc [HP] =KP [HP/ in.3/min]×C×Q[in.3/min]×W Pc [kW] = KP [kW/ cm3/s] ×C×Q [cm3/s] ×W
Pc[HP]=0.25[HP/in.3/min]×1.08×2.42[in.3/min]×1.30= 1.23HP
Pc [kW] = 0.68[kW/ cm3/s]×1.08×1.06[cm3/s]×1.3=1.01kw
PM= =1.25KW where E is 0.9 for Direct and belt drive
21
PHP= =1.36HP
3.2.4 Driving speed

Formulas for calculating the rotational speed N [RPM] [5]
N= Rotation speed in [RPM]

V= cutting speed 377feet/min from table 3.6
D = drill bit diameter in inches or mm [0.25 to 20mm] maximum drilling diameter is
20mm=0.78in
N= = =1847RPM 1850RPM
3.2.5 Driving Motor Torque

Formulas for calculating of Driving Motor Torque [5]
Tm= = =6452NM
3.3 CHAIN DRIVES

The chains are made up of number of rigid links which are hinged together by pin joints
in order to provide the necessary flexibility for wrapping round the driving and driven wheels.
Fig 3.2 chain drives
22
3.3.1 Advantages of chain drive over belt or rope drive
1. As no slip takes place during chain drive, hence perfect velocity ratio is obtained.
2. Since the chains are made of metal, therefore they occupy less space in width than a belt
or rope drive.
3. It may be used for both long as well as short distances.
4. It gives high transmission efficiency (up to 98 percent).
5. It gives fewer loads on the shafts.
6. It has the ability to transmit motion to several shafts by one chain only.
7. It transmits more power than belts.
8. It permits high speed ratio of 8 to 10 in one step.
9. It can be operated under adverse temperature and atmospheric conditions
3.3.2 Design Procedure of Chain Drive
1. First of all, determine the velocity ratio of the chain drive.

2. Select the minimum number of teeth on the smaller sprocket or pinion
3. Find the number of teeth on the larger sprocket.
4. Determine the design power by using the service factor, such that
5. Design power = Rated power × Service factor
6. Choose the type of chain, number of strands for the design power and r.p.m.
7. Note down the parameters of the chain, such as pitch, roller diameter, minimum width of
roller
8. Find pitch circle diameters and pitch line velocity of the smaller sprocket.
9. Determine the load (W) on the chain by using the following relation, i.e.
10. W=
11. Calculate the factor of safety by dividing the breaking load (WB)
12. Fix the centre distance between the sprockets.
13. Determine the length of the chain. [1]
3.3.3 Material for roller chain and sprocket

Steel transmission roller chain is made to close tolerances with excellent joint articulation,
permitting a smooth efficient flow of power. Any friction between the chain rollers and sprocket
teeth is virtually eliminated because the rollers rotate on the outside of the bushes, independent
of bearing pin articulation inside the bush. As a result, very little energy is wasted and tests have
shown chain to have an efficiency of between 98.4% and 98.9%. This high level of efficiency,
achieved by a standard stock chain drive under the correct conditions of lubrication and
installation, is equaled only by gears of the highest standard with teeth ground to very close
tolerances.
23
3.3.4 Gear shift Mechanism
The actual mechanism to shift the gear ratios in the flywheel system will be the same
system used in caliper brakes. This is an off-the-shelf, cheap part that is easy to implement on a
bike. The only change will be removing the line from the brake calipers and attaching it to the
end piece. There are many other possible gear shifters that would work, but since this part can
easily be purchased and implemented, it is the best choice. Many machines use gears. A very
good example is a bicycle which has gears that make it easier to cycle, especially up hills.
Bicycles normally have a large gear wheel which has a pedal attached and a selection of gear
wheels of different sizes, on the back wheel. When the pedal is revolved the chain pulls round
the gear wheels at the back. Look at the gear wheel with the pedal attached and compare it in size
to the gear wheels in the centre of the back wheel. Most people have cycled a bicycle up a hill.
The steeper the hill gets the more difficult it is to pedal and normally a cyclist will change gears
to make it easier. When the cyclist changes gear, the chain moves from a small gear to a larger
gear with more teeth, making it easier to push the pedals round. The more teeth the back gear
has, the easier it is to cycle uphill although the bicycle moves forward more slowly.
This machine operated by different velocity ratio depend on work piece and feed rate always
when we machine hard material we operate within slower speed this is use also for good surface
finish when we machine softer material we use speed than harder material if we increase the feed
rate also it is no problem therefore we must use gear ratio to change speed into desired one.
1. Velocity Ratio of Chain Drives

The velocity ratio of a chain drive is given by
V.R. = =
Where
N1= Speed of rotation of smaller sprocket in r.p.m.,
N2= Speed of rotation of larger sprocket in r.p.m.,
T1= Number of teeth on the smaller sprocket, and
T2= Number of teeth on the larger sprocket.
The normal function of a chain sprocket is not only to drive or be driven by the chain, but
also to guide and support it in its intended path. Sprockets manufactured from good quality iron
castings are suitable for the majority of applications. For arduous duty it may be necessary to use
steel sprockets having low carbon content. For extremely arduous duty the tooth flanks should be
flame hardened. There are other materials which may be specified for particular requirements.
Stainless steel for example is used in high temperature or corrosive conditions.
Sprockets are usually of 3 main types.
 One piece sprockets of steel or cast iron.
 Two pieces split sprockets.
 Sprockets with bolt-on-tooth segments.
Number of teethes on the smaller sprocket. [1]
24
Figure 3.3 sprocket
Table 3.8 Number of teeth at velocity ratio

Type of Number of teeth at velocity ratio
chain
1 2 3 4 5 6
Roller 31 27 25 23 21 17
Silent 40 35 31 27 23 19
 Number of teethes on the smaller sprocket is 23 from table 3.8

Assume number of teeth on the larger sprocket is double of number of teethes on the smaller
sprocket then number of teeth on the larger sprocket is 46
Speed of motor = 1850rpm (is driving speed)
Velocity Ratio of Chain Drives
V.R1 = =
V.R1 = =2
The second velocity ratio V.R then let the maximum speed reduced by quarter, and the second by
triple, and the third by half, then number tooth the number of tooth of pinion is T1=23
T2=46, T3=92, T4= 69, T5=23
Then velocity ratio VR1=2, VR2=4, VR3= 3, VR4=1
The maximum allowable speed for chains is equal with speed of the motor= 1850rpm
Speed ratio= =2= = N2=925rpm is speed of larger sprocket
= = =462RPM
= = =616RPM
= = =1850RPM
2. The design power by using the service factor

From driving power transmitted by chain 1.25kw
Rated power=1.25kw
25
Such that Design power = Rated power × Service factor
= P KS
KS= Service factor = K1.K2.K3
The service factor (KS) is the product of various factors, such as load factor (K1), lubrication
factor (K2) and rating factor (K3). The values of these factors are taken as follows:
1. Load factor (K1) = 1, for constant load
= 1.25, for variable load with mild shock

= 1.5, for heavy shock loads
2. Lubrication factor (K2) = 0.8, for continuous lubrication
= 1, for drop lubrication
= 1.5, for periodic lubrication
3. Rating factor (K3) = 1, for 8 hours per day
= 1.25, for 16 hours per day
= 1.5, for continuous service
Where K1=1.25, K2= 1.5 K3=1 KS=1.25 1.5 1=1.875
Design power = Rated power × Service factor
= 1.25kw× 1.875
=2.34kw
3. Characteristics of roller chains based on ISO Chain number

Table 3.9 Characteristics of roller chains according to IS: 2403 — 1991. [1]
ISO Pitch Roller Width Transverse Breaking load (KN)
Chain (p) mm diameter between pitch
Number (d1)mm Inner plates (p1)mm Minimum
Maximum (b1)mm Simple Duplex Triplex
Maximum
26
05B 8.00 3.00 5.64 4.4 7.8 11.1
06B 9.325 5.72 10.24 8.9 16.9 24.9
08B 12.70 7.75 13.92 17.8 31.1 44.9
Characteristics of roller chains is depend on power and speed of chain for low speed and low
power (ISO Chain number 06B) then Pitch (p) mm=9.325, Roller diameter (d1)mm Maximum=
6.35, Width between Inner plates (b1)mm Maximum=5.72 transversal pitch (p1)mm=10.24,
breaking load for simple 7.8KN
4. Determine the load (W) on the chain

W=
=v=
We know that pitch circle diameter of the smaller sprocket or pinion
d1=pcosec
d1=9.325cosec
=9.325x7.98= 273.57mm=0.027357m
Pitch circle diameter of the larger sprocket
d2=9.325cosec
=9.325x482=450mm=0.045m
d2=9.325cosec
=9.325x820=760mm=0.76m
v= =
W= =735N
5. The factor of safety by dividing the breaking load (WB)
Factor of safety= = =10.6
 Factor of safety is high because chain is possible transmit maximum power up to 110 kW
this machine is transmit minimum power, chains drive be used for long centre distance of
up to 8 meters. The chains are also used for velocities up to 25 m / s.
6. Centre distance between the sprockets
1. The minimum centre distance for the velocity transmission ratio of 3, may be taken as
x= +30 to 50 mm
Where d1 and d2 are the diameters of the pitch circles of the smaller and larger sprockets
2. For best results, the minimum centre distance should be 30 to 50 times the pitch.
3. The minimum centre distance is selected depending upon the velocity ratio so that the arc of
contact of the chain on the smaller sprocket is not less than 120º. It may be noted that larger
27
angle of arc of contact ensures a more uniform distribution of load on the sprocket teeth and
better conditions of engagement.
x= +30 to 50
But for long center distance from geometrical analysis the length of the machine is 1.46m by
consideration of distance between the sprockets center distance between two sprockets
X1= +30=0.86m
For horizontal chain
X1=0.86m
For vertical chain
X2= +50=1m
X2=1m
7. Length of the chain
For vertical chain the length of the chain (L) must be equal to the product of the number of chain
links (K) and the pitch of the chain (p). Where x is centre distance mathematically,
L=K.p
The number of chain links may be obtained from the following expression,
K= + + ]2
K= + + ]2
K=179.79
L=K.p =179.9x9.325mm=3676mm= 3.676 m for both horizontal and vertical chain
For horizontal chain the length of the chain (L) must be equal to the product of the number of
chain links (K) and the pitch of the chain (p). Where x is centre distance mathematically,
L=K.p
The number of chain links may be obtained from the following expression,
K= + + ]2
K= + + ]2
K=157
L=K.p =157x9.325mm=2102mm= 2102m for both horizontal and vertical chain
3.4 SHAFT
A shaft is a rotating machine element which is used to transmit power from one place to another.
28
Figure 3.5 shaft
The power is delivered to the shaft by some tangential force and the resultant torque (or twisting
moment) set up within the shaft permits the power to be transferred to various machines linked
up to the shaft. In order to transfer the power from one shaft to another, the various members
such as pulleys, gears etc., are mounted on it. These members along with the forces exerted upon
them causes the shaft to bending. In other words, we may say that a shaft is used for the
transmission of torque and bending moment. The various members are mounted on the shaft by
means of keys or splines.
3.4.1 Material Used for Shaft

The material used for shafts should have the following properties:
1. It should have high strength.
2. It should have good mach inability.
3. It should have low notch sensitivity factor.
4. It should have good heat treatment properties.
5. It should have high wear resistant properties.
Then based on the above property we use the following material.
The material used for stationery shafts is carbon steel of grades 40 C 8, 45 C 8, 50 C 4 and 50 C
12. The mechanical properties of these grades of carbon steel are given in the following table.
Table 3.10 Mechanical properties of steels used for shafts. [1]

Indian standard designation Ultimate tensile strength, Mpa Yield strength, MPa
40 C 8 560 – 670 320
45 C 8 610 – 700 350
50 C 4 640 640 – 760 370
50 C 12 700 Min 390
From types of material we select designation no. 45 C 8 ultimate tensile strength 650 MPa and
having Yield strength of 350 MPa.
29
3.4.2 Diameter and length determination
To calculate the diameter we use the moment and rpm vale of the wheel.
So the given parameters are:-design power=1250watts
N=1850RPM
Torque=
T= =6452NM
To get the diameter we use the following formula:-
T= for shafts Subjected to Twisting Moment Only
Where, shear stress of the shaft, we get from ultimate strength of the material is
equal to 0.18 ultimate stergth
=117MPA
D=diameter of the bar or connecting rod or shaft
=
=
=27041.4MM3
D=
D=30mm
3.4.3 Standard Sizes of Transmission Shafts the standard sizes of transmission shafts
The standard sizes of transmission shafts are: 25 mm to 60 mm with 5 mm steps; 60 mm to 110
mm with 10 mm steps; 110 mm to 140 mm with 15 mm steps; and 140 mm to 500 mm with
20mm steps. The standard length of the shafts is 5 m, 6 m and 7 m.
 The length of this shaft is depending on the face width of chain fly wheel thickness of
support or housing the clearance between parts and the pulley width.
 Then length of the shaft (L) =thickness of the housing +clearance between parts + width
of all parts from 140 mm to 500 mm with 20 mm steps the length the shaft is L=500mm
by considering all dimension [L=500mm] standard shaft length.[1 page 531]
3.4.4 Manufacturing process of Shafts

Shafts are generally manufactured by hot rolling and finished to size by cold drawing or turning
and grinding. The cold rolled shafts are stronger than hot rolled shafts but with higher residual
stresses. The residual stresses may cause distortion of the shaft when it is machined, especially
when slots or keyways are cut. Shafts of larger diameter are usually forged and turned to size in a
lathe.
30
3.5 Key and Coupling
A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to connect
these together in order to prevent relative motion between them. It is always inserted parallel to
the axis of the shaft. Keys are used as temporary fastenings and are subjected to considerable
crushing and shearing stresses. A keyway is a slot or recess in a shaft and hub of the pulley to
accommodate a key. [1 page 532]
3.5.1. Types of key

The following types of keys are important from the subject point of view:
1. Sunk keys,
2. Saddle keys,
3. Tangent keys,
4. Round keys,
5. Splines.
Sunk key are provide half in the way of shaft and half in key way of the hub or boss of wheel the
sunk keys are the following types
1. Rectangular sunk key
2. Square sunk key
3. Paralleled sunk key
4. Gibb head key
5. Feather key
6. Woodruff key
3.5.2 Keys and coupling material
Material for keys and coupling are carbon steel graded 40c8, 45c8, and 50c8.
There are two basic function of the key the primary function of key is to transmit the torque from
the shaft to the of mating element and vice versa the second function of key is to prevent relative
motion between the shaft and the joined machine element like gear, pulleys, and wheels in most
of cases key also prevent axial motion between two element, except in case of feather key or
splined connection The length of key (L) is obtained by considering the failure of key in
shearing. [1 page 512]
The Gibb head key is rectangular sunk key with ahead at one end known as Gibb head it is
usually provided to facilitate the removal of Gibb head [1 page 532]
31
Figure 3.7 Gibb head key
The usual proportional of Gibb head key is

W= t=2w/t d/6
W= width of the key
t =thickness of the key
d=diameter of the key
Where d is shaft diameter d=30mm from shaft design
w=d/4,30/4=7.5mm
t=2w/3=d/6 =30/6=5mm
w=width of the key = 7.5mm
t=thickness of the key = 5mm
We know that the maximum torque transmitted by the shaft T=6452NM
T= L× w× τ× d1/2 where d1 is shaft diameter and w is width of key
Taking τ= 400 MPa = 400N/mm2 from key material
6455x103Nmm=L x 7.5mm x 400N/mm2 x 30mm/2
6455x103Nmm =90000L
L=71.7mm is length of key
3.5.3 Shaft coupling
Shaft Coupling: - Shafts are usually available up to 7 meters length due to inconvenience in
transport. In order to have a greater length, it becomes necessary to join two or more pieces of
the shaft by means of a coupling but in this machine the power transmission shaft is short but the
power is transmitted from motor to chain drive by means of short shaft motor shaft and chain
drive shaft the two shaft are connected by coupling. Shaft couplings are used in machinery for
several purposes, the most common of which are the following
1. To provide for the connection of shafts of units that is manufactured separately such as a
motor and generator and to provide for disconnection for repairs or alternations.
2. To provide for misalignment of the shafts or to introduce mechanical flexibility.
3. To reduce the transmission of shock loads from one shaft to another.
4. To introduce protection against overloads.
5. It should have no projecting parts
3.5.4 Types of coupling

1. Rigid coupling. It is used to connect two shafts which are perfectly aligned. Following types
of rigid coupling are important from the subject point of view
32
2. Flexible coupling: - It is used to connect two shafts having both lateral and angular
misalignment. Following types of flexible coupling are important from the subject point of view
(a) Sleeve or muff coupling.
(b) Clamp or split-muff or compression coupling, and
(c) Flange coupling
This machine shaft are connected by flexible coupling because the machine is operated by both
motor and human power when the machine is operated by motor, motor shaft and transmission
shaft is connected by coupling and in other case when the machine is operated by human power
transmitted shaft is directly connected with pedal.
The usual proportions of the muff for the clamp or compression coupling are:
Diameter of the muff or sleeve, D=2d+ 13 mm
Length of the muff or sleeve, L= 3.5 d
Where d= Diameter of the shaft.
Figure 3.6 Clamp or compression coupling.

Diameter of the muff or sleeve, D=2d+ 13 mm
D=2 x 30mm + 13 mm = 73mm
Length of the muff or sleeve, L= 3.5 d
L= 3.5 x 30 = 105mm
Design for bolt Nominal diameter for bolts db= Root or core diameter of bolt
T= ×τ× d3
6455NM = ×τ× d3
 where τ allowable shear stress τ=400N/mm2, coupling material is the same with keys
material
6455 x 10 = ×400× d3
3
db= =15.2mm
db= 15 mm we find that the standard core diameter of the bolt for coarse series is 18 mm and the
nominal diameter of the bolt is 18mm (M 18)
3.6 BEARING SELECTION

Is used to rotate the wheal structure for these application we use radial boll bearing having the
following standard dimensions’ from table 3.11
Bearing no. 206
33
Bore diameter= 30mm
Outside diameter =62mm
Width of bearing= 16 mm
Figure3.8 Ball bearing
Table 3.11 principal dimensions for radial ball bearing [1]

Outside
Bearing no Bore(mm) Width(mm)
diameter(mm)
200 10 30 9
30 10 35 10
202 15 35 11
302 15 42 13
204 20 47 14
304 20 52 14
404 20 72 21
206 30 62 16
306 30 72 19
3.6.1 Materials and Manufacture of Ball Bearings

The following are the widely used bearing metals: 1.Copper-base alloys, 2.Lead-base alloys, 3.
Tin-base alloys and 4.Cadmium-base alloys the copper base alloys are the most important
bearing alloys. These alloys are harder and stronger than the white metals (lead base and tin base
alloys) and are used for bearings subjected to heavy pressures. It is used for medium loaded
bearings subjected to high temperature. The selection of a particular type of bearing metal
depends upon the conditions under which it is to be used. It involves factors relating to bearing
pressures, rubbing speeds, temperatures, lubrication, etc. A bearing material should have the
following properties:
1. It should have low coefficient of friction.
2. It should have good wearing qualities.
3. It should have ability to withstand bearing pressures.
4. It should have ability to operate satisfactorily with suitable lubrication means at the
maximum rubbing speeds.
5. It should have a sufficient melting point.
34
6. It should have high thermal conductivity.
7. It should have good casting qualities.
8. It should have minimum shrinkage after casting.
9. It should have non-corrosive properties.
10. It should be economical in cost.
Since the rolling elements and the races are subjected to high local stresses of varying magnitude
with each revolution of the bearing, therefore the material of the rolling element (i.e. steel)
should be of high quality. The balls are generally made of high carbon chromium steel. The
material of both the balls and races are heat treated to give extra hardness and toughness.
The balls are manufactured by hot forging on hammers from steel rods. They are then heat
treated ground and polished. The races are also formed by forging and then heat-treated, ground
and polished.
3.6.2 Lubrication of Ball Bearings

The ball and roller bearings are lubricated for the following purposes:
1. To reduce friction and wear between the sliding parts of the bearing,
2. To prevent rusting or corrosion of the bearing surfaces,
3. To protect the bearing surfaces from water, dirt etc., and
4. To dissipate the heat.
In general, oil or light grease is used for lubricating ball and roller bearings. Only pure mineral
oil or calcium-base grease should be used. If there is a possibility of moisture contact, then
potassium or sodium-base greases may be used. Another additional advantage of the grease is
that it forms a seal to keep out dirt or any other foreign substance. It may be noted that too much
oil or grease cause the temperature of the bearing to rise due to churning. The temperature should
be kept below 90ºC and in no case a bearing should operate above 150ºC.
3.7 Fly Wheel

A flywheel is an energy storage device that uses its significant moment of inertia to store energy
by rotating. Flywheels have long been used to generate or maintain power and are most
identified with the industrial age and the steam engine. In one sense it can be thought of as a
rechargeable battery that store energy in the form of mechanical energy instead of
electrochemical. Flywheels have been gaining popularity as a possible replacement for chemical
batteries in vehicles, but until last year there was no record of a flywheels being used to increase
the efficiency of a bicycle.
Fly wheel in this machine is used to increase human power when, when we cycling the pedal
within chain power transmitted to this wheel it is increase the power by storing energy
 Diameters of the wheel: 609mm, 660mm, and 685mm are common. Teeth on the chain
wheel 24 to 58, Teeth on the rear sprocket 12 to 38. For this machine diameter of the
wheel is 660mm, teeth on the chain wheel 40, teeth on the rear sprocket 30 [12]
35
Figure wheel 3.9
 This wheel is also available in the market for specified dimension:- (For this machine
diameter of the wheel is 660mm, teeth on the chain wheel 40, teeth on the rear sprocket
30)
3.8 Belt and pulley

The belts are used to transmit power from one shaft to another by means of pulleys which rotate
at the same speed or at different speeds. . The amount of power transmitted depends upon the
following factors:
1. The velocity of the belt.
2. The tension under which the belt is placed on the pulleys.
3. The arc of contact between the belt and the smaller pulley.
4. The conditions under which the belt is used
The belt drives are usually classified into the following three groups:
1. Light drives. These are used to transmit small powers at belt speeds up to about 10 m/s as in
agricultural machines and small machine tools.
2. Medium drives. These are used to transmit medium powers at belt speeds over 10 m/s but up
to 22 m/s, as in machine tools.
3. Heavy drives. These are used to transmit large powers at belt speeds above 22 m/s as in
compressors and generators.
Figure 3.10 Belt drive
36
For this drilling machine it is better to use belt power or motion transmission system due to
different reasons. they are different types of belt from these types of belt v-belt is more
preferable for drilling machine used in the rural area-belt is used where a great amount of power
is to be transmitted from one pulley to another when the two pulleys are very near to each other.
The material of the belt must be strong flexible and durable .it must be have high coefficient of
fiction so The V-belts are made of fabric and cords molded in rubber and covered with fabric and
rubber .these belts are molded to a trapezoidal shape and are made endless. These are particularly
suitable for short drives. The included angle for the V-belt is usually from 30° to 40°action
between the belt and the V-groove in the pulley or sheave.
Table 3.12 Dimensions of standard V-belts according to IS: 2494 – 1974. [1]
Type of belt Power ranges Minimum Top width Thickness (t) Weight per
in Kw pitch diameter (b)mm mm meter length
of pulley (D) in Newton
mm
A 0.7 – 3.5 75 13 8 1.06
B 2 – 15 125 17 11 1.89
C 7.5 – 75 200 22 14.3 3.43
D 20 – 150 355 32 19.5 5.96
E 30 – 350 500 38 23 -
From the above table it is better to take type a belt.

 Thickness (t) =8 mm
 Top width (b) =13mm
 Coefficient of friction =0.28
 The angle of grove on a pulley(2B)=40
 Weight per meter length =1.06N/m
 Permissible shear stress =42 mpa
 Center distance between pulley =600mm
 Density of pulley = 1200kg/
The length of the belt can be calculated by using the following formula:-
L= Where:-r2=radius of pulley no 2 from table
r1 =radius of pulley no one
Then r1=r2=37.5mm
X= center distance between two pulley
X=600mm
L= (37.5+37.5) +2(600) +
L=2035.5mm
From standard length of type a v- belt take length of belt 2068mm
37
To get the inside length of the belt subtract 36mm from length of belt for type A belt.
Inside length of belt =2068-36=2032mm
Checking failurty of belt by power
The pulley is attached to the chain drives they have the same no of revolution (rpm) when
velocity ratio is one and also the two pulleys are the same diameter.
So N1=N2= 1850rpm and d1 =d2=75mm
Since the belt is open belt
= Where:-r1 and r2 are the radius of two pulley
X is the center distance between two pulleys
Then = =0
=0
Angle of lap, =180 =180
Velocity of the belt=
=14.52m/s
Centrifugal tension (TC) =m
TC=1.06 =223N
The pulley for v-belt uses aluminum for better economic efficiency and strength, having better
mechanical property tensile strength and easily manufacture
3.10 A Rack and Pinion

A Rack and Pinion is composed of two gears, a Rack and Pinion arrangement is used to lift
vice or work piece holding device. The flat helical gear is the rack and the round helical gear is
the pinion. The rack has teeth cut into it and they mesh the teeth of the pinion gear. Also a spur
gear is connected to the shaft of the pinion a rack and pinion is used to convert between rotary
and linear motion. This rack and pinion lift is commonly used in many industrial applications.
Figure3.11 Rack and pinion
Rack-Cast iron= <390 N/mm²

Pinion-Cast iron= =30 N/ mm²
38
3.10.1 Specification of Rack
Material- Cast iron
Module =1.5mm
Cross section= (58×25) mm2
 Basic Dimensions Rack:
L=284mm
L1=L+35(grinding allowance)
L1=284+38=319mm
 Number of Threads on Rack
=L1÷ mx
=319÷ ( ×5)
=21
 Actual Length of Rack
=21× ×5
=330mm
3.10.2 Specification of Pinion:
Material-Cast iron
Outside diameter=58mm Dedendum=1.8m
Pitch circle diameter=55mm Circular tooth thickness=2.35mm
Circular pitch=4.7mm Fillet radius=0.45mm
Pressure angle=21° Clearance=0.
Addendum=1.5mm
39
39
3.11 Frame
Frame is used to carry the machine, and used to housing chain and belt drives attached by
welding to another frame. For these application is gray cast iron is selected.
St Designation FG150
Having tensile strength=150mpa
Compressive strength 600mpa
Height of the vertical frame=1.8m (only for vertical)
Length of the bar =1.8m
Diameter of the hollow bar =10cm
Thickness of the hollow bar=10mm
Length of the horizontal frame 1.45m
Width of the frame = 40cm
Thickness of the frame = 5mm
Frames used to support weight of the machine and housing for chains and belt drives
Figure 3.12 Frame for supporting Figure 3.13 Frame for housing
3.12 Seat
When the machine is operated by human power the man is seat on chair. The dimension of the
chair is according to human factor and ergonomics
Height of the chair = 70cm
The width of the chair = 40cm
40
Figure 3.14 chair (seat)
The chair is made from wood or metal may joined by welding, rivet or screw fasteners and it is
may fixed on floor or frame. To make it comfortable during working fixing soft material on top
of seat this may same as bicycle seat.
3.13 Drill Press
Drill Press is one of the most frequently used machine tools. They are used mainly for drilling
holes but reaming, countersinking, and boring can also be accomplished with the drill press.
Most machine shops are equipped with at least one pedestal-type drill press. These machines are
used to drill holes in wood, plastic, aluminum, brass, and most other common engineering
materials. Injuries on this equipment generally arise from careless operation by users who fail to
take the time to clamp their work to the table or who try to hold the drill press vise in one hand
while advancing the spindle in the other. When a drill begins to emerge from the bottom of the
work piece on through-holes, the feed rate needs to be reduced in order to prevent the drill flutes
from biting too aggressively into the work. This action sometimes causes cutting tool breakage.
Reduce the feed force and let the drill advance slowly. [2]
41
Figure 3.15 Pilot feed lever
 Feed lever the Feed Lever is used to raise and lower the spindle.
A twist drill is a pointed cutting tool used for making cylindrical holes in the work piece. This is
done when the pilot feed lever rotating we give the feed by rotating lever It has helical flutes
along its length for clearing chips from the holes. Twist drills are the most common used today,
but there are many other styles with different purposes. A twist drill is composed of three major
parts: a shank, body, and point. The shank is the part of the drill bit held in the spindle of the drill
press. The drill press’ power is transferred through the shank. Shanks are either one of two
styles, straight or tapered. Straight shank drills are held in a friction chuck. Slippage between the
drill bit and the chuck is often a problem, especially for larger drills. When using drill bits larger
than 1/2” dia., tapered shank drill bits are often used. These provide greater torque with less
slippage than straight shank drill bits. The body, as described above, generally has two flutes to
clear chips. These flutes are not cutting edges and should not be used for side cutting as an end
mill. The point of the drill bit does all of the cutting action, which produces the cut chips. The
point is ground on the end of the drill bit.
3.13 Working principle

This drilling machine is dual operated with in both electrical and human power and fitted with a
drill bit used for drilling holes in various materials the drill bit rotated while cycling the pedal or
when electrical motor is attached to driving shaft and the tip of the cutting tool does work cutting
material by using drilling chuck and rotating lever to drilling press work piece in to the target
point of drilling and power is transmitted by using combination of belt and roller chain drives. It
is drill piece of material made of metal, wood, PVC and operated by electrical power to drill
nonferrous metals and when it is operated by human power it is drill some soft material made of
metal, wood, PVC therefore it can be used in areas was electricity is insufficient or irregular and.
It is used for small scale workers who can work in their work shop and simplistic in design
operation and handling
42
Table 3.13 Maintenance schedule
Component Maintenance
No Quantity Particular
name interval
1 Shaft 4 1 month Check wear, fitting with other

component
2 Roller chain 2 1 month Lubricating
3 Sprocket 6 1 month Lubricating
4 Bearing 8 1 week Lubricating
5 Belt 1 6 month Check whether it is slip
6 Pulley 2 6 month Check looseness of key
7 Rack 1 4 month Tooth breakage checking
8 Pinion 1 4 month Tooth breakage checking
9 Drill bit 1 day Sharp by grinding with in standard
angle
10 Key 6 1 month Check wear and tear
11 Coupling 2 1 month Looseness of bolt
12 Bolts, nuts and 2 month Tighten
pin
13 Frame 3 4 month Adjust
14 Fly wheel 1 6 month Adjust
15 Seat 1 1 week Adjust
16 Bar 1 2 month Adjust
14 Gear shifting 1 1 week Lubricate check whether tooth is
mechanism broken, tear or wear
43
Table 3.14 Resource requirement and cost analysis
No Component name Quantity Per unit birr Total birr
1 Shaft 4 150 600
2 Roller chain 2 500 1000
3 Sprocket 6 80 480
4 Bearing 8 80 640
5 Belt 1 75 75
6 Pulley 2 75 150
7 Rack 1 200 200
8 Pinion 1 70 70
9 Drill bit 70 280
10 Key 6 60 360
11 Coupling 2 50 100
12 Bolts, nuts and pin 250 250
13 Frame 3 800 2400
14 Fly wheel 1 1000 1000
15 Seat 1 300 300
16 Bar 1 900 900
17 Gear shifting mechanism 1 500 500
Total 10205 BIRR
44
4.13 Result and discussion
4.13.1 Basic result
Table 4.1 results of component dimensions

Co. No Component name Quantity Remark
Length Diameter Width Thickness
1 Horizontal roller chain 1 2102

2 Vertical roller chain 1 3676 6.25 5.72
3 Largest sprocket 5 450 5.32
4 Smallest sprocket 1 273 5.32
5 Shaft 4 500 30
6 Key 6 71.7 7.5 5
7 Coupling 2 105 73
8 Bolt 4 4 18
9 Bearing 8 10 30 16
10 Fly wheel 1 1 660
11 Belt 1 2068 13 8
12 Pulley 2 2 75 20
13 Rack 1 330
14 Pinion 1 1 55 2.35
15 Vertical frame 1 1800 40 5
16 Horizontal frame 2 1450 40 5
17 Bar 1 1800 100 10
18 Chair(seat) 1 700 400
4.13.2 Power speeds torques and another specification of the machine

 Driving power (motor power) 1.25Kw
 Driving power (Motor speed) 1850rpm
 Driving power for human =280watts
 Average cycling for human = 60rpm
 Overall length of the machine=1.46m
 Over all height of the machine=1.8m
 Radius of the pedal foot =30cm
 Centre distance between two horizontal sprockets 0.86m
 Centre distance between two vertical sprockets 1m
 Drill diameters ranging from 0.25 to 20 mm
45
4.13.3 Discussion
The above results are the basic design parameters of drilling machine that are used to
assemble or manufacture industries local work shop and in rural area. when we compare the
given power to machining power of non ferrous material such as the driving power is greater
than machining power constant and The dimensions each components are based on the design
calculation and the standards of the component from the standard tables and The above amount
of revolution per minute is safe for these drilling machine and also the power and speed required
is safe when we compare and calculate from the machining power and speed constant of
properties of non ferrous material.
4. CHAPTER FOUR
4. Conclusion, Recommendation and Future Research Work
4.1 Conclusion
Generally this machine is one of recommended types of machine in manufacturing industries
and for people in rural area it is used to get better revenue from drilling operation in rural area
and indirectly better to come up sustainable development in the world from the manufacturing
sector. This machine drill different work piece by electrically and manually, only one person can
operate this machine at both electrically and manually operating time, It can drill different types
of material changing the speed ratio, by use gear ratio to change the speed it is like bicycle gear
shifting mechanism, in this design considering different things and targeting on material that it
drills is important thing, The performance of the machine depends on the driving power
condition. It is required appropriate driving power and speed of the motor and human cycling
speed and driving power. Driving power (motor power) 1.25Kw, Driving speed (Motor speed)
1850rpm, Average cycling for human = 60rpm, Driving power for human =280watts
4.2 Recommendation
We recommend to all manufacturing sectors and rural people, use this machine to get better
revenue from drilling operation, it is most suitable for rural people drilling agricultural tool
46
material, house hold or transporting material is better than for traditional drilling method. This
machine also designed by based on low cost also rural capital.
4.3 Future work
Machining is not an easy operation in industry. Drilling is type single point machining
processes the development of machining process is always needed for manufacturing industries
and also for rural area because of lack of electrical power and also the machining process is in
traditional way because of these reason we will modify and improve the machine by considering
such things. From our design we recommended for the future work in the following additional
features must be considered
 Drilling high strength material like steel, alloy steel material
 Different sensing elements (trust force, driving torque, temperature sensing and
etc)
 Drilling standard precise dimension of hole by reducing machine vibration and
other factor that reduce machine efficiency
 Design analysis of trust force and driving torque
 Adding other function and feature for this machine
47
11 10
6
3
1
9 5
1
8
48
Table 4.2 Main components of the manually and electrically operated drilling machine
No Name of component Quantity
1 Chain 1
2 Sprocket 2
3 Chuck 1
4 Pedal 1
5 Vice 1
6 Shaft 4
7 Seat 1
8 Fly wheel 1
9 Gear and pinion 1
10 Pulley 6
11 Belt 2
49
5. REFERENCES
[1] A text book of machine design R.S KHURMI and J.K GUPTA, Eurasia publishing house
(PVT) ltd 2005
[2] Production engineering fifth edition McGraw-Hill, ISBN 007-252036-1, New York
[3] http://www.google.com short history of pedal operated drilling machine
[4] http://www.google.com drilling operation
[5] Engineering-Reference-Information PDF
[6] Ludwig, Oswald A. and Willard J. McCarthy. Metal work Technology and Practice.
Bloomington, IL: McKnight and McKnight Publishing Company
[7] Repcic, N. & Muminovic, A. (2007). Mechanical Elements II, Faculty of Mechanical
Engineering, Sarajevo
[8] Shigley, J.E., Mischke, C.R. & Budynas, R.G. (2004). Mechanical Engineering Design (7th
edition), McGraw-Hill, ISBN 007-252036-1, New York
[9] Spotts, M.F., Shoup, T.E. & Hornberger, L.E. (2004). Design of Machine Elements (8th
edition), Prentice Hall, ISBN 0-13-126955-0, Upper Saddle River, New Jersey
[10] Dassault Systems. (2007b). CATIA Web-based Learning Solutions Version V5 Release 18
Windows
[11] www.google.com Standard Wheel diameters for bicycle pdf
[12] Engineering Design Principles by Ken Hurst I SBN: 0340598298, Pub. Date: May 1999
Publisher: Elsevier Science & Technology Books
[13] Mechanical Engineering Handbook Ed. Frank Kreith Boca Raton: CRC Press LLC, 1999
[14] Standard Handbook for Mechanical Engineers Tenth Edition McGRAW-HILL, 1st-ed.
1916
[15] Mechanical design an integrated approach ANSEL C.UGURAL, Boca Raton: CRC Press
LLC, 1999
50

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Manual Drilling Machine

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WOLLO UNVERSITY

KOMBOLCHA INSTITUTE OF TECHNOLOGY DEPARTMENT OF

TITTLE:-DESIGN AND MODELING OF MANUALLY AND ELECTRICALLY

A Thesis Submitted to Department of ‘Mechanical Engineering’ Kombolcha

TITLE:- DESIGN AND MODELING OF MANUALLY AND ELECTRICALLY

Approved: Examiner: Advisor: Mr. Raja

Date: Chairperson: Co-advisor:

ID Number: - R/583/03, R/0113/03, R/285/03 and R/848/03

BSc, Mechanical Engineering

Kombolcha Institute of Technology 2015

1.2 Background ............................................................................................................................... 2

1.2.1 The short history of early drilling machines .......................................................................... 2

1.3 Statement of the problem .......................................................................................................... 3

1.4 Objective ................................................................................................................................... 4

1.4.1 General objective ................................................................................................................... 4

1.4.2 Specific objective ................................................................................................................... 4

1.5 Significance of the project ........................................................................................................ 4

1.6 Scope of the project .......................................................................................................... 4

1.7 Methodology .................................................................................................................... 5

2.1.1 Drilling operation ................................................................................................................... 6

2.1.2 Drilling and drilling allied operations .................................................................................... 7

2.2 Working principle of drill press ................................................................................................ 8

2.3 Drill Chucks .............................................................................................................................. 8

2.4 Twist drills ................................................................................................................................ 9

2.5 Drill bit Nomenclature and Geometry ...................................................................................... 9

2.6 work Materials ........................................................................................................................ 10

2.6.1 Non-ferrous Metals .............................................................................................................. 10

2.9 Estimating Machining Power .................................................................................................. 12

2.10 Estimating Drilling Thrust, Torque....................................................................................... 13

2.11Tool Wear and Tool Life Relationships................................................................................. 13

2.12 Literature review Discussion ................................................................................................ 13

3. CHAPTER THREE ................................................................................................................. 15

3.1 Geometrical analysis ............................................................................................................... 15

3.2 Given parameters .................................................................................................................... 16

3.2.1 Working principle of drilling machine ................................................................................ 16

3.2.2 Working material identification ........................................................................................... 16

3.2.3 Driving Motor Power ........................................................................................................... 17

3.2.4 Driving speed ....................................................................................................................... 22

3.2.5 Driving Motor Torque.......................................................................................................... 22

3.3 CHAIN DRIVES .................................................................................................................... 22

3.3.1 Advantages of chain drive over belt or rope drive ............................................................... 23

3.3.2 Design Procedure of Chain Drive ........................................................................................ 23

3.3.3 Material for roller chain and sprocket .................................................................................. 23

3.3.4 Gear shift Mechanism .......................................................................................................... 24

3.4 SHAFT .................................................................................................................................... 28

3.4.1 Material Used for Shaft ........................................................................................................ 29

3.4.2 Diameter and length determination ...................................................................................... 30

3.4.4 Manufacturing process of Shafts ......................................................................................... 30

3.5 Key and Coupling ................................................................................................................... 31

3.5.1. Types of key........................................................................................................................ 31

3.5.4 Types of coupling ................................................................................................................ 32

3.6 BEARING SELECTION ........................................................................................................ 33

3.6.1 Materials and Manufacture of Ball Bearings ....................................................................... 34

3.6.2 Lubrication of Ball Bearings ................................................................................................ 35

3.8 Belt and pulley ........................................................................................................................ 36

3.10.1 Specification of Rack ......................................................................................................... 39

3.11 Frame .................................................................................................................................... 40

3.12 Seat ........................................................................................................................................ 40

3.13 Working principle ................................................................................................................. 42

4.13.1 Basic result ......................................................................................................................... 45

4.13.3 Discussion .......................................................................................................................... 46

4. CHAPTER FOUR ..................................................................................................................... 46

4. Conclusion, Recommendation and Future Research Work ...................................................... 46