MINOR PROJECT

Design and Fabrication of Square Hole Drilling Machine

ABSTRACT
The mechanical design and of a square hole producing tool based on Reuleaux Triangle. The main aim of our
papaer is to investigate how the circular motion can be converted into a square motion by purely a mechanical
linkages; an application of which is to construct a special tool that drills exact square holes. The geometrical
construction that fulfils the laid objective is Reuleaux Triangle . Additionally, for this geometry to work like a
rotating drive (such as a drill press) must force the Reuleaux triangle to rotate inside a square, and that
requires a square guide to constrain the Reuleaux triangle as well as a special coupling to describe the fact that
the center of rotation also in moves within in the constrain. The practical importance of this enhancement is
that the driving end can be placed in a standard drill press; the other end is restricted to stay inside the fixed
square, will yield a perfectly square locus and this can be turned into a working square-to drill hole.
Keywords – Reuleaux , Eccentricity ,Drilling , Geometry
 I. INTRODUCTION
Hole serves various purposes in all machine elements. These holes may be round, square, rectangular or any other
shape depending on the requirement or design. For circular holes, the machines are available in the market. But for
square or any other type of holes, the Methods currently used are broaching, electrode-discharge machine
(E.D.M.), and electro-chemical machine. These are very much expensive and require special tools or machines.
The reuleaux triangle is one example of a wide class of geometrical discovery by germam mechanical engineer
Franz Reuleaux , discussed the famous curvy triangle that is started being used in numerous mechanisms Watts
Brother Tool Works[1]. Although Franz Reuleaux was not the first to draw and to consider the shape formed from
the intersection of three circles at the corners of an equilateral triangle .But the use of this curve and its special
properties for producing polygonal holes was given by Sir James Watts in 1914 and the geometry has been
constantly evolving from day to day exactly reproduce the square in which it revolves. The Reuleaux Triangle is
example of a wide classes of geometrical discoveries like Mobius strip that did not find many practical
applications until relatively late in humankind‟s intellective development. Not until around 1875, when the
distinguished German mechanical engineer Franz Reuleaux discussed the famous curvy Reuleaux triangle, that it
started being used in numerous mechanisms by Watts Brothers Tool Works[1].

I.I Problem statement

In this context, The technique utilizes rotating curvilinear tools for sinking regular and non-regular polygonal
cavities with sharp corners, Wire EDM is also used if broaching is not practical and it gives good quality result
with excellent surface finish, but every operations has its limitation and advantages. If the thickness criteria is not
allowed to control the process and still the blind one take square hole is required, then this gives the limit of these
operations. Thus there should be a tool which can directly provide the required cutting and is attachable to present
manufacturing equipment‟s with ease and accuracy. If such a tool is readily available and is economical to use, it
will definitely affect directly or indirectly in a positive way for machining industries and also to the customers.

I.II Scope
The scope of this paper is to machine the tool with three cutting edge and to select suitable material to
machine all surfaces , by connecting tool holder at end of RT. With options to replace the tool of various sizes
and can machine square hole of varying sizes .
The Polygonal holes made by drilling instead of broaching are better in different ways.

1.) If holes are drilled rather than Broached or press worked then stronger and better components can be
made.
2.) Broaching is practical if huge quantities of components are required. So Drilling is advantageous as small
quantities can be manufactured economically and efficiently.
3.) There is no need of Broaching undercuts and also the hole have a flat unimpeded ends.

I.III Result expected

Other method, to generate square hole is quite time consumable and costly. With development of Square
hole Drilling Machine, it simplify machining square hole at low cost and time.Machine is compact in size, which
provides flexibility to produce square holes with low manufacturing cost.This prototype can prove that square
hole can be generated by using Reuleaux triangle and universal joint arrangement.

III.METHODS
The following equations will explain the phenomena correctly, Let us take an equilateral triangle of side
„S‟ as shown in the figure. In the right angled triangle ACR [1],
AC= S
AR= 0.5
CR=
Considering ∆ACR,
AP= = 0.577 S
Considering Reuleaux triangle,
BP= S−AP = S − (0.577 s) = 0.423×S

Figure 1. Reuleaux triangle

[2]The geometric centroid does not stay fixed, nor does it move along a circle. In fact, the path consists of a curve
composed of four arcs of an ellipse. For a bounding square of side length, the ellipse in the lower-left quadrant has
the parametric equations.

x …………………..(1)

y= …………………….(2)

IV .WORKING PRINCIPLE
The main idea for manufacturing a special tool for fulfilling the laid objectives is to make a mechanism
which will transform the rotational motion of a shaft about its longitudinal axis to revolving motion around the
same axis in a given profile which is confined by four governing ellipses at each corner ,having their centre at the
vertices of confining square which will guide the tool in confined profile keeping the rotation intact. This will lead
to the cutting of the square geometry as required for the purpose. The rotation of tool with the same rpm as that of
the chuck , which is necessary to overcome a large amount of force to cut a metallic component. Revolution
becomes an integral part so the Reuleaux triangle centre is not fixed and it has to moved in a profile which is made
by those four ellipses. After following the basic principles a need arises to put the components together without
compromising the working of each components [2].
 V. DESIGN

Figure 2. Model of square hole drilling machine

V.I Reuleaux triangle

Side of equilateral triangle to construct reuleaux triangle is taken as S= 25mm. From one edge to centre of
RT =14.44mm Length of arc from each edge (width of RT) = 25 mm

Thickness of RT , t =20mm Area OF RT= =

439.98 mm2

Figure 3. construction of RT in solidworks

a. Reduce the overall cost of manufacturing a product by producing acceptable parts at lowest costŠ
b. Increase the production rate by designing tools that will make the parts as quickly as possible and maintain
quality by designing tools which will consistently make the parts with the required precision and accuracy.
c. Reduce the cost of special tooling by making the designs cost effective and efficient as possible.
d. Design tools that will be safe and easy to operate
 Figure 4. Cutting tool and RT

iii) Universal joint

Universal joint is used to connect two shafts at an angle for transmitting torque. The centre of RT must
rotate itself and also revolves in a noncircular path ,by using universal joint RT can revolve in noncircular path.
coupling or joint which can transmit rotary power by a shaft at any selected angle, coupling in a rigid rod that
allows the rod to 'bend' in any direction, and is commonly used in shafts that transmit rotary motion. It consists of a
pair of hinges located close together, oriented at 90° to each other, connected by a cross shaft. The universal joint is
not a constant-velocity joint.

iv) Drilling Machine

To provide rotating motion to RT and tool ,the impact drill is used .The end of universal jont is
connected to tool holder of drilling machine. The spindle speed is constant for all operations, while the cutting
speed varies all along the cutting edge. Cutting speed is normally computed for the outside diameter. The center of
the chisel edge the cutting speed is zero; at any point on the lip and it is proportional to the radius of that point.
This variation in cutting speed along the cutting edges is an important characteristic of drilling.

VIII. RESULT & DISCUSSION

The tool developed is approximately 250 mm in length and it is slightly heavy with approximate weight of
3kg. The cutting tool after proper assembly and installation is found to be accurate up to 90 %. That is, it is able to
cut a square profile with approximately 90% area of the original square with same dimensions as that of the cutting
tool. The remaining 10% which is not cut is present on the four corner of the square in an arc form. Working of the
present tool is done on cardboard sheet. It is not employed on the workshop material as it is made with mild steel as
the base material. So it does not have the required hardness to be able to check on market materials.The main aim is
to observe the feasibility of the mechanism in fulfilling the required motion and to check its employment with a
cutting tool for producing the square of its size. The first aim has been fulfilled as desired and success of about 80 %
has been achieved in the secondary goal. In the future studies, the tool will be studied in detail and required
modifications shall be provided thus there are certainly chances of 100% success rate.
 IX. CONCLUSION
Fabricated square hole drilling machine and it is found that it is capable of drilling square holes on various
wooden materials (pre-drilling is essential).The project is simple in construction and compact in size for use. With
less installation cost and less labour skill square holes can be drilled using this arrangement, hence it can be used in
small scale industries. The future scope of project is to clamp the machine on bench drill to obtain constant working
feed and also the size of drill bit can be made compact using Oldham coupling instead of universal joint.