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IS 7778-1 (2003): Small Tools Sampling InspectionProcedures, Part 1: Twist Drills, Countersink andCounterbores [PGD 32: Cutting tools]

IS 7778 (Part 1) :2003

dl-23hTliHr~mmmhfam

Indian Standard

SMALL TOOLS SAMPLING INSPECTIONPROCEDURES

PART 1 TWIST DRILLS, COUNTERSINK AND COUNTERBORES

(First Revision )

ICS 25.100.30

0 BIS 2003

BUREAU OF INDIAN STANDARDSMANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG

NEW DELHI 110002

. ——

January 2003 Price Group 3

Drills, Reamers and Threading Tools Sectional Committee, BP 10

...—

FORE WORD

This Indian Standard (Part 1) (First Revision) was adopted by the Bureau of Indian Standards, after the draftfinalized by Drills, Reamers and Threading Tools Sectional Committee had been approved by the Basic andProduction Engineering Division Council.

This standard was first published in 1975. In the light of experience gained over the years, in this revisionfollowing changes have been incorporated:

a) Definition of various terminologies used in the standard have been aligned with the practice followed

at 1S0 level,

b) Scale of sampling and criteria of conformity have been modified,

c) Classification of non-conformities for various type of cutting tools have been updated, and

d) To cater the specific need of the different industries and to make this standard.user friendly, thisstandard has been splitted in 11 Parts for easy adoption/acceptance and guide updation.

This standard has been prepared based on prevalent practice and experience available in the Indian Industries.While formulating this standard considerable assistance has been derived from IS 2500 (Part 1) :2000 ‘Samplinginspect ion procedures: Part 1 Attribute sampling plans indexed by acceptable quality level (AQL) for lot-by-lotinspection (third revision)’. IS 7778 ‘Small tools sampling inspection procedures’ is now being published in! I Parts. Other parts of the standard are given below:

Part 2Part 3Part 4Part 5Part 6Part 7Part 8Part 9Part 10

Part I 1

Reamers

Sleeves, sockets and adaptorsScrewing taps, dies and knurling toolsMilling cuttersMilling arbors and accessories

Gear cutting tools and broachesSawsSingle point (HSS and carbide tipped) tools

Carbide tips and indexable insertsHard metal burrs

IS 7778 (Part 1): 2003

Indian Standard

SMALL TOOLS SAMPLING INSPECTIONPROCEDURES

PART 1 TWIST DRILLS, COUNTERSINK AND COUNTERBORES

(First Revision )

1 SCOPE

This standard (Part 1) specifies sampling plans and

procedures for twist drills, countersink andcounterbores submitted for inspection in lots.

2 REFERENCES

The following standards contain provisions whichthrough reference in this text, constitute provisions ofthis standard. At the time of publication, the editionsindicated were valid. All standards are subject torevision and parties to agreements based on thisstandard are encouraged to investigate the possibilityof applying the most recent editions of the standardsindicated below:

IS No. Title

2500 (Part 1) : Sampling inspection procedures:2000 Part 1 Attribute sampling plans

indexed by acceptable quality level(AQL) for lot-by-lot inspection (third

revision)

4905:1968 Methods for random sampling

3 TERMINOLOGY AND DEFINITIONS

For the purpose of this standard the followingdefinitions shall apply. For terms not defined belowand for other clarifications, reference may be made toIS 2500 (Part 1).

3.1 Defect — A departure of a quality characteristicthat results in a product, process or service notsatisfying its intended normal usage requirements.

3.2 Non-Conformity — A departure of a qualitycharacteristic that results in a product, process orservice not meeting a specified requirement. Non-conformities will generally be established by theirdegree of seriousness, such as:

Class A — Those non-conformities of a typeconsidered to be of the highestconcern for the product or service.In acceptance sampling, such typesof non-conformity will be assignedvery small AQL values.

Class B — Those non-conformities of a type

considered to have the next lower

degree of concern. Therefore these

can be assigned a larger AQL valuethan those in Class A and smaller

than in Class C, if a third class exists.3.3 Non-Conforming Unit — A unit of product orservice containing at least one non-conformity. Non-conforming units will generally be classified by theirdegree of seriousness such as:

Class A — A unit which contains one or more,

non-conformities of Class A and mayalso contain non-conformities of

Class B and/or Class C.Class B — A unit which contains one or more

non-conformities of Class B and mayalso contain non-conformities ofClass C, but contains no non-conformity of Class A.

3.4 Percent Non-Conforming — The percent non-conforming of any given quantity of units of productsis 100 times the number of non-conforming units

divided by the total number of units of products, thatis:

Percent non-conforming

= Number of non-conforming units ~ ~O.

Total number of units

3.5 Acceptable Quality Level (AQL) — When a

continuous series of lots is considered, the quality level

which for the purpose of sampling inspection is a limit

of a satisfactory process average.

3.6 Sampling Plan — A specific plan which indicates

the number of units of products from each lot which

are to be inspected (sample size or series of sample

sizes) and the associated criteria for determining the

acceptability of the lot (acceptance and rejectionnumbers).

3.7 Lot — A collection of units of product from which

a sample shall be drawn and inspected to determine

conformance with the acceptability criteria, and which

may differ from a collection of units designated as a

lot for other purposes (for example, production,

shipment, etc).

.—

1

IS 7778 (Part 1) :2003

3.8 Sample — A sample consists of one or more unit%of product drawn from a lot, the units of the samplebeing selected at random without regard to theirquality. The number of units of product in the sampleIS the sample size.

4 SCALE OF SAMPLING

4.1 All small tools shall be selected at random from alot as per 1S 4905 to ensure randomness of selection.

4.2 Small tools shall be selected and examined foreach lot separately for ascertaining its conformity tothe requirements of the relevant specification.

The number of small tools to be selected from a lotshall depend on the sizes of the lot and type ofsampling plans and shall be in accordance withTables 1, 2 and 3.

5 DETERMINATION OF ACCEPTABILITY

5.1 To determine acceptability of a lot under percentnon-conforming inspection, the single sampling planshall be used in accordance with 5.1.1 for hardnesstest and performance test and the double sampling planshall be used in accordance with 5.1.2 for dimensionaland visual characteristics.

S. 1.1 Single Sampling Plan

The number of sample units inspected shall be equalto the sample size given by the plan. If the number ofnon-conforming units found in the sample is equal toor less than the acceptance number, the lots shall beconsideredconforming

acceptable. If the number of non-units is equal to or greater than the

rejection number, the lot shall be considered notacceptable.

5.1.2 Double Sampling Plan

The number of sample units first inspected shall beequal to the first sample size given by the plan. Ifthe number of non-conforming units found in thefirst sample is equal to or less than the first

acceptance number, the lot shall be considered

acceptable. If the number of non-conforming unitsfound in the first sample is equal to or greater thanthe first rejection number, the lot shall be considered

not acceptable.

If the number of non-conforming units found in thefirst sample is between the first acceptance andrejection numbers, a second sample of the size given

by the plan shall be inspected. The number of non-

conforming units found in the first and second samplesshall be accumulated. If the cumulative number of non-

conforming units is equal to or less than the second’acceptance number, the lot shall be consideredacceptable. If the cumulative number of non-conforming units is equal to or greater than the secondrejection number the lot shall be considered notacceptable.

6 CLASSIFICATION OF NON-CONFORMITY

Non-conformities of various inspection parameters for

HSS twist drills, carbide tipped twist drills andcountersink and counter bore covered under variousIndian Standards have been classified as Class A and

Class B and are tabulated in Tables 4, 5 and 6. .

Table I Scale of Sampling and Criteria for Conformity for Lot Quality for Visual and DimensionalCharacteristics (Double Sampling Plan for Normal Inspection — Inspection Level 111)

SI Lot SizeNo.

=

(1) (2)

i) up to 150

ii)

I

151t0280

iii)

I

281 tO 500

iv) I 501 to i 200

\,) I 201 to 3200

(Clause 4.2)

Y

(3) (4) (5)

First 20 20

Second 20 40First 32 32Second 32 64First 50 50Second 50 100First 80 80Second 80 160First 125 125Second 125 250

2

Non-Conformity

Class A Class BAQL 1.5 AQL 4.0

Ac Re Ac

(6) (7) (8)

o 2 1

1 2 4

0 3 23 4 61 4 34 5 82 5 56 7 123 7 78 9 18

Re

(9)

4

557799131119

.—

-. .-. ...

IS 7778 (Part 1) :2003

Table 2 Scale of Sampling and Criteria forConformity for Lot Quality for Hardness Test

(Single Sampling Plan for NormalInspections -– Inspection Level I)

(Ckmse 4.2)

sl Lot Size Sample Size AQL 1.5No.

Ac Re

(1) (2) (3) (4) (5)—.—i) UP to 280 8 0 1ii) 281 to 1200 32 I 2iii) I 201 to3200 50 2 3

---t

(1) (2)

i) 5100

ii) \ 5101I

=-l--=-—7iv) 5103

I

v) 5104

=--l-==

Tviii) 5362

ix) 5363

=1==

+-xi) 5365

T

Txv)

I

6710

Table 3 Scale of Sampling and Criteria forConformity for Lot Quality for Performance Test

(Single Sampling Plan for RedugedInspection — Inspection Level S-3)

(Clause 4.2)

SI Lot Size Sample AQL 4.0No. Size

Ac Re

(1) (2) (3) (4) (5)

i) up to 150 2 0 1ii) 151t03200 5 0 2

Table 4 Classification of Non-Conformity in Twist Drills

(Clause 6)

Type of Tool Class A Non-Conformity Class B Non-Conformity

(3) (4) (5)

Twist drills, parallel shank, stub Hardness, Drill diameter, Point angle, Flute length, Overall length and

series Backtaper and Run out Helixangle

Twist drills, parallel shank, jobber Hardness, Drill diameter, Performance Flute length, Overall length andseries point angle, Back taper and Run out Helix angle

Twist drills, parallel shank, long Hardness, Drill diameter, Performance Flute length, Overall length andseries point angle, Back taper and Run out Helix angle

Twist drills, morse taper shanks Hardness, Drill diameter, Performance Flute length, Overall length andmorse taper shank, Point angle, Back Helix angletaper and Run out

Twist drills, over size morse tapershank

Twist drills, taper square shanks forratchet braces

Twist drills, taper square shanks forcarpenters braces

Twist drills, parallel shank, stubseries, left hand cutting forautomatics

Micro drills

Hardness, Drill diameter, Morse taper Flute length, Overall length andshank, Point angle, Back taper and Run Helix angleout

Hardness, Drill diameter, Square shank, Flute length, Overall length andPoint angle, Back taper and Run out Helix angle

Hardness, Drill diameter, Square shank, Flute length, Overall length andPoint angle, Back taper and Run out Helix angle

Hardness, Drill diameter, Point angle, Flute length, Overall length andBack taper and Run out Helix angle

Hardness, Drill diameter, Shank Flute length, Overall length anddiameter, Point angle, Back taper and Helix angle

Run out

Twist drills for taper pin holes with Hardness, Drill diameter, Shank Flute length, Overall length andtaper I: 50 diameter, Morse taper shank, Taper Helix angle

angle, Point angle and Run out

Core drills, parallel shank Hardness, Core drill diameter, Run out Flute length, Overall length andand Back taper Helix angle

Core drills, morae taper shank Hardness, Core drill diameter, Morse Flute length, Overall length andtaper shank, Back taper and Run out Helix angle

Centre drills-Type A Hardness, Pilot diameter, Shank Pilot length, Overa[l length anddiameter and Point angle 60° angle

Centre drills-Type B Hardness, Pilot diameter, Shank Pilot length, Overall length, 60°diameter and Point angle and 120° angle and dl diameter

Centre drills-Type R Hardness, Pilot diameter, Shank 1 length, Overall length anddiameter and Point angle Radius

Twist drills for jig boring machines Hardness, Drill diameter, Morse taper Flute length, Overall length andshank and Radial runout Helix angle

3

.—

1S 7778 (Part 1) :2003—

Table 4 (Concluded) —

slNo.

IS No. Type of Tool Class A Non-Conformity

(4)

Class B Non-Conformity

(5)

Length, dz diameter, Drivingslot, Width, Depth and Helixande

(1)

xvii)

(2) (3)

7772 Shell core drills Hardness, Drill diameter, Bore diameterand Runout

Hardness, Drill diameter, Morse tapershank, Runout and Point angle

Hardness, Drill diameter, Shankdiameter. Runout and Point anrzle

Twist drills, morse taper shank, extralong series

Twist drills, parallel shank, extra longseries

Twist drills, morse taper shank, longseries

Sub land twist drills with morse tapershanks for holes prior to tapping screwthreads

Flute length, Overall lengthand Helix arwle

xviii) 7822

7823

8305

12687

Flute length, Overall lengthand Helix ande

xix)

Flute length, Overall lengthand Helix angle

xx)

xxi)

Hardness, Drill diameter, Morse taperkhank, Runout and Point angle

Hardness, Drill diameter, Stepdiameter, Morse taper shank, Runout,Point angle and Countersink angle

Hardness, Drill diameter, Stepdiameter, Morse taper shank, Runout,Point angle and Countersink angle

Flute length, Overall length,Step length and Helix angle

Flute length, Overall length,Step length and Helix angle

xxii)

xxiii)

12688

12689

Sub land twist drills with morse tapershanks for clearance holes andcountersinks for countersunk headscrews

Sub land twist drills with parallelshank for clearance holes andcounterbores for slotted cheese headscrews

Hardness, Drill diameter, Stepdiameter, Shank diameter, Runout andPoint angle

Hardness, Drill diameter, Stepdiameter, Morse taper shank, Runoutand Point angle

Flute length, Overall length;Step length and Helix angle

Flute length, Overall length,Step length and Helix angle

xxiv)

xxv)

12690

1269 I

Sub land twist drills with morse tapershanks for clearance holes andcounterbores for slotted cheese headscrews

Sub land twist drills with parallelshank for holes prior to tapping screwthreads

Hardness, Drill diameter, Stepdiameter, Shank diameter, Runout pointangle and Countersink angle

Hardness, drill diameter, Step diameter,Shank diameter, Runout point angleand Countersink angle

Flute length, Overall length,Step length and Helix angle

Flute length, Overall length,Step length and Helix angle

12692 Sub land twist drills with parallel shankfor clearance holes and countersinks forcountersunk head screws

XXVI)

Table 5 Classification of Non-Conformity in Carbide Tipped Drills

(Clause 6)

S1 No. IS No. Type of Tool Class A Non-Conformity Class B Non-Conformity

(1) (2) (3) (4) (5)

i)I

8306

I

Carbide tipped twist drills morse taper Hardness on shank, Drill diameter Flute length, Overallshanks and Morse taper shank length and Point angle

ii)

i

8307

I

Carbide tipped twist drills parallel Hardness on shank, Drill diameter Flute length, Overallshanks and Shank diameter length and Point angle

iii) 9771 Carbide tipped core drills with morse Hardness on body and tang, Drill Flute length and Overalltaper shanks diameter and Morse taper shank length

4

IS 7778 (Part

Table 6 Classification of Non-Conformity in Countersinks and Counterbores

(Clause 6)

sl IS No.

N(I.

(1) (2)

1) 5693

-1----il) 5703

Iv)

I

5705

7!,) 5710

II

\i) I 3303

-1---vii) 13304

Type of Tool

(3)

Countersinks 90° parallel shank and solidpilots

Countersinks with morse taper shank

Counterbore with parallel shank and solidpilots

Pilots for countersinks and counterbores

Counterbore with morse taper shank

Countersinks 60°, 90° and 120° withmorse taper shank

Countersinks 60°, 90° and 120° withparallel shank

5

Class A Non-Conformity

(4)

Hardness, Cutter diameter,Pilot diameter, Shank diameterand Countersink angle

Hardness, Countersinkdiameter, Morse taper shankand Countersink angle

Hardness, Counterborediameter, Pilot diameter andShank diameter

Hardness, Shank diameter andHead diameter

Hardness, Counterborediameter and Morse tapershank

Hardness and Morse tapershank

Hardness and Shank diameter

Class B Non-Conformity

(5)

Cutting edge length, Shanklength and Overall length

Cutting edge length, Overalllength, dz and d~ diameters andf, and fl lengths

Cutting edge length, Overalllength and Shank length

Head length and Overall length

Cutting edge length, Overalllength, dz and d, diameters and/3 and f,i Iengtbs

Nominal diameter, Smalldiameter, Body length, Overalllengthand Countersinkangle

Nominal diameter, Smalldiameter, Body length, Overalllength and Countersink angle

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This Indian Standard has been developed from Doc : No. BP 10 (0324).

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

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