Drill Press Fundamentals

1
Drill Press Fundamentals
2
Overview

• Safety
• Shop Etiquette
• Basic Terminology
• Drill Chucks
• Calculating Speeds
• Changing the Drill Speed
• Drilling Operations
• Maintenance

3
Safety

• Respect the machines
• Common Sense
• Wear safety glasses
• Avoid loose clothing
• Restrain long hair
• Never wear gloves
• Never wear shorts or sandals
• Use chip brushes to clear chips away
• Stay alert

4
Shop Etiquette

• COE Shop
• Always leave machines cleaner
• Ask for help, if needed
• Come prepared
• Tooling list
• Plan of action
• Dimensioned drawings

5
Basic Terminology

• Ellis Drill Press

Hand Spindle Lever
On/Off Switch
Table Locks
Table Lift Crank
Speed Control
Forward/Reverse switch
Spindle
Chuck
6
Basic Terminology

• Walker-Turner Drill Press

Belt cover
Spindle
Belt tension lever
Hand spindle lever
Chuck
Table lock
Table lift crank
7
Basic Terminology

• Tooling
• Center Drill
• Keeps holes accurately positioned used first
• Twist Drill
• Reamer
• Usually pre-drill to 1/64th under

8
Basic Terminology

• Fixturing
• Vise
• Clamping Kit
• T-slot nuts
• Flange nuts
• Coupling nuts
• Step blocks
• Step clamps
• V-blocks

9
Drill Chucks

• Drill Chuck Types
• Key-Type Chuck
• Keyless Chuck
• Pin Chuck
• Sensitive Drill Chuck

10
Drill Chucks

• Key-Type Chuck
• Used to hold small drills, usually under ½ inch
  in diameter.
• Holds only straight shank drills and tooling
  i.e. reduced shank drill bits, reamers and
  countersinks
• Has three jaws that open and close simultaneously
  against straight shanks using a drill chuck key.

Reduced Shank Drill Bit
Chuck Key
11
Drill Chucks

• Keyless Chuck
• Used to hold small drills, usually under ½ inch
  in diameter.
• Holds only straight shank drills and tooling
  i.e. reduced shank drill bits, reamers and
  countersinks
• Has three jaws that open and close simultaneously
  against straight shanks using firm hand pressure
  only
• Quicker loading and un-loading of tooling
  compared to key-type chucks

Note If chuck is not tight enough drill bit will
be damaged resulting in deep groves in the bit
shankand possibly making the bit off center.
12
Drill Chucks

• Pin Chuck
• Used to hold very small drills, usually 0 to 3/32
  inch in diameter.
• Has 3 interchangeable collets
• Fits in a larger collet or drill chuck

13
Drill Chucks

• Sensitive Drill Chuck
• The sensitive drill feed/chuck provides fingertip
  control when drilling very small holes on a drill
  press or milling machine.
• This tool bypasses the machines coarse quill
  feed, giving the operator better feel and control
  of the feed rate.
• Breakage of small diameter drills is greatly
  reduced and the tendency for drill walking is
  minimized.
• Has a ½ inch straight shank that will mount in a
  collet, chuck or toolholder

14
Changing the Drill Chuck

• To remove the drill chuck insert the drift as
  shown slot in spindle
• Tap the wide end of the drift with a
  hammer/mallet and catch the drill chuck so it
  does not hit the table
• Put in the new chuck or tapered drill bit so the
  tang lines up with the slot where the drift was
  inserted in the spindle

Spindle Drift Slot
Tang
15
Calculating Speeds No Math

• Information Station
• Use this if you dont feel like doing any math
• Follow the Drill Press Drill Bit Speed Program

16
Calculating Speeds Other Factors

• Drill Bit Cutting Speeds (RPM)
• Although you have calculated the RPM, remember
  that this is only a recommendation. Some judgment
  must be made in selecting the actual RPM setting
  to use for the current job.
• There are always outside factors that must go
  into deciding on the proper speed to use. Ask
  yourself these 3 basic questions before deciding
  on an RPM setting. How rigid/sturdy is my setup?
  Go slower for setups which lack a great deal of
  rigidity. Am I using coolant? You may be able to
  use a faster speed if you are using a flood
  coolant system. How deep am I drilling? If youre
  drilling a deep hole, there is no place for the
  heat to go and is harder to clear the chips out
  and away. You may have to slow the RPM down for
  drilling a deep hole.

17
Changing the Drill Speed

• Walker-Turner
• The speed is adjusted by loosening the belt
  tension lever (move forward), then move the belt
  from one pulley to another. Speed guide is on top
  of drill press.
• Make sure the belt is horizontal (on the
  opposite same number pulley). Tighten the belt
  tension lever (pull back). Close the belt cover
  before turning on machine.
• NEVER adjust speed with
• machine on.

Belt on Number 3 Pulley
18
Changing the Drill Speed

• Ellis
• Set speed dial to zero
• Set switch to forward position
• Set power switch to on
• Turn speed dial to desired speed
• When done drilling hole turn speed dial to zero
  and then turn machine off
• NOTE Use percentage/speed chart on top of the
  drill press for setting speeds

19
Drilling Operations

• Securing the Work Piece
• Be sure the work piece is securely fastened to
  the work table (clamps mounted on the wall
  between drill presses)
• The importance of securely mounting the work to
  the table cannot be over emphasized. Injuries can
  occur by hand holding the work or not clamping
  the vise to the table Note Make sure the vise
  handle is facing left when mounted to the table,
  this way, if the drill bit catches and spins the
  vise, the handle will hit the drill press column
  and not the operator

Vises are located on the work table by drill
presses
Clamps are located on the wall between drill
presses
20
Drilling Operations - Using A Vise

• Note Always make sure you are drilling a
  workpiece within the jaw clamping area of the
  drill press vise. Never drill a hole in a
  workpiece hanging out of the drill press vise.

YES
NO
21
Drilling Operations Spotting A Hole

• It very important that you have your hole
  location marked on your workpiece with the use of
  a center punch, center drill or spot drill

Center Drill
Spot Drill
Center Punch
22
Drilling Operations Drill Hole To Size

• After the hole has been marked and spotted,
  proceed with drilling the hole to size. If you
  are drilling a hole larger than ¾ inch, drill
  through with a size between 0 and ¾.
• Make sure you use cutting fluid from the white
  cups throughout the shop and keep the chips out
  of your hole and off your drill bit with the blue
  chip brushes shown below
• NOTE Do NOT use cutting fluid on PLASTICS Use
  soapy water

23
Drilling Operations Countersinks

• A tool used to produce a conical enlargement of
  the end of a hole.
• Used as a chamfering or deburring tool 1/32 to
  1/16 is sufficient for most holes. Used prior to
  tapping or reaming, protects hole from burrs and
  nicks.
• Used for recessing the head of a machine screw
  (Flat Head).
• 82 degree single flute is the most common
  countersink used for this purpose.
• The cutting speed used when countersinking should
  be slow enough to avoid chattering. A good
  starting point would be 1/3 the drill speed.

Countersunk For A Flat Head Screw
82 Degree Single Flute
24
Drilling Operations Reamers

• A tool used to finish a previously drilled hole
  to an exact size.
• There are many different types of reamers
  available, but they are classified in two ways.
• Chucking or Machine Reamers cut with their
  chamfered end (45 deg). Used mainly in mills,
  lathes and drill presses under machine power.
• Hand Reamers cut on the periphery (outside) at
  the tapered portion of the reamer. Can also be
  used in mills, lathes and drill presses but only
  with hand power.

Adjustable Hand Reamer
Straight Flute Chucking Reamer
Spiral Flute Chucking Reamer
Chucking Reamer Morse Taper End
25
Drilling Operations Reamers

• Chucking / Machine Reamers
• Come with either a straight or tapered shank
  (morse taper). Can be mounted in a drill chuck,
  collet or tailstock.
• May come with either straight or spiral flutes.
• Straight Flutes Work well for reaming average
  materials
• Spiral Flutes Designed for reaming materials
  which are considered difficult to ream. The
  spiral flutes aid in producing smoother and more
  accurate holes.
• Drill holes to the following size prior to
  reaming
• 1/64 smaller for holes up to 1 diameter.
• 1/32 smaller for holes larger than 1 diameter.
• Speeds and Feeds For Chucking Reamers
• The speed for reaming should be much slower than
  for drilling (1/2 -1/3 of Drill Speed starting
  point) while the feed is usually faster than
  drilling.
• NOTE Always Use Cutting Fluid When Reaming
  Metals Use Soapy Water On Plastics

26
Drilling Operations Reamers Solid Flute

• Hand Reamers Used when extreme accuracy is
  required
• Come with a straight shank and a square driving
  end for a wrench
• May come with either solid straight or spiral
  flutes
• Straight Solid Flutes General high accuracy
  reaming.
• Spiral Flutes Designed for reaming materials
  which are considered difficult to ream. The
  spiral flutes aid in producing smoother and more
  accurate holes.
• A cut of .002 - .005 is usually recommended for
  hand reamers
• May be necessary to drill and rough ream a hole
  prior to hand reaming
• Used as a final finished cut
• Hand Reaming Procedure
• It helps when hand reaming not to remove the work
  from the drilling machine vise after drilling the
  initial hole. Use a dead center in the drill
  chuck and hold it tightly against the small hole
  in the end of the reamer while turning the reamer
  with a tap wrench. It steadies the reamer and
  holds it straight while getting the reamer
  started.

Always Use Cutting Fluid When Reaming Metals
Use Soapy Water On Plastics
27
Drilling Operations Reamers Adjustable

• Adjustable Can produce any size holes within
  reamer size adjustment range.
• Come with a straight shank and a square driving
  end for a wrench
• Adjustability - Sizing
• Their size (dia. of cutter) may be changed by
  sliding, or otherwise moving , the blades toward
  or away from the reamer axis using the adjustment
  nuts.
• ¼ 15/16 available in step ranges of 1/32
• 15/16 or larger available in step ranges of
  1/16
• A cut of .002 - .005 is usually recommended for
  hand reamers
• Hand Reaming Procedure
• It helps when hand reaming not to remove the work
  from the drilling machine vise after drilling the
  initial hole. Use a dead center in the drill
  chuck and hold it tightly against the small hole
  in the end of the reamer while turning the reamer
  with a tap wrench. It steadies the reamer and
  holds it straight while getting the reamer
  started.
• Use Soapy Water When Reaming Plastics

Always Use Cutting Fluid When Reaming Metals
Adj. Nuts
28
Drilling Operations Reamers

• Final Notes
• Never rotate the reamer backwards to remove it
  from the hole
• In all hand reaming with solid, or adjustable
  reamers never rotate the reamer backwards to
  remove it from the hole, as this will dull the
  reamer rapidly.
• If possible , pass the reamer through the hole
  and remove it from the far side without stopping
  the forward motion. If this is not possible , it
  would be removed while maintaining the forward
  rotation.

Always Use Cutting Fluid When Reaming Metals Use
Soapy Water On Plastics
29
Drilling Operations Hand Tapping

• Procedure Before a tap can be used, a hole must
  be drilled.
• The Drill used to make a hole before tapping is
  called a Tap Drill
• A hole of a certain diameter must be drilled
  before it can be tapped. If the hole is too
  large, a full thread will not be formed if too
  small, it will be hard to turn the tap and may
  break.
• Most tap charts are based on a 75 thread
  produces threads which are about 75 of the depth
  of external threads.

Example ¼ - 20 thread needed must drill a 7
tap drill hole
30
Drilling Operations Hand Tapping

• Tapping The forming of screw threads on the
  inside of a hole
• 3 Most common types Taper , Plug, Bottoming
• HSS (High Speed Steel) Most common material
  manufactured from

Hand Taps Use for through-hole and blind-hole
tapping. Have straight flutes that store chips
during hand and machine threading.
Bottom Tap Aprox. 1-2 chamfered threads
Taper Tap Aprox. 6-8 chamfered threads First
choice as a starter tap
Plug Tap Aprox. 3-4 chamfered threads
31
Drilling Operations Hand Tapping

• Tapping General Procedure
• Mark/layout, then center punch or center drill
  your hole location .
• Drill your hole with the appropriate Tap Drill
  follow the chart. (see previous slide)
• Clamp your workpiece.
• Using a taper tap, along with a drill press, tap
  stand or tap block align tap mounted in a tap
  handle/wrench straight over the hole.
• Put light pressure on the tap handle, start
  turning the handle clockwise. A steady, downward
  pressure is needed to get the thread started.

32
Drilling Operations Hand Tapping

• Tapping General Procedure
• Using the appropriate cutting fluid, continue
  turning the tap into the hole. After the tap is
  started, back off the tap a turn or two to break
  the chip away. Then continue this cycle until the
  hole is finished.
• You may want to switch to a different tap
  (earlier slide) depending on if the hole is a
  through or blind hole.
• If you need as many threads as possible in a
  blind hole, you will need to use a bottoming tap
  (use to finish off a blind hole with max thread
  count.
• If the hole is deep, back the tap all the way out
  and clear the hole and tap with a blast of air
  (protect your eyes). Depending on the thickness
  and toughness of the material , you may want to
  repeat this a few times.
• Make sure you did not leave any burrs on the face
  of the hole. Remember you can countersink the
  hole prior to tapping and reduce that chance.
• NOTE Use cutting fluid on metal soapy water on
  plastics.

33
Drilling Operations Hand Tapping

• Tapping The forming of screw threads on the
  inside of a hole
• Other types available NPT (National Pipe
  Thread)
• The National Pipe Thread (NPT) is a thread with
  a ¾ taper per foot
• For this reason it is very important NOT to
  thread the tap all the way through the hole. That
  is why pipe fittings tighten together and seal
  with teflon tape or pipe joint compound. Commonly
  you can stop threading the hole with 6-8 threads
  showing on the tap.

NPT -TAP DRILL SIZE Using the tap chart on the
next slide you can see that a ½ - 14 NPT thread
requires a tap drill hole of 23/32
Leave about this much of the tap exposed when
tapping an NPT threaded hole
34
Drilling Operations Hand Tapping

• Tapping On A Drill Press
• Before clamping the vise to the table and
  drilling the tap drill hole, make sure you will
  have room for a tap handle and tap.
• You do not want to move the vise or table after
  the hole is drilled.
• Use a dead center in the drill chuck and into the
  end of the tap handle. This will make sure the
  tapped hole is true and perpendicular.

35
Drilling Operations Hand Tapping

• Tapping On A Drill Press
• Maintain light pressure on the tap handle/dead
  center with the drill press spindle handle as you
  continue to tap and feed the tap into the hole.
• Follow the earlier general tapping procedures to
  complete the job. (earlier slides)
• NOTE Remember to back that tap off and keep the
  hole and tap clean if it is deep.
• Use the appropriate cutting fluid.

36
Drilling Operations Hand Tapping

• Tapping Using A Tap Stand
• Another excellent option to get a true and
  perpendicular tapped hole is using a Tap Stand.
• This allows you to drill the part on a drill
  press and then move it to a bench and tap it
  using the stand.
• Works best for smaller parts
• The stand uses collets loaded with various size
  taps. Quick changing capability.

37
Drilling Operations Hand Tapping

• Tapping Using A Tap Block
• This is a quick and easy method to obtain a true
  and perpendicular tapped hole.
• Using a tap block allows you to take a drill and
  tap handle w/tap to a job or site where a drill
  press or tapping stand would not be available or
  for work to large for a stand or drill press.

38
Drilling Operations Threading Dies

• Threading Dies The cutting of screw threads on
  the outside of a round bar of material.
• The most common type of threading die is a round,
  adjustable , split die.
• The tool for holding and turning the threading
  die is called a diestock.

39
Drilling Operations Threading Dies

• Adjustable, Split Dies Most dies can be set to
  cut a little oversize or undersize. This is done
  by turning the set screw with a screwdriver.
• Cutting threads on a piece of round stock with a
  die and diestock is called Threading
• The end of the work to be threaded should be
  beveled (chamfered) to make it easier for the die
  to start onto the piece.
• Clamp the work upright in a vise
• Fasten the die into the diestock

Set Screw
40
Drilling Operations Threading Dies

• Adjustable, Split Dies
• The threads are beveled a little more on one side
  of the die than the other to make starting the
  die easier and to form the thread gradually.

2 Thread Lead-In
1 Thread Lead-In
41
Drilling Operations Threading Dies

• Adjustable, Split Dies
• Place the die over the end of the work , grasp
  the diestock with both hands near the work, and
  at the same time, slowly screw it on the work
  clockwise.
• The die cuts the thread as it goes. Be sure that
  the die goes on squarely. It takes time to become
  proficient with this skill.
• After the thread is started, grasp the two
  diestock handles out towards the ends and with a
  steady movement continue screwing the die on the
  work. It is no longer necessary to press down
  because the die will draw itself on the work when
  turned.
• Back up the die now and then to break and clean
  away the chips and to make the threads smooth.
  Back up one step and go ahead two
• Continue in this way until you have the length of
  thread you want.
• NOTE Remember to use cutting fluid when
  threading metals

42
Drilling Operations Threading Dies

• Solid Dies National Pipe Thread (NPT)
• There are other types of threading dies used for
  particular jobs
• The solid pipe thread dies are used to
  produce a tapered thread ¾ per foot. This allows
  pipe fitting to tighten up and produce a seal
  with teflon tape or pipe dope.
• Remember to back up the die now and then to break
  and clean away the chips as done with adjustable
  split dies. Back up one step and go ahead two
• Continue in this way until you have the length of
  thread you want dont go too far for a good
  pipe thread.
• NOTE Remember to use cutting fluid when
  threading metal pipe

NPT pipe threading set
NPT Solid Pipe Die
43
Maintenance

• Clean up
• Vacuum and/or sweep up chips
• Limit use of air hose
• Wipe down table

44
Conclusion
College Of Engineering Shops University Of
Wisconsin Madison Never be afraid to ask for
help Experience is the best way to learn!