Lab Session # 3 (2)

“To perform drilling operation (cylindrical work piece) on lathe

machine using drill bit”

1. Introduction
1.1. Lathe Machine
A lathe is a machine tool which rotates the work piece on its axis to perform
various operations such as cutting, sanding, knurling, drilling, or deformation,
facing, turning, with tools that are applied to the work piece to create an object
which has symmetry about an axis of rotation. [1] (“lathe machine,2006”)

Figure 3.1 # Lathe Machine

1.1.1. Parts of Lathe Machine
1-1.1.1 Bed:
Usually made of cast iron. Provides a heavy rigid frame on which all the
main components are mounted.

1-1.1.2 Headstock:
Mounted in a fixed position on the inner ways,
usually at the left end. Using a chuck, it rotates
the work.

1-1.1.3 Spindle:
Hole through the headstock to which bar stock can be fed, which allows
shafts that are up to 2 times the length between lathe centers to be
worked on one end at a time.

1-1.1.4 Chuck:
Allows the mounting of difficult work pieces that are
not round, square or triangular.

1-1.1.5 Tailstock:
Fits on the inner ways of the bed and can slide
towards any position the headstock to fit the length
of the work piece. An optional taper turning
attachment would be mounted to it.

1-1.1.6 Carriage:
Moves on the outer ways. Used for mounting and moving most the cutting
tools.

1-1.1.7 Hand Wheel

Mounted on the traverse slide of the carriage, and uses a hand wheel to
feed tools into the work piece.

1-1.1.8 Tool Post:

To mount tool holders in which the cutting bits are clamped.

1-1.1.9 Lead Screw:

For cutting threads.
 1-1.1.10 Feed Shaft:
Has a keyway, with two reversing pinion gears, either of which can be meshed
with the mating bevel gear to forward or reverse the carriage using a clutch.

1-1.1.11 Gear box:

Inside the headstock, providing multiple speeds with a geometric ratio by
moving levers.

1-1.1.12 Apron:
Attached to the front of the carriage, it has the mechanism and controls for
moving the carriage and cross slide. [2] (“Chern, 1994”)

2. Drilling operation
Drilling:

In simple terms drilling means using rotary machine to remove metal/material

from a surface in order to make a hole. The drill bit is usually a rotary cutting
tool, often multipoint. The bit is pressed against the work piece and rotated at
rates from hundreds to thousands of RPM. This forces the cutting edge against
the work piece, cutting off chips from the hole as it is drilled.

Here we have made a hole in a metal work piece with the help of drill bit.

Tooling nomenclature:
Two types of drill bits are used, one for smaller holes with straight shank
and one for larger diameter with tapered shank. Here we have used a straight
shank drill bit.

It mainly consists of three parts:

1) Shank
2) Body
3) Point
Shank:

It is the point where drill bit is held by chuck. It can be straight so to get fixed in
chuck or can be tapered to get held directly in spindle. In some drills, there is
relieved portion after shank between shank and body called neck. [3] (“Grimm,
1964”)
 Body:

It is mostly back tapered (in microns) to provide clearance between drill and
work.

It consists of:

 Flutes: helical grooves that provides space for coolant and exit for chip

 Land: It is the part between the flutes and provides torsional strength to bit

 Margin: Part of drill that is not cut away for clearance, presents full diameter and
prevents jamming of drill

 Web: Central portion that connects the lands, its thickness varies according to the
strength required

Point:

It is cone shaped cutting end of drill, made from heels. [4] (“Tool path”)

Some important angles used in drill bits required for maximum efficiency are:

Helix angle: Angle of spiral with axis of bit. It can be slow spiral i.e. have small
helix angles but are stronger as compared to fast helix angles that are weaker
but drills deeper holes

Point angle: Angle between one lip to another seen from a side. It is usually
118°. Higher point angles flatter point) is for harder materials as compared to
lower point angles.

Lip clearance angle: Angle between margin and horizontal line. If it is

insufficient extra press will be required to make a drill and if it is excessive than
it will break corners of drill bit

Chisel edge angle: Angle between chisel edge and lip, indicates lip clearance
[5] (“Active control of machine”)

Fig # 3.2 Drilling lathe

3. Operations
 Drill bit is fixed in drill chuck (located at dead center) mounted on spindle and tightened
with a chuck key.
 Spindle control lever is used to move tail stock forward
 Work piece is held in chuck located at head stock
 Center of drill bit and work piece are coincident
 Before starting drilling, centering of work piece is required. It can be done through
center drill or with the help of turning or facing tools, it is done so that lip angle of drill
bit matches with job
 We can mark on drill bit for precise dimensions
 Feed rate of tail stock is done manually by controlling spindle lock lever, it should be
uniform for better results
 During drilling, move drill bit out after an interval to remove particle size chips
 Here, work piece is rotating and bit is stationary
 If we have to make hole of larger diameter, one drill bit can be used directly, use bit of
small diameter and then of our required diameter, otherwise bit will heat up and wear
out before time

4. Results and conclusions

4.1. Table
Size of bit used 11mm
RPM of chuck 375
Feed rate Manual
Material of work piece MS
Material of bit (with HSS
chromium coating)
Depth of hole 250mm
Diameter of hole 11 mm

4.2. Conclusions
 Machining on the universal lathe machine is one of the old methods of
machining have a lot of errors because it has been done manually.
 Drilling is concerned with the tailstock. so, tailstock must be aligned with
the live center and oiling of this should be controlled perfectly.
 These errors could easily be reduced by using new model CNC
(computerized numeric controls) and NC (numeric controls) lathes in
which measurements and calculations is also automatically done

5. References
[1] Pan, G., Xu, H., Kwan, C. M., Liang, C., Haynes, L., & Geng, Z. (1996).
Modeling and intellligent chatter control strategies for a lathe machine. Control
Engineering Practice, 4(12), 1647-1658.
[2] Chern, S. T. (1994). U.S. Patent No. 5,309,368. Washington, DC: U.S.
Patent and Trademark Office.

[3] Skoglund, D. M., Petersen, P. S., & Grimm, R. J. (1964). U.S. Patent No.
3,121,357. Washington, DC: U.S. Patent and Trademark Office.
[4] Ramli, R., Yamamoto, H., & Qudeiri, J. A. (2009). Tool path of lathe
machine in flexible transfer lines by using genetic algorithms. International
Journal of Production Economics, 121(1), 72-80.
[5] Claesson, I., & Håkansson, L. (1998). Adaptive active control of machine-tool
vibration in a lathe. International Journal of Acoustics and Vibration, 3(4), 155-
162.