AB S T R A CT

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

K ey words: Drilling machine, Performance, Movement, Material, Operation etc.

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CONTENTS
CETIFICATE DECLARATION

ACKNOWLEDGEMENT

INTRODUCTION

GENERAL ASPECTS OF DRILLING MACHINE

DRILLING PROCESS

LITARATURE SURVEY

DEVELOPMENT OF DRILLING MACHINE

MOVEMENTS IN FLEXIBLE DRILLING MACHINE

SETUP PROCEDURE

WORKING PROCEDURE

METHODOLOGY

COMPONENT & SPECIFICATION

FUTURE SCOPE

CONCLUSION & SUMMARY

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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 variations of bow and strap drills have developed for the various uses

of either boring through materials or lighting fires.

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 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.

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. Th e machine used for drilling is called drilling machine. T h e

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.

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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.

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. W e 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

b e mo u n ted o n a table or wall an d can b e u sed to drill holes horizontally, vertically o r

ev en upside do wn . S o this mak es it possible for easy drilling in ev en

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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.

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 an d 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 co mmon drilling method,

where the hole is drilled in solid material to a

predetermined diameter and in a single operation.

Trepan is principally used for larger hole diameters since this
ning

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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 o f an existing hole with a

specifically designed tool. This machines away a substantial amount of

material at the periphery of the hole.

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

D c, where D c 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.

Reco mmended cutting speeds are for the highest speed at the periphery.

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The feed per revolution (ƒ n) 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.

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.

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The main factors that characterize

A hole from the machining view point are:

- diameter - depth

- quality

- material

- conditions

- reliability

- productivity

3 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 V imal 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

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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 M R R is affected mostly by feed.

Confirmation 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

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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.

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(5 6 ) 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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4 D E V E L O P M E N T O F D RI L L I NG M A C H I N E

A. Equipments used for the Experiment as shown:

Base plate

Vertical arm

Horizontal arm

Suspension spring

Rollar bearing

Motor

Drill bit

Copper wire

Switch board

Guider

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Fig. 1: Experimental Setup Diagram

5 M OVE MENT S IN FLEXIBLE DRILLING MACHINE

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

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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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6 W O RK ING P RO CEDU RE

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.

Fig. 2: Concept Design

7 M E T HO D O LO GY

Step 1: Part collection

After some survey from market finally w e bought pneumatic gun, pressure regulator,
pipes, wheels for table & adaptor at the reasonable price.

Fig 3: Pneumatic Gun

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Fig 4: Pressure Regulato

Fig 5: 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.

W e can switch to an automation by using servo motor in the defined joints for
future scope.

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Fig 6: Joints

Step 3: Design arms or linkages

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

W e can use telescopic arms to extend the work envelope of pneumatic drilling
machine for future scope.

Step 4: Fabrication of table

W e 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

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Fig 7: 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 w e assembled all the components in the one single unit and mad e universal
drilling machine to justify our project title “DESIGN & DEV ELOP MENT O F
UNIVERSAL PNEUMATIC DRILLNG MACHINE”.

Fig 8: Partial Assembling

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Fig 9: 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.

Fig 10(a): Experiment 1

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Fig 10(b): Experiment 2

8 C O M P ON EN T & SPECIFICATION

Fig 11: Component & specification (All dimensions are in mm)

9 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 mak e 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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