DRILLING, REAMING & TAPPING

In each of these operations we are producing one or the other kind of hole either blind or through. Drilling Reaming or Tapping isnt a really tricky operation, but there are certainly some precautions you need to take. The first step in any venture lies in knowing exactly what you need to do. Drilling Reaming or Tapping metal requires the right drill bit, the right measurements and the right amount of patience. Layout-Very first step will be laying out the positions of these holes.

Producing centre marks. The process is called centre punching. Centre punching will produce a small indentation at the given position. The mark will help to start the drill hole at a certain position.

Drilling,
A drill bit enters the workpiece axially and cuts a blind hole or a through hole with a diameter equal to that of the tool. A drill bit is a multi-point tool and typically has a pointed end. A twist drill is the most commonly used, but other types of drill bits, such as a center drill, spot drill, or tap drill can be used to start a hole that will be completed by another operation.

Secure the piece that you want to drill with a vise or a clamp so it cant slip. Youll need both of your hands to keep the drill steady as well, since youll be drilling slowly. Use good-quality drill bits that are clearly labeled "high speed steel" o that are sharp o a golden titanium nitride finish on the bits are better. Use cutting oil. A pilot hole is a good idea for larger holes. Drill straight down into the metal, at a 90-degree angle when drilling with hand-drill. o If you drill at an angle, you are more likely to break your drill bit - especially with the smaller sizes. Use firm downward pressure. o Too little pressure and you will just spin around without cutting. If the metal or drill-bit starts to discolor, it is overheating - Stop! If it takes too long, it's probably not working - Stop! Ease up on downward pressure when drill is about to go through, when drilling through holes. When drilling deep holes, you need to bring the drill out of the hole more often to evacuate chips.

If you are just not making progress, the metal might be too hard. Worse, your continued efforts to drill the metal might be making it harder! (This is called "work-hardening).

Feed & Speed for Drilling, It is best to start with a moderate speed and feed, increasing either one, or both, after observing the action and condition of the drill.
Recommended feeds of various diameter drills (HSS) Diameter of Drill - Inches Feed Inches per Revolution Under 1/8 1/8 to 1/4 1/4 to 1/2 1/2 to 1 inch 1 inch and over .001 to .003 .002 to .006 .004 to .010 .007 to .015 .015 to .025

RPM Chart for HSS drills

Online Feed & Speed calculator. http://www.custompartnet.com/calculator/drilling-speed-and-feed Concept of calculation of feed and speed is exactly the same as Lathe machine of Milling machine.

Drill Geometry,

Drill Kinds,

Straight Shank

Stepdown Shank

Tapered Shank & Sleeves

Note! Extra-long drills are also available in all kinds and designs.
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Drill Sizes (Diamete er), SAE (Sta andard Amer rican Equiva alent) drill si izes have thr series. ree Number sizes #80 to #1 N s Letter sizes A to Z L A Fractional siz 1/64 to 31/32 zes

Metric dr sizes are defined by its diameter in decimal n rill i numbers. Mo common sizes starts from ost n 0.5mm to 25mm. Chart on the fo o ollowing pag covers all SAE and M ge Metric sizes & shows decimal equivalen in inches of all these sizes. nts s

D aditional twist drill bits may tend to w m wander whe started on an unprepar en n red Centre Drilling- Tra surface. Once a bit wanders off-c O w course it is difficult to br d ring it back o center. A center drill bit on educed tend frequentl provides a reasonable starting poin as it is sho and there ly nt ort efore has a re dency to wande when drilling is started Center dri bits are us in metal er d. ill sed lworking to p provide a sta arting hole for a larger-sized drill bit or to make a conical inden r c ntation in a w workpiece. Centre dr bits are classified by # sizes. Tab below rel rill c ble lative dimen nsions of most commonly y used cent drills. ter

Decimal Equivalents of SAE and Metric sizes

Englis h .. .. 80 79 1/64 .. 78 77 . 76 75 74 . 73 72 71 .. 70 69 68 1/32 .. 67 66 65 . 64 63 62 61 .. 60 59 58 57 56 3/64 55 54 53 1/16 52 51 50 49 48 5/64 47 .. 46 Metri c .1 .2 .3 .34 .37 .40 . .41 .46 .5 .51 .53 . .61 .64 .66 .7 .71 .74 .79 .79 .8 .81 .84 .89 .9 .91 .94 .97 .99 1. 1.02 1.04 1.07 1.09 1.18 1.19 1.32 1.40 1.51 1.59 1.61 1.70 1.78 1.85 1.93 1.98 1.99 2. 2.06 Decim al .0039 .0079 .0118 .0135 .0145 .0156 .0157 .0160 .0180 .0197 .0200 .0210 .0225 .0236 .0240 .0250 .0260 .0276 .0280 .0292 .0310 .0312 .0315 .0320 .0330 .0350 .0354 .0360 .0370 .0380 .0390 .0394 .0400 .0410 .0420 .0430 .0465 .0469 .0520 .0550 .0595 .0625 .0635 .0670 .0700 .0730 .0760 .0781 .0785 .0787 .0810 Englis h 45 44 43 42 3/32 41 40 39 38 37 36 7/64 35 34 33 32 .. 31 1/8 30 29 28 9/64 27 26 25 24 23 5/32 22 .. 21 20 19 18 11/64 17 16 15 14 13 3/16 12 11 10 9 .. 8 7 13/64 6 Metri c 2.08 2.18 2.26 2.37 2.38 2.44 2.50 2.53 2.58 2.64 2.71 2.78 2.79 2.82 2.87 2.95 3.0 3.05 3.18 3.26 3.45 3.57 3.57 3.66 3.73 3.80 3.86 3.91 3.97 3.99 4.0 4.04 4.09 4.22 4.31 4.37 4.39 4.50 4.57 4.62 4.70 4.76 4.80 4.85 4.91 4.98 5.0 5.05 5.11 5.16 5.18 Decim al .0820 .0860 .0890 .0935 .0937 .0960 .0980 .0995 .1015 .1040 .1065 .1094 .1100 .1110 .1130 .1160 .1181 .1200 .1250 .1285 .1360 .1405 .1406 .1440 .1470 .1495 .1520 .1540 .1562 .1570 .1575 .1590 .1610 .1660 .1695 .1719 .1730 .1770 .1800 .1820 .1850 .1875 .1890 .1910 .1935 .1960 .1968 .1990 .2010 .2031 .2040 Englis h 5 4 3 7/32 2 1 A 15/64 .. B C D 1/4 F G 17/64 H I .. J K 9/32 L M 19/64 N 5/16 .. O P 21/64 Q R 11/32 S .. T 23/64 U 3/8 V W 25/64 .. X Y 13/32 Z 27/64 .. Metri c 5.22 5.31 5.41 5.56 5.61 5.79 5.94 5.95 6.0 6.05 6.15 6.25 6.35 6.53 6.63 6.75 6.76 6.91 7.0 7.04 7.14 7.14 7.37 7.49 7.54 7.67 7.94 8.0 8.03 8.20 8.33 8.43 8.61 8.73 8.84 9.0 9.09 9.13 9.35 9.53 9.56 9.80 9.92 10.0 10.08 10.26 10.32 10.49 10.72 11.0 Deci mal .2055 .2090 .2130 .2187 .2210 .2280 .2340 .2344 .2362 .2380 .2420 .2460 .2500 .2570 .2610 .2656 .2660 .2720 .2756 .2770 .2810 .2812 .2900 .2950 .2969 .3020 .3125 .3150 .3160 .3230 .3281 .3320 .3390 .3437 .3480 .3543 .3580 .3594 .3680 .3750 .3770 .3860 .3906 .3937 .3970 .4040 .4062 .4130 .4219 .4331 Englis h 7/16 29/64 15/32 .. 31/64 1/2 .. 33/64 17/32 35/64 .. 9/16 37/64 .. 19/32 39/64 5/8 .. 41/64 21/32 .. 43/64 11/16 45/64 .. 23/32 47/64 .. 3/4 49/64 25/32 .. 51/64 13/16 .. 53/64 27/32 55/64 .. 7/8 57/64 .. 29/32 59/64 15/16 .. 61/64 31/32 .. 63/64 1 Metric Deci mal .4375 .4531 .4687 .4724 .4844 .5000 .5118 .5156 .5312 .5469 .5512 .5625 .5781 .5906 .5937 .6094 .6250 .6299 .6406 .6562 .6693 .6719 .6875 .7031 .7087 .7187 .7344 .7480 .7500 .7656 .7812 .7874 .7969 .8125 .8268 .8281 .8437 .8594 .8661 .8750 .8906 .9055 .9062 .9219 .9375 .9449 .9531 .9687 .9842 .9844 1.000

11.11 11.51 11.91 12.0 12.30 12.70 13. 13.10 13.49 13.89 14.0 14.29 14.68 15.0 15.08 15.48 15.88 16.0 16.27 16.67 17.0 17.07 17.46 17.86 18.0 18.26 18.65 19.0 19.05 19.45 19.84 20.0 20.24 20.64 21.0 21.03 21.43 21.84 22.0 22.23 22.62 23.0 23.02 23.42 23.81 24.0 24.21 24.61 25.0 25.0 25.40

Deburr ring & Chamfering, ,

When a hole is drilled into a wor piece, usu h rk ually a rough edge will ap h ppear around the top of the d hole. Cou untersink or deburring tool can remove these rough edges and put a chamfer betw g s ween the hole and the surfa into which the hole was drilled. Sometimes t is a safe measure other a ace w this ety times it is needed. De eburring can be dne by a hand debur n rring-tool or by counters r sink-tools on the n machine. . Hand deb burring tools s

Chamfer is a small an ngled surfac added to an edge of a w ce a workpiece. A chamfer r removes the sharp edg and helps eliminate burrs. Chamf has certai dimension Usually co ge s fer in n. ountersink to ools are used for chamferi Chamfe ing. ering tools co omes in vari iety of differ sizes and kinds they all rent d y have 45 degrees angl d le.

Countersinking,
Another use of these tools is to make countersink on a hole for fastening countersink type screws. In this case chamfer (which is called countersink here) should be deep enough to seat the screw-head properly, so that head sits below the surface when tightened. Countersinks are available in different angles. Most common ones are 90 and 60 degrees included angle.

Counterboring,
A flat-bottomed cylindrical enlargement of the mouth of a hole, usually of slight depth, as for receiving a cylindrical screw head. Counterbores are made with standard dimensions for a certain size of screw. The tip of the counterbore has a reduced diameter section referred to as the pilot, a feature essential to assuring concentricity between the counterbore and the hole being counterbored. Counterbores matched to specific screw sizes generally have integral pilots that fit the clearance hole diameter associated with a particular screw size (e.g., 0.191 inches for a number 10 machine screw).

 Guideatthefrontofacounterboringtoolisnormalytwofractionalsizesbiggerthanthegivenscrew size,forexampleifwearecounterboringfora1/4screwtheguidediameterwillbe9/32(0.281),soitis veryimprtantthatthedrilledholeisrightsizeotherwisethecounterboringtoolwilljamandbreak.

Tapping,
A tap enters the workpiece axially and cuts internal threads into an existing hole. The existing hole is typically drilled by the required tap drill size that will accommodate the desired tap. The tap is selected based on the major diameter and pitch of the threaded hole. Threads may be cut to a specified depth inside the hole (bottom tap) or the complete depth of a through hole (through tap). Let us look at the three main component of a thread (1) Major Dia (2) Minor Dia, (3) Pitch

For tapping or internal threads we should drill a hole equal or slightly bigger than minor diameter of a given thread size bofore comencing for tapping. For external or mail threads we will premachine a boss or rod equal or slightle smaller than given thread size and then run a Threading Die to machine threads. To make life easier charts are avilible to find out the right drill size for a given tap. First let us look at thread-pitch series. (What is Right hand & Left hand threads) no no not our topic here.

National Course threads (UNC or NC)- Coarse threads are those with larger pitch (fewer threads per axial distance like 1/4-20 or 1/2 -13. This is most commonly used series. National Fine threads (UNF or NF)- Fine threads are those with smaller on finer pitch (more threads per axial distance like 1/4-28 or 1/2 -20

Hand Taps

Machine Tap

National Pipe threads (NPT)- NPT is US standard for tapered threads used on threaded pipes and fittings. The taper rate for all NPT threads is 116 (34 inch per foot) measured by the change of diameter (of the pipe thread) over distance. The angle between the taper and the center axis of the pipe is 1 47. Threaded pipes can provide an effective seal for pipes transporting liquids, gases, steam, and hydraulic fluid. These threads are now used in materials other than steel and brass, including PVC, nylon, bronze and cast iron. The taper on NPT threads allows them to form a seal when torqued as the flanks of the threads compress against each other.

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Tap identification- If a tap label reads 1/4-20 or M10 x 1.5 what does it mean? First number 1/4 or M10 always represents major diameter of the thread, second part indicated the pitch, in SAE it is thread per inch and in metric it is distance between two threads. Sometime we see NC or NF mentioned in the label as well. NC or NF are available in Metric taps as well. In NPT threads are identified by fractional size but this size do not relate to any of the dimensions on the actual threads, 1/8 NPT threads will have 0.405 major diameter and 27 threads per inch. NPT threads do not have coarse and fine series. Tapping Steps, Identified right size drill for the tap Machine a hole Machine a chamfer at the opening of the hole. Chamfer should be slightly bigger than nominal size of the tap i.e. 1/4 or 10mm. Chamfer will help the tap to align and guide. Run Tapper then Plug and then Bottoming taps, if available. Lot of time on Plugtap is used. Make sure tap is perpendicular to the surface, Care is needed specially at the start.

Note! Extreme care is needed when tapping. Taps are extremely hard and brittle and can snap very easily. Use cutting fluid and run tap progressively.

Tap Handles

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Tap Drill Chart SAE

NC (National Coarse)
Tap size Screw major dia. Tap drill size for 75% .dia clearance drill

#0-80 #1-64 #2-56 #3-48 #4-40 #5-40 #6-32 #8-32 #10-24 #12-24 1/4-20 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 3/4-10 7/8-9 1"-8 1 1/8-7

0.060 0.073 0.086 0.099 0.112 0.125 0.138 0.164 0.190 0.216 .2500 .3125 .3750 .4375 .5000 .5625 .6250 .7500 .8750 1.000 1.1250

3/64 (.0469) 53 (.0595) 50 (.0700) 47 (.0785) 43 (.0890) 38 (.1015) 36 (.1065) 29 (.1360) 25 (.1495) 16 (.1770) 7 (.2010) F (.2570) 5/16 (.3125) U (.3680) 27/64 (.4219) 31/64 (.4844) 17/32 (.5312) 21/32 (.6562) 49/64 (.7656) 7/8 (.8750) 63/64 (.9844)

50 (.0700) 46 (.0810) 41 (.0960) 35 (.1100) 30 (.1285) 29 (.1360) 25 (.1495) 16 (.1770) 7 (.2010) 1 (.2280) H (.2660) Q (.3320) X (.3970) 15/32 (.4687) 17/32 (.5312) 19/32 (.5938) 21/32 (.6562) 25/32 (.7812) 29/32 (.9062) 1-1/32 (1.0313) 1-5/32 (1.1562)

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Tap Drill Chart SAE

NF (National Fine) Tap size
(major dia. threads / inch)

#1-72 #2-64 #3-56 #4-48 #5-44 #6-40 #8-36 #10-32 #12-28 1/4-28 5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 5/8-18 3/4-16 7/8-14 1"-12 1 1/8-12

Screw major dia. 0.073 0.086 0.099 0.112 0.125 0.138 0.164 0.190 0.216 .2500 .3125 .3750 .4375 .5000 .5625 .6250 .7500 .8750 1.000 1.1250

Tap drill size for 75% .dia 53 (.0595) 50 (.0700) 45 (.0820) 42 (.0935) 37 (.1040) 33 (.1130) 29 (.1360) 21 (.1590) 14 (.1820) 3 (.2130) I (.2720) Q (.3320) 25/64 (.3906) 29/64 (.4531) 33/64 (.5156) 37/64 (.5781) 11/16 (.6875) 13/16 (.8125) 15/16 (.9375) 1-3/64 (1.0469)

Clearance drill

46 (.0810) 41 (.0960) 35 (.1100) 30 (.1285) 29 (.1360) 25 (.1495) 16 (.1770) 7 (.2010) 1 (.2280) H (.2660) Q (.3320) X (.3970) 15/32 (.4687) 17/32 (.5312) 19/32 (.5938) 21/32 (.6562) 25/32 (.7812) 29/32 (.9062) 1-1/32 (1.0313) 1-5/32 (1.1562)

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Tap Drill Chart Metric

NC (National Coarse)
Tap size Major dia. mm (inch) Tap drill mm Tap drill inch Cleara Cleara nce nce mm inch

M1.6x0.35 M2x0.4 M2.5x0.45 M3x.05 M3.5x0.6 M4x0.7 M5x0.8 M6x1 M8x1 M10x1.5 M12x1.75 M14x2.0 M16x2.0 M18x2.5 M20x2.5 M22x2.5 M24x3 M27x3

1.6 (.0630) 2.0 (.0787) 2.5 (.0984) 3.0 (.1181) 3.5 (.1378) 4.0 (.1575) 5.0 (.1969) 6.0 (.2362) 8.0 (.3150) 10.0 (.3937) 12.0 (.4724) 14.0 (.5512) 16.0 (.6299) 18.0 (.7087) 20.0 (.7874) 22.0 (.8661) 24.0 (.9449) 27.0 (1.063)

1.25 1.60 2.05 2.50 2.90 3.30 4.20 5.0 6.8 8.5 10.2 12.0 14.0 15.5 17.5 19.5 21.0 24.0

#55 #52 #46 #39 #32 #30 #19 #8 J 11/32 27/64 1/2 37/64 21/32 47/64 13/16 7/8 1

1.8 2.4 2.9 3.4 3.9 4.5 5.5 6.6 9.0 12.0 14.0 16.0 18.0 20.0 22.0 25.0 27.0 30.0

#49 #41 #32 #29 #23 #16 7/32 G T 31/64 35/64 5/8 45/64 51/64 7/8 1 1-5/64 1-3/16

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NPT & NPS - Pipe Treads

TAP SIZE TAPER NPT Threa Normal DRILL * DEC. EQUIV. d OD ngageme SIZE nt (MAX) C .242 .3125 .2611 Q .332 .405 .2639 7/16 .438 .540 .4018 9/16 .562 .675 .4078 45/64 .703 .840 .5337 29/32 .906 1.050 .5457 1-9/64 1.141 1.315 .6828 STRAIGHT NPS DRILL DEC. SIZE EQUIV. 1/4 S 29/64 19/32 47/64 15/16 1-3/16 .2500 .3480 .4531 .5938 .7344 .9375 1.187

1/16-27 1/8-27 1/4-18 3/8-18 1/2-14 3/4-14 1-11 1/2

* Drill sizes given permit direct tapping without reaming the hole, but only give a full ead for the first two or three threads.

Fine pitch Metric

Tap size Major dia. mm (inch) 7.0 (0.275) 9.0 (0.354) 10.5 (0.413) 12.5 (0.492) 14.5 (0.570) 16.0 (0.629) 18.0 (0.708) 20.0 (0.787) Tap drill (mm) 6.8 8.5 10.2 12.0 14.0 15.5 17.5 19.5 Tap drill (inch) H R 13/32 15/32 35/64 39/64 11/16 49/64 Clearance Clearance inch (mm) (dec.) 9.0 12.0 14.0 16.0 18.0 20.0 22.0 25.0 T 31/64 35/64 5/8 45/64 51/64 7/8 1

M8x1.0 M10x1.0 M12x1.5 M14x1.5 M16x1.5 M18x2.0 M20x2.0 M22x2.0

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Reamin ng,
The geom metry of a ho drilled in metal by a twist drill m not be ac ole n may ccurate enou (close ugh enough to a true cylin o nder of a cer rtain precise diameter) an may not have the req and quired smoot th surface finish for cer fi rtain enginee ering applica ations. Altho ough modern twist drills can perform n m excellent in many casesusua producin sufficientl accurate h tly c ally ng ly holes for most applicatio ons sometime the stringency of the requirements for the hol geometry and finish necessitate t es r le's y two operation a drilling to slightly undersize, fo ns: g u ollowed by r reaming with a reamer. T planned h The differenc between th drill diam ce he meter and the reamer diam e meter is called an allowa ance. (It allo ows for the re emoval of a certain small amount of material.) T allowanc should be < 0.2 mm (. c The ce .008 in) for so materials and < 0.13 mm (.005 in for hard m oft m n) materials. Lar rger allowan nces can dam mage the reame The drille hole shou not be en er. ed uld nlarged by m more than 5% of the drille diameter. % ed . Drilling followed by reaming gen f nerally produ uces hole ge eometry and finish that is as close to theoretical perfection as possible n e. A reamer enters the workpiece ax r w xially and en nlarges an ex xisting hole to the diame of the to A eter ool. reamer is a multi-poi tool that has many flu s int h utes, which m be straig or in a h may ght helix. Reamin ng removes a minimal amount of ma a aterial and is often perfo s ormed after d drilling to ob btain both a more accurate diameter and a smoother internal fin nish.

nd Reamers are availabl in wide ra le ange of sizes and designs such as Han reamer, M s Machine ream mer, Tapper Reamer and Expandable reamer. R E Followin table gives approxima stock a re ng ate eamer should remove. In other word drilled hol d n ds le should be this much smaller for a certain size reamer. e e

RPM- Ap pproximately reamer sho y ould run at half or even l h little bit slow than the speed of a s wer same size HSS drill. S

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Trouble Shooting Symptom Drill produces a very high pitch squeal Drill Bit becomes very hot Drill bit dulls very quickly Lubrication is required Drill bit becomes very hot Damaged Drill bit Drill bit Wobbles Ensure the Bit is correctly positioned in the chuck Centre punch is too small Smaller pilot hole is needed Too much Pressure Drill is running too fast Solution Drill is running too fast

Drill Bit skates across the metal surface Drill Bit grabs as it breaks through

Drill Press Safety 1. Operate only with the instructor's permission and after you have received proper instruction. 2. Remove jewelry, eliminate loose clothing and confine long hair. 3. Make sure all guards are in place and operating properly. 4. Always use proper eye protection. 5. Hold material securely with a vice or clamps. 6. Be sure the chuck key is removed from the chuck before starting the machine. 7. Select a properly sharpened bit. For metal, center punch when a hole is to be drilled. 8. Turn off the power if the work piece becomes caught in the drill. Do not stop the chuck rotation by hand. 9. Adjust the table or depth stop to avoid drilling into the table. 10. Select the correct speed: Normally, slower for drilling metal, faster for wood. The larger the bit, the slower the speed.

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