Design of Drill Tool Introduction

Drilling
• Creates a round hole in
a workpart
• Contrasts with boring
which can only enlarge
an existing hole
• Cutting tool called a
drill or drill bit
• Customarily performed Figure 21.3 (b) drilling
on a drill press
 Introduction
Upright Drill
Stands on the
floor

Bench Drill
Similar but
smaller and
mounted on a
table or bench
Figure 22.15 ‑ Upright drill press
 INTRODUCTION

• Drill is a cutting tool used for producing a hole in

a solid work.
• It may also be used for enlarging an existing hole.
• During drilling rotary motion about the axis of the
tool and straight line feed motion along the tool
axis are required.
• Twist drills are widely used in normal
circumstances in making a hole.
• Drill is more complex tool than a single point tool.
 TWIST DRILL CONSTRACTION
• The main elements and parts of twist drill
are shown in fig 15.1
• In the construction of the drill the elements
to be considered for the design are:
• Drill diameter : D
• Point angle : 2Ǿ
• Flute helix angle: W
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 Shape of the flute section

• The cutting edge or the lip of a twist drill which

is formed by the intersection of face and the
relief surface of cutting edge is normally a
straight line.

• The profile of cross section the flute is shown

in fig. 15.2 . Dimension on the profile B and Ro
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 Flute length
• The over all length and the flute length affects
the rigidity of the drill.
A longer fluted length permits for larger number
of sharpening along the length of the tip.
• The overall length of the drill is made to the
standard keeping in view with the rigidity of the
drill for the given diameter.
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 Example Design of a Drill
• Suggest various dimensions of a two flute
twist drill of diameter 50 mm based on the
information given below:
Work material: Bronze
Tool material: HSS
Diameter of the fluting cutter: 5 mm
The design should include Flute Angle, Point
Angle, Core Diameter, Land Width,
Margin, Shape of the flute section.
 Solution
i) Flute Angle (ω) :
Flute angle depends on the diameter of the drill and on the metal
being cut. Since the
work material is Bronze, from Table 15.2 the flute helix angle is 8-
20o
Say ω =14o.
ii) Point Angle ( 2φ ) :
Point angle depends on the work material. Again from Table 15.2
the point angle, 2φ = 125o – 1300. Say 2φ = 1300.
(iii) Core Diameter (d) :
It depends on the tool material and the diameter of the drill. From
Table 15.3, for HSS tool material and drill dia. Over 10 mm,
d= (0.13 to 0.16) D
Say d = 0.15 D = 0.15 X 50 mm
∴ d = 7.5 mm
• (iv) Land Width (b) :
The proportion of the land width, b = 0.58 D
∴ b = 0.58 X 50 = 29 mm
(v) Margin (f) :
The width of the margin is given by f = 0.06 to 0.07 D
Say f = 0.065 D
∴ f = 0.065 X 50 = 3.25 mm
Height of margin = 0.02 D to 0.03 D
∴ Height = 0.025 X 50 = 1.25 mm
• (vi) Profile of the flute cross-section:
The dimensions of the profile B, Ro and Rf are given
as follows:
Ro = C1C2C3D
• ∴Ro = C1C2C3D = 1.09 X 0.9969 X 1.2058 X 50 = 65.5123 mm
Also Rf = C4 D
C4 = 0.015 ω0.75
∴ C4= 0.015 X 140.75 = 0.1086
∴ Rf = 0.1086 X 50 = 5.43 mm
B = Ro + Rf
∴B = 65.5123 + 5.43 = 70.9423 mm
 Design of milling cutter Introduction
Milling
Machining operation in which work is fed past a
rotating tool with multiple cutting edges
• Axis of tool rotation is perpendicular to feed
direction
• Creates a planar surface; other geometries possible
either by cutter path or shape
• Other factors and terms:
– Milling is an interrupted cutting operation
– Cutting tool called a milling cutter, cutting
edges called "teeth"
– Machine tool called a milling machine
 Conti……..

Figure 21.3 ‑ Two forms of milling:

(a) peripheral milling, and (b) face milling
 Conti……..

Peripheral Milling vs. Face Milling

• Peripheral milling
– Cutter axis is parallel to surface being machined
– Cutting edges on outside periphery of cutter
• Face milling
– Cutter axis is perpendicular to surface being milled
– Cutting edges on both the end and outside periphery
of the cutter
 Conti……..

Figure 22.23 (a) horizontal knee-and-column milling machine

 Conti……..

Figure 22.23 (b) vertical knee‑and‑column milling machine

 Conti……..

• Milling cutters are bodies of multiple edge tools.

• They are bodies of revolution with cutting edges arranged on the
circumferential surfaces.
• The cutting process of milling consists of two motions, rotation of
the cutter about its axis which is the primary cutting action and a
feed motion.
• In plain milling cutter the cutting teeth may be either parallel to the
axis or of helical form.
• In a plain milling cutter with straight flutes the rake and clearance
angle are specified in plane perpendicular to the cutter axis and are
similar to those in single point tools.
• These angles in this plane are known as radial rake angle and radial
clearance angle.
In a plain milling cutter with helical flutes i.e with helical teeth
provide a number of teeth in engagement during cutting thereby
distributing the load on the teeth.
They operate much smoother and produce a better surface finish.
But the helical fluted cutters produces an axial forces on the cutter,
the magnitude of which increases with the helix angle of the teeth.
Helix angle is provided up to 45o in milling cutters.
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• One of the principle design elements of a milling cutter is its
outside diameter.
• An increase in diameter of a plain milling cutter enables a larger
more rigid arbor to be used permitting an increased cutting load.
• A bigger cutter diameter have improved heat dissipation, which
contributes for a longer tool life.
• On the other hand bigger cutters are costlier.
• The cutting torque and the machining time are increased.
• The arbor diameter is found by strength and rigidity
analysis governed by the forces acting on the cutter in
the cutting process.
• In the practice it is selected from a set of
commercially available standard sizes as 16, 22, 27,
32, 40, 50 and 60mm diameter.
• The diameter of the plain milling cuter = (2 to 3)d
• The cutter hub diameter D1 is taken to be
• D1 = d + 2m = (1.5 to 2.5)d
• The
 Design of Form – Relieved Milling Cutter
• Form relieved milling cutters are used for milling
contour surfaces.
• A form relieved tooth is sharpened by grinding
the tooth face, not on the tool flank as in the
case of pro file sharpened cutters.
• Thus, the profile of the cutting edge is preserved
in the cutter.
• In practice , the profile of the relieving curve used
on form – relieved milling cutters is the
Archimedean spiral.
• In relieving along an Archimedean spiral,
uniform rotation of the milling cutter about its
axis corresponds to a uniform translatory motion
of the relieving tool. As has been explained earlier
( fig16.4) the relief value K is found as :
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 Example Design of a Milling Cutter

• The arbour of a Profile-sharpened, Carbide tool

tipped, plain milling cutter is subjected to
a torque of 80 X 103 Kgf-mm. It is given that the
shear stress of the material is 40 Kgf/mm2.
Design all the elements of the cutter assuming the
axial forces are negligible. Also find the
diameter of relieving tool.
• Given
- Cutter type / Profile-sharpened, HSS, Carbide tool tipped
- Torque (T ) = 80 x103 kgf-mm
- Shear stress of the material (τ) = 40 kgf/mm2