A PROJECT REPORT

On
“360 Degree Flexible Drilling Machine”
Submitted in the partial fulfillment of the requirements for the award of

DIPLOMA IN MECHANICAL ENGINEERING

BY

2Nd year , 3 semester

Saddam Hussain (D192002377)

Sebu Alam (D192002381)

UNDER THE GUIDANCE OF

Mr.Sourav Chatterjee

Lecturer

Department of Mechanical Engineering

BENGAL COLLEGE OF POLYTECHNIC, DURGAPUR

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 ACKNOWLEDGEMENT

This survey was supported by Dept. of Mechanical Engineering , Bengal College

of Polytechnic Durgapur under guidance of Mr.Sourav Chatterjee (Lecturer of
Mechanical Engineering ., BCP Durgapur). I am thankful to our colleagues who
provided expertise and greatly assisted the survey.

SADDAM HUSSAIN / SEBU ALAM

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 Index
 Introduction…………………………………………………………5.
 General aspects of drilling machine………………………………..7.
 Drilling process……………………………………………………9.
 Literature survey…………………………………………………..12.
 Development of drilling machine…………………………………15.
 Movements in flexible drilling machine…………………………..16.
 Setup procedure…………………………………………………...17.
 Working procedure………………………………………………..18.
 Methodology………………………………………………………19.
 Component & specification……………………………………….24.
 Future scope……………………………………………………….24.
 Conclusion & summary…………………………………………...25.
 Reference………………………………………………………….26.

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 ABSTRACT
Directional drilling machine which can be used based on drilling holes in

various location and movement and easily operation done with high accuracy.

Productivity can be improved by reducing total machining time and reduced

human effort and reduced manufacturing cycle time. In this present age the

application of micromachining operations continues to grow. These operations

are required to fabricate the products required for sectors like medical science,

automobile industries and electronics manufacturing etc. which deals with

miniature trends. Drilling process is one of the machining processes which is

used to drill micro holes not only in micro products but also in relatively larger

work pieces which require ultra-small features which can be accomplished only

by drilling process.

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 INTRODUCTION

Around 35,000 BCE, Homo sapiens discovered the benefits of the application of

rotary tools. This would have rudimentarily consisted of a pointed rock being

spun between the hands to bore a hole through another material. This led to the

hand drill, a smooth stick that was sometimes attached to flint point, and was

rubbed between the palms. This was used by many ancient civilizations around

the world including the Mayans. The earliest perforated artifacts such as bone,

ivory, shells and antlers found, are from the Upper Paleolithic era.

Bow drill (strap-drills) are the first machine drills, as they convert a back-and

forth motion to a rotary motion, and they can be traced back to around 10,000

years ago. It was discovered that tying a cord around a stick, and then attaching

the ends of the string to the ends of a stick(a bow), allowed a user to drill

quicker and more efficiently. Mainly used to create fire, bow-drills were also

used in ancient woodwork, stonework and dentistry. Archeologist discovered a

Neolithic grave yard in Mehrgrath, Pakistan dating from the time of the

Harappans, around 7,500-9,000 years ago, containing 9 adult bodies with a total

of 11 teeth that had been drilled. There are hieroglyphs depicting Egyptian

carpenters and bead makers in a tomb at Thebes using bow-drills. The earliest

evidence of these tools being used in Egypt dates back to around 2500 BCE. The

usage of bow-drills was widely spread through Europe, Africa, Asia and North

America, during ancient times and is still used today. Over the years many slight
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variations of bow and strap drills have developed for the various uses of either

boring through materials or lighting fires.We had chosen the user defined project

(UDP) for our final year project. We are decided our topic to develop the

automatic multi-operational portable machine say like tapping, drilling,

grinding, reaming, and other relative operation. This will make use of

compressed air (pneumatic mechanism) for its operation. We will trying to

develop the portable machine which will easily handle and cover a maximum

working area from one station and make it more flexible to working easily. As

a small industries the machine and operation method use for drilling,tapping and

other similar process is not economically and eco friendly. As we know that

drilling machine use the electricity as there power source these machine have

many limitation like it is not flexible and not moveable, consume more floor

area and main problem is that it need continuous electricity which increase the

cost of production. The tapping operations are performed by use of convention

tap or hand tap. during operation it is necessary with a hand tap to periodically

reverse rotation to break the chip formed during the cutting process, thus

preventing effect called crowding that may cause defect. In convention method,

main problem causes during the tapping operation for big job industries and

complex job these causes are created defect on tap tool, increasing operational

lead time, inaccuracy of thread geometry, more production cost and more labour

cost

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1.1 General Aspects of Drilling Machine:

Drilling is the operation of producing circular hole in the work-piece by using a

rotating cutter called DRILL. The machine used for drilling is called drilling

machine. The drilling operation can also be accomplished in lathe, in which the

drill is held in tailstock and the work is held by the chuck. The most common

drill used is the twist drill.

It is the simplest and accurate machine used in production shop. The work

piece is held stationary i.e. Clamped in position and the drill rotates to make a

hole.

Drilling machine is kind of machine rotating cutting tool which direction the

drill feeds only on the machine axis(workmanship perforation). Drilling is

operating while producing round holes in the piece work by using a rotating

cutter called DRILL.

A Drill is a tool fitted with a cutting tool attachment or driving tool attachment,

usually a drill bit or driver bit, used for boring holes in various materials or

fastening various materials together with the use of fasteners. The attachment is

gripped by a chuck at one end of the drill and rotated while pressed against the

target material.The tip, and sometimes edges, of the cutting tool does the work

of cutting into the target material. This may be slicing off thin shavings grinding

off small particles crushing and removing pieces of the work piece,

countersinking, counter boring, or other operations.

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Drills are commonly used in woodworking, metalworking, construction and do-

it- yourself projects. Drills are available with a wide variety of performance

characteristics, such as power and capacity.

Drill machines have been the heart of every industry. Drilling holes in parts,

sheets and structures is a regular industrial work. Perfect and well aligned

drilling needs fixed and strong drills. Some parts cannot be drilled using fixed

drills due to low space between drill bit and drill bed. We need to use hand drills

in such cases but hand drills have alignment problems while drilling. So here we

propose a 360 degree flexible drill that can be mounted on a table or wall and

can be used to drill holes horizontally, vertically or even upside down. So this

makes it possible for easy drilling in even.

complicated parts and surfaces. Thus we use rotating hinges and connectors with

motor mount and supporting structure to design and fabricate a mini 360 degree

drill for easy drilling operations.

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2. DRILLING PROCESS

Drilling is the method of making holes in a work piece with metal cutting tools.

Drilling is associated with machining operations such as trepanning, counter

boring, reaming and boring. A main rotating movement is common to all these

processes combined with a linear feed. There is a clear distinction between short

hole and deep hole drilling. The drilling process can in some respects be

compared with turning and milling but the demands on chip breaking and the

evacuation of chips is critical in drilling. Machining is restricted by the hole

dimensions, the greater the hole depth, the more demanding it is to control the

process and to remove the chips. Short holes occur frequently on many

components and high material removal rate is a growing priority along with

quality and reliability.

Solid drilling is the most common drilling method, where the hole is drilled in

solid material to a predetermined diameter and in a single operation.

Trepanning is principally used for larger hole diameters since this method is

not so power- consuming as solid drilling. The trepanning never machines the

whole diameter, only a ring at the periphery. Instead of all the material being

removed in the form of chips, a core is left round the center of the hole.

Counter boring is the enlargement of an existing hole with a specifically

designed tool. This machines away a substantial amount of material at the

periphery of the hole.

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Reaming is the finishing of an existing hole. This method involves small working

allowances to achieve high surface finish and close tolerances.

The cutting speed, or surface speed (vc) in for drilling is determined by the

periphery speed and can be calculated from the spindle speed (n) which is

expressed in number of revolutions per minute. During one revolution, the

periphery of the drill will describe a circle with a circumference of π x Dc, where

Dc is the tool diameter. The cutting speed also varies depending upon which

cutting edge across the drill- face is being considered.

A machining challenge for drilling tools is that from the periphery to the center of

the drill, the cutting speed declines in value, to be zero at the center.

Recommended cutting speeds are for the highest speed at the periphery.

The feed per revolution (ƒn) in mm/rev expresses the axial movement of the tool

during one revolution and is used to calculate the penetration rate and to

express the feed capability of the drill.

The penetration rate or feed speed (vf) in mm/min is the feed of the tool in

relation to the work piece expressed in length per unit time. This is known as the

machine feed or table feed. The product of feed per revolution and spindle speed

gives the rate at which the drill penetrates the work piece. The hole depth (L) is

an important factor in drilling as is the radial cutting depth (ap) and feed per tooth

(fz) for calculations.

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Machining holes

Holes are either made or finish machined. Most work pieces have at least one

hole and depending upon the function of the hole, it needs machining to various

limitations

The main factors that characterize

A hole from the machining view point are:

- diameter

- depth

- quality

- material

- conditions

- reliability

- productivity

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 LITERATURE REVIEW
Micromachining operations play an important role in precision production

industries. Out of the various machining processes, micro-drilling is used to

produce micro holes in fuel injectors, printed circuit board, aerospace materials

etc. So in order to achieve the optimum working conditions various research

were conducted by different researchers from across the globe. This report

reviews some of the journal published by them regarding optimization

processes.

Yogendra Tyagi,Vadansh Chaturvedi and Jyoti Vimal have conducted an

experiment on drilling of mild steel, and applied the taguchi methods for

determining the optimum parameters condition for the machining process using

the taguchi methods and analysis of variance. The work piece used is mild steel

(100mm×76mm×12mm) and the tool used is HSS with a point angle of 118°

and diameter of 10 mm. Taguchi L9 orthogonal

arrays is used here in order to plan the experiment. The input parameters are

feed rate, depth of cut and spindle speed whereas the output responses are

surface roughness and metal removal rate (MRR).In case of signal to noise ratio

calculation, larger the better characteristics is used for calculation of S/N ratio

for metal removal rate and nominal and small the better characteristics is used

for the calculation of S/N ratio for surface roughness. After the analysis of the

data obtained it is found that MRR is affected mostly by feed. Confirmation

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experiment was conducted using the data obtained from S/N ratio graphs and it

confirmed with the results of taguchi methodology. In case of surface roughness

analysis same procedure was followed where the significant parameter was

found to be the spindle speed. Here too the confirmation experiment was

conducted and this confirms the successful implementation of taguchi methods.

Timur Canel,A. Ugur Kaya,Bekir Celik studied the laser drilling on PVC

material in order to increase the quality of the cavity. Taguchi optimization

methods was used to obtain the optimum parameters. The material used in the

experimental setup is PVC samples with dimensions of 5mm×85mm×4.5mm.

Surelite Continuum Laser is used to form the cavities. The input parameters are

wavelength, fluence and frequency and the output response are aspect ratio,

circularity and heat affected zone. Taguchi L9 orthogonal array is used to find

the signal to noise ratio. Smaller the better characteristics is used for HAZ,

larger the better characteristic is used for aspect ratioand nominal the better

characteristic is used for circularity. Variance analysis is performed usingthe

calculated S/N ratio to conclude optimum stage. It is found that most effective

parameter for aspect ratio is frequency, second is wavelength and last is

fluence. For circularity it is found that the most effective parameter is

wavelength, fluence and frequency. For HAZ it is found that the most effective

parameter is wavelength, second is frequency and last is fluence. The

experimental results are compatible with Taguchi method with 93% rate.

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Thiren G. Pokar,Prof. V. D. Patel used grey based taguchi method to determine

the optimum micro drilling process parameters. hivapragash, K.Chandrasekaran,

C.Parthasarathy, M.Samuel have tried to optimize the drilling process involving

metal matrix composites(MMC) in order to minimize the damage done to it

during the process by using taguchi and grey rational analysis. The work piece

used is Al- TiBr2(MMCs),with dimension of 100mm × 170mm × 15mm.The

tool material is HSS with diameter of 0.6 mm. The input parameter are spindle

speed, depth of cut and feed rate whereas the output parameter are MRR and

surface roughness. For finding out the optimal combination of cutting

parameters the results are converted into S/N ratios and higher the better type

characteristics is used for MMR, and smaller the better characteristics is used for

surface roughness.

Wen Jialing and Wen Pengfei used an orthogonal experimental design in order

to find out the optimum process parameters for injection molding of aspheric

plastic lens, to reduce volumetric shrinkage and volumetric shrinkage variation.

Six input parameters were taken, each with 5 levels(Fill Time/sec, holding

pressure/Mpa, holding pressure/times, cooling time/s, melt temperature/°C, mold

temperature/°C.L25(56) orthogonal array is used to plan the above experiment.

The parameters affecting both volumetric shrinkage and volumetric shrinkage

variation are identified in order.

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 DEVELOPMENT OF DRILLING MACHINE
A. Equipments used for the Experiment as shown:

 Base plate

 Vertical arm

 Hrizontal arm

 Suspension spring

 Rollar bearing

 Motor

 Drill bit

 Copper wire

 Switch board

 Guider

Experimental Setup Diagram

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 MOVEMENTS IN FLEXIBLE
DRILLINGMACHINE

This drilling machine possesses a radial arm which along with the drilling head
can swing and move vertically up and down as can be seen in Fig. The radial,
vertical and horizontal arm movement of the drilling head enables locating the
drill spindle at any point within a very large space required by large and odd
shaped jobs.

The tubular column on that the radial arm which moves up and down manually
or it can powered movement then the drilling head here this is called drilling
head which holds the drill spindle here in which the drill is mounted and is
subjected to rotation. The entire head is mounted on the radial arm and this can
move inward and outward from the drill axis. Also the horizontal arm can slide
linearly on vertical arm. Not only that, as this

along with this radial arm the drilling head moves upward and downward to
have large gap between the to drill and job or there is a stoke length. Not only
that further this radial arm can be rotated about the column rotated about the
column, say about 360 degree.
The main movements in the machine are:

 360 degrees rotation of arm joint.

 Up & down movement of the horizontal arm on vertical arm.

 Linear slide movement of horizontal arm.

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 Setup Procedure

1) Base:

The base acts a support for the whole machine. It’s made of a mild steel. The
base of the drilling machine supports the entire machine and when bolted to
the floor, provides for vibration-free operation and best machining accuracy.
The top of the base is similar to the worktable and may be equipped with t-
slot for mounting work too larger for the table.

2) Arm:

There are two arms:

 Vertical arm
 Horizontal arm

The primary arm holds the secondary arm and it is with the help of this arm
the 360° of rotation is transferred from the t plate to the secondary arm in
order to move the drill head at angles. They are made up of stainless steel.

3) Cross Slide:

We have used a hand drilling machine to be fixed on the cross slide.

Our drilling machine can drill holes on concrete, wood and metal. The
drill bit can be rotated both clockwise and anticlockwise direction

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 WORKING PROCEDURE

Pneumatic multi-operation machine make use of compressed air obtained from

compressor passes through pressure regulator & then passes through pneumatic
gun. In pneumatic gun air exerts a axial spinning force on the spindle located
inside the tool head which causes the drill tool to rotate inside the work piece
with required RPM.

Concept Design

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 METHODOLOGY

Step 1: Part collection

After some survey from market finally we bought pneumatic gun,

pressure regulator, pipes, wheels for table & adaptor at the reasonable price.

Pneumatic Gun

Pressure Regulato

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 Connecting pipe

Step 2: Define Joints

 We defined joints which are used for relative motion of arms & also
to rotate gun in 360 degree.
 We designed mainly three types of joints such as ball joints, pin
joints & rotational top head.
 We can switch to an automation by using servo motor in the
defined joints for future scope.

Joints

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Step 3: Design arms or linkages

 We made arms or linkages having material of mild steel with help of

fabricator.
 We can use telescopic arms to extend the work envelope of
pneumatic drilling machine for future scope.

Step 4: Fabrication of table

 We made supporting table to sustain the load of pneumatic drilling

machine by mounting it on the table.
 We provide wheels to the table to provide the portability to the machine

Supporting table

Step 5: Assembling of component

After collection & designing of all parts we go for the final assemble to give
the final touch to our machine.
Finally we assembled all the components in the one single unit and made
universal drilling machine to justify our project title “DESIGN &
DEVELOPMENT OF UNIVERSAL PNEUMATIC DRILLNG
MACHINE”

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 Partial Assembling

Final assembly

Step 6: Fabrication of table

 We did some experiment by drilling the material as wood, aluminium

& cast iron using the appropriate tool & air pressure.

 The experiments in the image shows the drilling of the workpiece.

The other operation such as tapping, boring, grinding, thread cutting
can also Performed by our machine.

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Experiment 1

Experiment 2

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 COMPONENT & SPECIFICATION
Component & specification (All dimensions are in mm)

FUTURE SCOPE
 We can use servo motor in our machine to provide the automation by
giving auto feed.
 We can use telescoping arm to increase the working envelope of the
machine to reach in any direction easily.
 We can use hydraulic system or hydraulic lubrication to operate the
machine in smooth manner without including the less fatigue of man
power.

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 CONCLUSION & SUMMARY

 Due to the various problems faced by conventional operation processes

such as Poor thread finish, more time consumption, frequent tool
breakage and many more. So, we have decided to design the machine
which will make use of compressed air as a power source.

 Above is the Future model of pneumatic machine on which the tapping

,drilling, boring etc operation is achieved by Pneumatic system and it
eliminates all the problem faced by conventional operation process.

 This pneumatic multi-operation Machine is to be presented for increasing

their productivity as well as quality of job. It also gives the detailed
description of machine mechanism and their different main parts of
machine. In this we are defining different process parameters like spindle
speed (rpm), cutting feed rate, cutting force, torque and power for their
efficient working of operation.

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 REFERENCE
1. R.Anandhan, P.Gunasekaran. 2016, Design and Fabrication of Angular
Drilling Machine,International Journal of Innovative Research in Science,
Engineering and Technology.
2. Bhupendra Singh Tomar, Abhinav Kumar Y, 2019, DESIGN &
FABRICATION OF 360° FLEXIBLE DRILLING MACHINE, International
Journal For Technological Research In Engineering.
3. Ms. P.H.Dahake, Computerized Drilling Machine, International Journal on
Recent and Innovation Trends in Computing and Communication.
4. U. Hema Nikhitha, 2019, Design of 360 Degree Flexible Drilling Machine,
International Journal of Engineering Research & Technology (IJERT).
5. Lookesh Kumar Sahu, 2018, Design & Fabrication of 360° Flexible Drilling
Machine, IJSRD - International Journal for Scientific Research & Development.
6. 360 DEGREE DRILLING MACHINE, Atmiya Institute of Technology and
Science for Diploma Studies.
7. 360 DEGREE FLEXIBLE DRILLING MACHINE, SBM POLYTECHNIC
COLLEGE, T.N.Paraipattai Pirivu, Thamaraipaadi(po), Trichy Main Road,
Dindigul-624 005.
8. Raut Shreyank Prakash, Routela Dinesh Singh Bahadur Singh, 2018, Design
and Fabrication of Multi Axis Drilling Machine, IJIRT.
9. Kamli Harsh, Parth Mistry, 2019, A Review on 360 Degree Flexible Rotating
Drilling Machine, International Journal of Research in Engineering, Science and
Management.
10. G.Prasanth Kumar, P.Guna Sekhar, 2018, Design & Fabrication of 360°
Flexible Drilling Machine, International Journal of Engineering Trends and
Applications (IJETA).
11. Weishin-cnc.com
12. Mpimagnet.co.in

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