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We are manufacturers and suppliers of drill bits to the industrial market. Our sales representative has had several requests for new type of long series drill bit.
Our existing long series drills can operate with no problem so long as the drill is frequently cleared (pecking). Many of our customers find this process time consuming and expensive.
If peck drilling does not occur then the flutes fill up with swarf and the drill jams. Depending on the size of the drill, it may snap in the material being drilled. This incurs further cost in replacing the drill, and wasting a piece of material.
This problem exists with all long series drills regardless of diameter. Long series drills are produced with both straight and tapered shanks. The new drill should be compatible with these existing fittings.
A new long series drill needs to be designed that will maintain the standard long series drill lengths. It must be able to drill out a piece of material in one single action.
2. Determine the major design parameters
Hint: Underline or highlight the important information in the brief.
List what you think the customers requirements are. These will be found in the customer brief. There may be more or less than ten requirements.
After listing the customer requirements, consider what limitations and boundaries may be involved in the design.
This might include standards, materials, sizes, etc. Name the parameter and add a brief description
The drills are supplied in metric and imperial sizes. Long series drills are supplied in metric sizes from 2mm to 30mm in graduations of 0.5mm, the imperial sizes are supplied from 1/8” to1½” in graduations of 1/16”. These existing sizes should be considered in the new design
Brief for a long series drill
This problem exists with all long series drills regardless of diameter. Long series drill are produced with both straight and tapered shanks. The new drill should be compatible with these existing fittings.
A new long series drill needs to be designed, which will maintain the standard long series drill lengths, but will be able to drill out a piece of material in one single action.
1. Identify and list all customer requirements.
I.e. What are the customer requirements shown in the brief?
I.e. What are the limitations and boundaries of the design?
3. Produce a design specification for this problem
4. Ensure the design specification meets the customer requirements by describing how each aspect meets their needs
1. The customers are manufacturers of drill bits. (This may be relevant for the type of production).
2. Peck drilling is a time consuming process. The customer would like the hole to be drilled in one single process.
3. On the existing long series drills, if there is no peck drilling the flutes fill up with swarf and jam, this can result in breakage.
4. The problem exists in all long series drills regardless of its diameter.
5. Long series drills are produced with both straight and tapered shanks.
6. Maintain the standard long series drill lengths
7. The new drill should be compatible with existing fittings
length length 8
sha ‹mm› ‹mm) Order code each
6.00 115 175 02-3Z82 7.76
B.S0 115 175 02-3Z83 6.BB
J0.00 121 184 02-3284 9.K
10.z0 121 184 W-0705 t4A5
11.00 188 195 02W86 t2AZ
11.50 128 195 02-5287 13.01
12.00 134 20S 02-3288 15.05
12.50 1M 205 02-3208 T&64
13.00 134 205 024200 1Y.46 !
14.00 140 214 02-3292 ZIP !
DIN 340 RN/BS 328
standard helix, right hand apiral pqjgt gngje
9urface treatment Bright: below mm, Y» Blue: mm, °/›e and above mgs
1 - 15mm, h e - 1in
General purpose long reach drills.
ZS0 . 02-SZ94 27.15
17.00 154 235 OS-S298 30•77 !
17.50 158 241 OS-M99 69•77
1B.00 158 241 0Z-3300 42.OZ
19.Q} 182 247 02-3502 ¥7.71
20,00 1B8 M4 02-3904 4SA0
21.00 171 261 02-3305 Sb.6S
ZZ.00 176 208 OZ-5S06 51.01
He 50 75 OS-B215 1.S9slze lmmJ ‹mm) Order code eBoh
1ength length *•• w sz ss az-sz1y 1.eo
Siza fmm) (mm) Order cade oach +@ 66 100 02-3214 1.94
2.03 ’I +
The drills are supplied in metric and imperial sizes. Long series drills are supplied in metric sizes from 1mm to 22mm, the imperial sizes are supplied from 1/16” to1”. The graduations between sizes vary, see the attached data sheet for exact diameters. These existing sizes should be considered in the new design.
Drill lengths vary depending on the drill diameter. See the attached data sheet for long series drill lengths. The customer has asked that the existing drill lengths be maintained.
The existing drills are made from HSS (high speed steel). The same material or a harder material should be considered if the improved product is a modified drill.
BS 328 PART 1 Drills and Reamers Part 1: Specification for Twist Drills ISO 494:1975 Parallel shank twist drills - Long series
ISO 3291:1995 Extra-long Morse taper shank twist drills
ISO 10899:1996 High-speed steel two-flute twist drills -- Technical specifications
The new design must still fit in a standard drill chuck or morse tapers (No.1 to No.5). Also it should still fit in existing drill sharpening machines.
In the existing drill the coolant is able to reach the cutting edge to provide cooling and lubrication. The new design should be no different.
The swarf must be constantly removed with no blockage. If the swarf builds up in the flutes then jamming can occur and this may result in the breaking of the drill.
The new design must be able to drill the hole in one operation, removing the need for peck drilling.
The operating environment will be the same as the existing drills. An industrial environment, where production rate is of paramount importance. The drill will be used repeatedly for long periods of time.
Maintenance of the drills will be limited to sharpening. This is usually achieved by placing the drill in a drill sharpener.
The new drill price must be comparable to the existing drills. To achieve this, research should be carried out on modern cost effective manufacturing techniques
Product Design Specification
possible markets (e.g. general public, armed forces, businesses etc.)
2 related specifications (e.g. British Standards, Codes of Practice, etc.)
3 maintenance programmes / spares (e.g. availability)
4 safety (e.g. fail safe devices / guards)
5 maximum price (e.g. selling / manufacture)
6 overall size, i.e. dimensions
7 power supply (e.g. battery, mains, generator)
8 appearance, ergonomics, style, surface finish, etc.
9 operating environment (e.g. temperature, corrosion, fatigue etc.)
10 working schedule (e.g. prototype, completion dates)
11 testing procedures (e.g. prototype tests, inspection)
14 noise levels
15 life – span
Writing a Product Design Specification (P.D.S.)
Specifications are a means of communicating information from one person to another in a clear and concise form. This invariably involves the use of the written word, engineering drawings and sketches. Writing a specification is the best way of clarifying your ideas, and updating the specification regularly, will ensure that you remain on the required route as the project progresses. The specification is a statement of the characteristics that a design must possess in order to be a solution to an identified need.
A specification is essentially a means of communicating the needs or intentions of one party to another.
It may be a user’s description to designer, of his / her requirements for purpose or duty. It may be a designer’s description to a manufacturer, of an embodiment of these requirements.
It may be a manufacturer’s detailed description to her / his operator, of the components, materials and manufacturing methods to be employed.
It may be a statement by a vendor describing suitability for a purpose to satisfy a need of a user or potential user. It may of course, be some, or all of these.
Writing a P.D.S.
In a specification certain items will be quantifiable, i.e. obtained by calculation, e.g. power, size, pressure, load, maximum temperature, etc.
These include factors such as: potential market, appearance of product.
These include: safety standards, user skill, service requirements.
1 possible markets (e.g. general public, armed forces, businesses etc.)
8 maintenance programmes / spares (e.g. availability)
9 safety (e.g. fail safe devices / guards)
10 maximum price (e.g. selling / manufacture)
11 overall size, i.e. dimensions
12 power supply (e.g. battery, mains, generator)
8 appearance, ergonomics, style, surface finish, etc.
16 working schedule (e.g. prototype, completion dates)
17 testing procedures (e.g. prototype tests, inspection)
20 noise levels
21 life – span
PDS Example Layout
Title: Flux Capacitor in DeLorean
Foreword I have always been interested in time travel and finally, I have the opportunity to design and develop a prototype time travel machine.
Scope of Specification: The machine must be a form of vehicle, as it is required
to travel at speeds in excess of 88 mph in order to warp time and thus achieving time travel. Using an aluminium chassis (based on Audi design) a turbo diesel fuel injected 98 cylinder engine will be obtained from a scrap yard and mounted to the chassis with connections to the flux capacitor. The flux capacitor will be manufactured from a specialist titanium alloy and engineering drawings will be produced prior to manufacture. The flux capacitor will have 1000 000 field windings thus allowing for high levels of induced magnetic flux.
Definitions: Flux Lines of force caused by a magnetic field.
Capacitor: An electrical component that stores a charge.
Space-Time Continuum: The connection between
space and time.
Unified Field Theory: Combination of all known forces
Theory of Relativity: States that: in order for time travel to occur, it would be necessary to travel faster than the speed of light.
Wormholes: Randomly occurring gateways through space and time.
Quantum Leaps: The movement of electrons when quantum energy is released.
Possible Markets: This product would attract attention from scientists and
historians wishing to verify events that have occurred and gain a better understanding of why they happened. The general public may also wish to use this to visit their families in the past. Schools would use this as a teaching aid (source: Bill and Ted’s Excellent Adventure).
Related Specifications: This product already will have to confirm to
Maintenance: The flux capacitor will have to be regularly maintained and replaced every 1000 years of time travel. Availability of parts will be restricted due to the delicate nature of time travel.
Safety: Auto-return and cloaking devices will be mandatory in all vehicles, as this type of technology will have to be kept away from scientists in the past. After a specified period of time has elapsed, the vehicle will return with the traveller.
Maximum Price: Prices for this product will be in the region of £6
million, but by the year 2006, they will have dropped to around £99.95. Government grants are to be made available to interested parties (subject to status), this product will also be available for rent.
Overall Dimensions: The overall dimension will be 350 mm ´ 250 mm ´ 25 mm.
Power Supply: The power source will be renewable and makes use of recycled garbage to act as fuel. H2O, in the form of steam, will be the only by-product and as such, the engine will be classified as environmentally sound
Appearance Appearance: non applicable, the object is purely functional.
Ergonomics Ergonomics: non applicable.
Operating The product in its operating environment would be affected by
Environment: ‘time corrosion’ and ‘temporal pressures’, however, the chassis will prevent any damage to the flux capacitor.
Work Schedule: The prototype will be completed by the end of 2005 and go into mass production by 2006. Please refer to Gantt Chart.
Testing: The testing procedures for the product will be based on British Standard BS 2364; Temporal and Time Distortions Vehicles Mandatory Criteria (TATMAC).
Performance: Performance of this product will mean that it has to be
able to travel 64 million years in either direction (past or future), at speeds no greater than 186 299 miles per second with only minor services after every 3000 miles.
Weight: Weight is an important consideration and must be kept as low as possible because as the speed of light is approached, the mass of the vehicle will increase. The flux capacitor therefore, will be manufactured from the lightest possible materials in order to keep weight at a minimum.
Noise Levels: Noise production levels from the vehicle will not be problematic as the component utilises anti-sound generators, similar to Stealth Bombers, approximately Db » – 0 .5 (this sounds like hmmmmmmmm).
Life Span: As mentioned previously, the life span of the flux capacitor is that of 1000 years of time travel at which time it will need to be replaced.
Drill Related Definitions
Axis: The imaginary straight line which forms the longitudinal center line of the drill
Back Taper: A slight decrease in diameter from front to back in the body of the drill Body: The portion of the drill extending from the shank or neck to the outer corners of the cutting lips
Body Diameter Clearance: That portion of the land that has been cut away so it will not rub against the walls of the hole
Built-Up Edge: An adhering deposit of nascent material on the cutting lip or the point of the drill
Cam Relief: The relief from the cutting edge to the back of the land, produced by a cam actuated cutting tool or grinding wheel on a relieving machine
Chip Breaker: Nicks or Grooves designed to reduce the size of chips; they may be steps or grooves in the cutting lip or in the leading face of the land at or adjacent to the cutting lips Chip Packing: The failure of chips to pass through the flute during cutting action
Chipping: The breakdown of a cutting lip or margin by loss of fragments broken away during the cutting action
Chisel Edge: The edge at the end of the web that connects the cutting lips
Chisel Edge Angle: The angle included between the chisel edge and the cutting lip, as viewed from the end of the drill
Clearance: The space provided to eliminate undesirable contact between the drill and the workpiece
Clearance Diameter: The diameter over the the cut away portion of the drill lands
Core Drilling: Core drills are 3- and 4-fluted cutters used to enlarge previously drilled core or pierced holes.
Counter Bore: Used to enlarge a portion of a cylindrical bore hole.
Counter Sink: A cutter that makes a cone-shaped enlargement at the end of the hole. Crankshaft or Deep Hole Drills: Drills designed for drilling oil holes in crankshafts, connecting rods and similar deep holes; they are generally made with heavy webs and higher helix angles than normal
Cutter Sweep: The section formed by the tool used to generate the flute in leaving the flute Deep Hole Drilling: Any hole longer than four times its diameter is considered a deep hole. Double Margin Drill: A drill whose body diameter clearance is produced to leave more than one margin on each land and is normally made with margins on the leading edge and on the heel of the land
Drift: A flat tapered bar for forcing a taper shank out of its socket
Drift Slot: A slot through a socket at the small end of the tapered hole to recieve a drift for forcing a taper shank out of its socket
Drill Diameter: The diameter over the margins of the drill measured at the point
Exposed Length: The distance the large of a shank projects from the drive socket or large end of the taper ring gage
Flat (Spade) Drill: A drill whose flutes are produced by two parallel or tapered flats
Flutes: Helical or straight grooves cut or formed in the body of the drill to provide cutting lips, to permit removal of chips, and to allow cutting fluid to reach the cutting lips
Flute Length: The length from the outer corners of the cutting lips to the extreme back end of the flutes; it includes the sweep of the tool used to generate the flutes and, therefore, does not indicate the usable length of the flutes
Gage Line: The axial position on a taper where the diameter is equal to the basic large end diameter of the specified taper
Gun Drill: Special purpose straight flute drills with one or more flutes used for deep hole drilling; they are usually provided with coolant passages through the body; they may be either solid or tipped
Half-Round Drill: A drill with a transverse cross-section of approximately half a circle and having one cutting lip
Heel: The trainling edge of the land
Helical Flutes: Flutes which are formed in a helical path around the axis
Helix Angle: The angle made by the leading edge of the land with a plane containing the axis of the drill
Land: The peripheral portion of the body between adjacent flutes
Land Width: The distance between the leading edge and the heel of the land measured at a right angle to the leading edge
Lead: The axial advance of a leading edge of the land in one turn around the circumference Lips: The cutting edges of a two flute drill extending from the chisel edge to the periphery Lip Relief: The axial relief on the drill point
Lip Relief Angle: The axial relief angle at the outer corner of the lip; it is measured by projection into a plane tangent to the periphery at the outer corner of the lip
Margin: The cylindrical portion of the land which is not cut away to provide clearance Multiple-Margin Drill: A drill whose body diameter clearance is produced to leave more than one margin in each land
Neck: The section of reduced diameter between the body and the shank of a drill Oil Grooves: Longitudinal straight or helical grooves in the shank, or grooves in the lands of a drill to carry cutting fluid to the cutting lips Oil Holes or Tubes: Holes through the lands or web of a drill for passage of cutting fluid to the cutting lips
Overall Length: The length from the extreme end of the shank to the outer corners of the cutting lips; it does not include the conical shank end often used on straight shank drills, nor does it include the conical cutting point used on both straight and taper shank drills Periphery: The outside circumference of a drill
Peripheral Rake Angle: The angle between the leading edge of the land and an axial plane at the drill point
Pilot: A cylindrical portion of the drill body preceding the cutting lips; it may be solid, grooved, or fluted
Point: The cutting end of a drill, made up of the ends of the lands and the web; in form it it resembles a cone, but departs from a true cone to furnish clearance behind the cutting lips Point Angle: THe angle included between the cutting lips projected upon a plane parallel to the drill axis and parallel to the two cutting lips
Relief: The result of the removal of tool material behind or adjacent to the cutting lip and leading edge of the land to provide clearance and prevent rubbing (heel drag)
Shank: The part of the drill by which it is held and driven
Socket: The tapered hole in a spindle, adaptor, or sleeve, designed to receive, hold, and drive a tapered shank
Step Drill: A multiple diameter drill with one set of drill lands which are ground to different diameters
Straight Flutes: Flutes which form lands lying in an axial plane
Tang: The flattened end of a taper shank, intended to fit into a driving slot in a socket Tang Drive: Two opposite parallel driving flats on the extreme end of a straight shank Taper Drill: A drill with part or all of its cutting flute length ground with a specific taper to
produce tapered holes; they are used for drilling the original hole or enlarging an existing hole
Taper Square Shank: A taper shank whose cross section is square
Web: The central portion of the body that joins the lands; the extreme end of the web forms the chisel edge on a two-flute drill
Web Thickness: The thickness of the web at the point, unless another specific locationis indicated
Web Thinning: The operation of reducing the web thickness at the point to reduce drilling thrust
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