Al-Quds University
Faculty of Engineering
Dual studies
Industrial Engineering Department
Industrial Workshop II
Manuscript
(1840108)
Prepared by:
Dr. Tarek Abu Leil
2024-2025
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Introduction about Industrial Workshop II
Safety
This manual serves as a comprehensive guide to ensure safety, efficiency, and competent
practices during industrial workshop 2. The students should read and follow all instructions
carefully during this workshop.
1) Rules and Safety Guidelines
1-
The students should wear suitable personal protective equipment, including gloves,
safety goggles, and safety shoes.
2-
It is very important to keep a clean and organized workspace to prevent industrial
accidents in the workshop.
3-
The students should follow all fire and emergency rules as mentioned in the facility.
4-
It is very important to ensure all tools and machinery are properly shut down and
collected and stored after operation.
2) Equipment Handling Use
1-
Before using any machine, please read and understand the operational manual for
each piece of it.
2-
At the beginning of each experiment only the technician can only operate heavy
machinery like lathe, milling, cutting or bending equipment.
3-
To prevent any damage or personal injury, please always use the correct tools for
specific tasks.
3) Workshop Layout and Organization

The student, technician, and the supervisor should keep designated walkways, and
emergencies always exist clearly.

The technician labeled all tools and equipment appropriately for easy identification
for the students.

The technician stored hazardous materials in designated areas with proper labeling.
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
The students should dispose of waste materials following environmental and safety
regulations.
4) Emergency Procedures
1-
In case of fire, the student should use the nearest extinguisher and follow evacuation
procedures.
2-
If it is possible, report all injuries to the designated first aid personnel.
3-
Follow lockout actions when checking machinery.
5) Quality Control and Excellent Practice
1-
Follow standard operating procedures to ensure consistent output quality.
2-
Double-check measurements and specifications before commencing work.
3-
Maintain documentation of all completed tasks for reference and compliance.
4-
Encourage teamwork and communication to improve workflow efficiency.
6) Conclusion
Using the guidelines mentioned ensures a safe and productive working environment.
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Experiment (2)
Objectives
1. To conduct drilling processes on different material types.
2. To analyze the impact of spindle speed on the required drilling force.
3. To determine the drilling force required for various materials under constant spindle speed.
4. To assess the safety considerations during the drilling process, ensuring proper protective
measures and minimizing risks.
5. Introduction
The process of drilling Drilling is a cutting process to make holes of circular cross
section by using drill bit and it is one of the important machining processes having vast
application.
Figure 1: Drilling of a hole.
Twist drill bits are the most common type of drill bits, used for everyday drilling in various
materials. However, they can be confusing due to the wide range of sizes, tip designs, and
materials they are made from.
Figure 2: Twist Drill.
Twist drills have a tapered shank that fits into a matching tapered sleeve in the drilling
machine, allowing rotation through friction. They feature two cutting lips with an angle of
118°, and the chips are automatically guided through helical grooves (flutes) to prevent
interference during drilling. The performance of the drill depends on its geometric design, as
its dimensions affect drilling forces, cutting dynamics, and tool wear.
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Figure 3 illustrates the common operations closely associated with drilling. Several types of
drilling machines are used for drilling operations, such as the radial drilling machine, as
shown in Figure 4.
.
Figure 3: Common operations closely associated with drilling.
 Core Drilling:
This operation is used to create holes in castings using cores, which are rough
and require a special kind of drill called a core drill to clean the holes.
 Step Drilling:
More than one diameter can be ground on the drill body, which saves an
additional operation.
 Counter Boring:
Often, a flat surface is needed around a hole to provide a good seating area for
washers and nuts/bolthead. The counterboring tool has a pilot that ensures the
counterbore is concentric with the hole.
 Counter Sinking:
This operation is used to prepare a hole that allows bolts or screws to sit flush
with the surface, ensuring the bolt head is recessed into the material.
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Figure 4: Radial drilling machine
The radial drilling machine is used for drilling holes in large and heavy workpieces that
cannot be moved. The drilling head is mounted on a radial arm that can be moved vertically
and horizontally around a round column, allowing drilling at any point on the workpiece
without shifting it. It is ideal for drilling, counterboring, reaming, and tapping large, heavy
parts.
1. Base: Made of cast iron for high compressive strength and wear resistance, it supports
the assembly and absorbs vibrations.
2. Column: Located at the bed's end, it supports the radial arm and enables 360° rotation.
3. Radial Arm: Connected to the column, it slides along guideways to move the drill head.
4. Motor: Mounted on the drill head to drive the spindle.
5. Table: The machine vice is mounted on a swivel table to hold the workpiece.
6. Handwheel: Connected to the spindle, it moves the workpiece vertically down.
7. Drive Head: Consists of two levers that adjust the speed of the chuck.
8. Chuck: One end is connected to the spindle and the other to the drill bit.
9. Tool-Drill Bit: Used to drill holes in the workpiece.
10. Workpiece: Fixed in the machine vice on the table.
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Types of Materials Used
In this experiment, drilling operations were performed on different types of materials to study
their behavior during machining. The materials include:
6. Procedures
1. Perform the drilling operation for different types of materials (wood, steel,
aluminum) at a constant speed of rotation.
2. Measure the time required for each drilling operation.
3. Repeat the process while changing the speed of rotation.
7. Data Analysis
Type of material
Group
speed
(%)
Aluminum
1
200m/s
13.75s
Aluminum
1
500m/s
6.25s
Brass
2
200m/s
4.25s
Brass
2
500m/s
4.5s
Steel
3
200m/s
19.5S
Steel
3
500m/s
7.2S
Wood
4
200m/s
1s
Wood
4
500m/s
1.66s
Table 1:Speed of Materials and Response Time at Different Speeds
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 the Aluminum drilling process
analyze the data from the aluminum drilling process using two different speeds (200rpm and
500rpm) and discuss the effect of rotational speed on the drilling time, as well as the effect
of the material type on the force required for drilling.
Data and Observations
The experiment was conducted on two aluminum samples with different specifications
Initial Observations:
 The drilling time decreased by 54.5% when the speed increased from 200rpm to
500rpm.
 There is a slight difference in the dimensions of the samples between the two teams,
but the greater effect is attributed to the rotational speed.
Effect of Rotational Speed on Drilling Time
Aluminum (Aluminum):
 Slow Speed (200rpm): Average time = 13.75 seconds.
 Fast Speed (500rpm): Average time = 6.25 seconds.
 Conclusion: Increasing the speed significantly reduces the time due to the increase in
the Material Removal Rate (MRR).
Effect of Material Type on Drilling Force
 Relatively low drilling force due to its softness.
 Higher speed reduces the time without requiring much force.
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 The Wood Drilling Process
we analyze the data from the wood drilling process using two different speeds (200rpm and 500rpm),
and discuss the effect of rotational speed on drilling time, while comparing the results with other
metals such as aluminum and brass
Data and Observations
The experiment was conducted on two wood samples with different specifications:
Initial Observations:
 The drilling time decreased by 40.5% when the speed increased from 200rpm to
500rpm.
 There is a slight difference in the dimensions of the samples between the two teams,
but the major effect is attributed to the rotational speed.
 Wood requires significantly less time compared to aluminum due to its softness...
Effect of Rotational Speed on Drilling Time

Wood:
 Slow Speed (200rpm): Average time = 1 second.
 Fast Speed (500rpm): Average time = 0.595 seconds.
 Conclusion: Increasing the speed significantly reduces the time due to the ease of
chip removal in wood.
Comparison with Other Materials:

Aluminum: Time is higher due to the hardness of the metal.
Effect of Material Type on Drilling Force
 Very low drilling force required due to the softness of the material.
 Higher speed reduces the time without requiring much force.
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 The Brass Drilling Process
we analyze data from the brass drilling process using two different speeds (200rpm and
500rpm), and discuss the effect of rotational speed on drilling time, while comparing the
results with other materials such as aluminum and wood.
Data and Observations
The experiment was conducted on two brass samples with different specifications:
Initial Observations:
 A slight increase in time at the higher speed (500rpm) compared to the slow speed
(200rpm), unlike what was observed with aluminum and wood.
 There is a slight difference in the dimensions of the samples between the two teams,
but it does not explain the increase in time.
Effect of Rotational Speed on Drilling Time
 Brass:
 Slow Speed (200rpm): Average time = 4.25 seconds.
 Fast Speed (500rpm): Average time = 4.5 seconds.
 Conclusion: Increasing the speed did not reduce the time, but instead caused a
slight increase, suggesting that brass may be affected by heat buildup or chip
adhesion at higher speeds
Comparison with Other Materials:


Aluminum: Significant decrease in time with increased speed.
Wood: Significant decrease in time with increased speed.
Effect of Material Type on Drilling Force
 Moderate drilling force due to its intermediate softness.
 May require effective cooling at higher speeds to prevent chip adhesion.
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 The Steel Drilling Process
we analyze the impact of two different rotational speeds (200rpm and 500rpm) on the steel
drilling process, examining the drilling time, hole depth, and process stability.
Data and Observations
The experiment was conducted on two steel samples with the following specifications:
Initial Observations:
 A 62.8% reduction in time when increasing the speed from 200rpm to 500rpm.
 The whole depth increased from 5mm to 7mm at higher speeds.
 Stability improved with a lower standard deviation (0.19 vs. 2.36).
Effect of Rotational Speed on Drilling Time

Steel:
 Slow Speed (200rpm): Average time = 19.5 seconds.
 Fast Speed (500rpm): Average time = 7.255 seconds.
 Conclusion: Faster speeds significantly reduce drilling time and improve hole depth.
The improvement is partly due to the increased Material Removal Rate (MRR).
Comparisons with Other Materials:


Aluminum: Drilling time was 40% shorter for aluminum compared to steel.
Brass (Copper): Steel responded better to increased speed than brass, showing a more
stable time reduction.
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Drilling Force Calculation Formula:
We use the mechanical force equation related to friction during drilling:
Where:
 F is the drilling force (Newtons).
 τ is the frictional resistance (Newtons per square meter).
 A is the cross-sectional area of the drill bit.
Calculating the Area:
Since the drill bit has a diameter d=6 mm , the cross-sectional area of the drill bit is the area
of a circle, calculated as:
Frictional Resistance Assumptions:
Now we can use approximate values for the material's frictional resistance (which depends
on the material type). Typically, these values are approximate:

Wood: Low resistance (0.3-0.5 N/mm²)

Brass: Medium resistance (0.7-1.0 N/mm²)

Aluminum: Medium resistance (1.0-1.2 N/mm²)

Steel: High resistance (1.5-2.0 N/mm²)
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Drilling Force Estimates:
Example 1: Wood (Resistance 0.5 N/mm²)
Example 2: Brass (Resistance 1.0 N/mm²)
Example 3: Aluminum (Resistance 1.1 N/mm²)
Example 4: Steel (Resistance 2.0 N/mm²)
Conclusion:
Based on these calculations, we observe that steel requires the greatest drilling force due to
its high resistance, while wood requires the least drilling force. This estimation helps
understand the relationship between material resistance and drilling force.
You can include these calculations and explanations in your report for a clearer
understanding of how material resistance impacts the drilling process.
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Results and Discussion
The results obtained from the drilling experiments highlight the impact of drilling speed on
the average drilling time for different materials. The data and charts provided allow for trend
analysis and help in determining the difficulty of drilling each material at different speeds, as
well as the effect of material resistance on the process.
1.Effect of Speed on Drilling Time
The results indicate that increasing the drilling speed from 200 RPM to 500 RPM generally
reduces the drilling time for all materials. This is clearly shown in the charts, where drilling
time is shorter at higher speeds. This effect is due to the increased material removal rate at
higher speeds, which significantly improves cutting efficiency.
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‫‪:‬ليك الترجمة مع إضافة مالحظات مبسطة‬
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Notes on Drilling Process in Brass Material (Speed 200 RPM)
I noticed during the drilling process in brass material at 200 RPM that:
1. Material: Brass has a medium friction resistance, so it was easier to drill compared to
harder materials.
2. Drilling Speed: 200 RPM was a suitable speed for stable drilling, and I didn’t
encounter major issues during the process.
3. Drill Size: I used a 6 mm diameter drill bit as calculated earlier.
4. Results: The drilling process went smoothly with moderate force required, and there
were no major issues like slipping or excessive wear.
Additional Notes:



The drilling process felt consistent, and the material did not cause too much
resistance.
There was minimal heat buildup, suggesting that the speed was optimal for this
material.
I did not notice any significant deformation or damage to the brass during drilling.
This version provides clear and simple observations from your experience while keeping it
relatable and straightforward.
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