Drilling

• Drilling is a machining process that uses a drill bit to cut a

hole of circular cross-section in solid materials.
• Creates a round hole in a workpiece

Two hole types: (a) through hole and (b) blind hole
 Drilling

• Contrasts with boring which can only

enlarge an existing hole
• Cutting tool called a drill or drill bit
• Customarily performed on a drill press

Fig. (b) drilling

 Drilling
• The bit is pressed against the workpiece and rotated at
rates from hundreds to thousands of revolutions per
minute to remove the material, with the material removal
rate as,
D = the drill diameter
fr = feed rate,

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 Drilling
Through Holes vs. Blind Holes
Through‑holes - drill exits the opposite side of work
Blind‑holes – drill does not exit work on opposite side

Fig. Two hole types: (a) through‑hole, and (b) blind hole
 Drilling

Machining operations
related to drilling:
(a) reaming
(b) tapping
(c) Counter boring
(d) countersinking
(e) center drilling
(f) spot facing
 Drilling

Reaming
Used to slightly enlarge a hole,
provide better tolerance on
diameter, and improve surface
finish

Fig.(a)Reaming
 Drilling

Tapping
• Used to provide internal
screw threads on an existing
hole
• Tool called a tap

Fig. (b) tapping

 Drilling

Counter boring
Provides a stepped hole, in which a
larger diameter follows a smaller
diameter partially into the hole
(process of enlarging a drilled hole
for a portion of length)

Fig. (c) Counter boring

 Drilling

Counter sinking
• Used to provide conical hole cut into workpiece
Center drilling
• Used to make centers in the workpiece
Spot facing
• Used to smoothing and squaring the surface at the end
of a hole.
 Drill Press

• Drilling is generally performed on a drill press,

although other machine tools also perform
this operation
• Types of Drill Press:
• Upright Drill (Stands on the floor)
• Bench Drill (Mounted on a table/bench)
• Radial Drill (For large workparts)
• Gang Drill (Multiple Upright Drills connected
together)
 Milling
• Milling is a machining operation in which a workpart is fed past a rotating
cylindrical tool with multiple cutting edges
• The axis of rotation of the cutting tool is perpendicular to the direction of
feed
• The cutting tool in milling is called a milling cutter and the cutting edges
are called teeth.
• Creates a planar surface
• Machine tool is called a milling machine
 Types of Milling Operations

Peripheral milling
• Cutter axis is parallel to surface being machined
Face milling
• Cutter axis is perpendicular to surface being milled
 Peripheral Milling Operations

Peripheral milling: (a) slab milling, (b) slotting, (c) side milling,
(d) straddle milling, and (e) form milling
Peripheral Milling Operations
Slab Milling
The basic form of peripheral milling in which the
cutter width extends beyond the workpiece on
both sides

Fig. Slab milling

 Peripheral Milling Operations
Slotting
• Width of cutter is less than work piece width, creating a
slot in the work

Fig. (b) Slotting

 Face Milling Operations

Face milling:
(a) Conventional face
milling
(b) partial face milling
(c) end milling
(d) profile milling
(e) pocket milling
(f) Surface contouring.
 Face Milling Operations

Conventional Face Milling

Cutter overhangs work on both
sides

Fig.(a) conventional face milling

 Face Milling Operations

End Milling
Cutter diameter is less
than work width, so a
slot is cut into part

Fig. (c) end milling

 Face Milling Operations

Profile Milling
Form of end milling in which
the outside periphery of a
flat part is cut

Fig. (d) profile milling

 Face Milling Operations

Pocket Milling
Pocket milling is used to mill
shallow pockets into flat
parts

Fig. (e) pocket milling

 Face Milling Operations

Surface Contouring
Ball‑nose cutter is fed back and forth
across the work along a curvilinear
path at close intervals to create a
three dimensional surface form

Fig. (f) surface contouring

 Milling Machines

• Milling is a machining process where

the cutting tool carries out a rotary
motion and the workpiece a
rectilinear motion
• The process is used to machine
external surfaces, slots, and
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 Milling Machines
• Milling machines must provide a rotating spindle for the cutter and a table for
fastening, positioning, and feeding the workpart
• Horizontal milling machine has a horizontal spindle, and this design is well
suited for performing peripheral milling (e.g., slab milling, slotting, side and
straddle milling)
• Vertical milling machine has a vertical spindle, and this orientation is
appropriate for face milling, end milling, surface contouring on relatively flat
workparts