Professional Documents
Culture Documents
Knee type:
In such small and medium duty machines the table with the job/work
travels over the bed (guides) in horizontal (X) and transverse (Y)
directions and the bed with the table and job on it moves vertically (Z)
up and down.
Bed type:
Usually of larger size and capacity; the vertical feed is given to
the milling head instead of the knee type bed
Planer type:
These heavy duty large machines, called plano-miller, look like
planing machine where the single point tools are replaced by one
or a number of milling heads; generally used for machining a
number of longitudinal flat surfaces simultaneously, viz., lathe
beds, table and bed of planning machine etc.
1 Rotary table type:
2 Such open or closed ended high production milling machines
possess one large rotary work-table and one or two vertical
spindles as typically shown in Fig.; the positions of the job(s)
and the milling head are adjusted according to the size and
shape of the job.
3
According to the orientation of the spindle(s).
Plain horizontal knee type
This non-automatic general purpose milling machine of small to
medium size possesses a single horizontal axis milling arbor; the
work-table can be linearly fed along three axes (X,Y, Z) only; these
milling machines are most widely used for piece or batch production
of jobs of relatively simpler configuration and geometry
Milling Cutters
Milling machines are mostly general purpose and have wide range of
applications requiring various types and size of milling cutters.
Intermittent cutting nature and usually complex geometry necessitate
making the milling cutters mostly by HSS which is unique for high
tensile and transverse rupture strength, fracture toughness and
formability almost in all respects
Tougher grade cemented carbides are also used without or with
coating, where feasible, for high productivity and product quality.
(b) Form relieved cutters – where the job profile becomes the replica
of the tool-form, e.g., viz.;
1 i. Form cutters
2 ii. Gear (teeth) milling cutters
3 iii. Spline shaft cutters
4 iv. Tool form cutters
5 v. T-slot cutters
6 vi. Thread milling cutter
2) Face Milling
Operation performed by a milling cutter to produce a flat surface
perpendicular to the axis of rotation of the cutter
Peripheral cutting edges of cutter do the actual cutting and face cutting
edges finish up the work surface by removing a very small amount of
material
When the cutter rotates through half of the revolution the direction of
movement of cutter tooth is opposite to the direction of feed
Condition reverses when the cutter rotates through other half of the
revolution
Chip thickness is minimum at the beginning & at the end of cut and is
maximum when the work passes through the center line of cutter
3) End Milling
Considered as the combination of peripheral & face milling operation
Cutter has teeth both on the end face & also on periphery
Suitable for pocket milling & slot milling operation
Indexing
Process of dividing the periphery of a work piece into any number of
equal parts
Equal spacing of teeth on the gear blank is performed by indexing
Indexing can be adopted for producing hexagonal and square head of
bolts, cutting splines on shafts, fluting drills etc.
Indexing is accomplished by using a special attachment known as
dividing head or index head.
Dividing head are of 3 types
• Plain or simple dividing head
• Universal dividing head
• Optical dividing head
Indexing methods
• Direct / Rapid indexing
• Plain / Simple indexing
• Compound indexing
• Differential indexing
• Angular indexing
Direct / Rapid indexing
Used when a large number of identical work piece are indexed by very
small divisions
With a rapid index plate having 24 holes, it is possible to divide the
work into equal divisions of 2, 3, 4, 4, 6, 8, 12 and 24 parts.
Rule for direct indexing
To find the index movement, divide the total number of holes in the
direct index plate by the number of divisions required on the work.
No. of holes to be moved = 24 / N [(Number of holes in index plate) /
(Number of divisions)]
(ex.) set the dividing head to mill 30 teeth on a spur gear blank
Index crank movement = 40 / 30 = 1⅓ x 7 / 7 = 1 7/21
Therefore, for indexing, one complete turn and 7 holes in 21 hole
circle of the index plate is to be moved by the index crank.
Compound Indexing
Two separate movements of the index crank in two different hole
circles of one index plate to obtain a crank movement which is not
possible in plain indexing
First movement is performed similar to the plain indexing
Second index movement is performed by removing the rear lock pin
and then rotating the plate together with the index crank forward /
backward through the calculated number of spaces of another hole
circle and then lock pin is engaged.
Effective indexing movement will be the summation of the two
movements
Rule for compound indexing
40 / N = n1 / N1 ± n2 / N2
Where, N – No. of divisions required
N1- Hole circle used by crank pin
N2 – Hole circle used in lock pin
n1 – Hole spaces moved by the crank pin in N1 hole circle
n2 – Hole spaces moved by the plate and crank pin in N2 hole
circle
Differential Indexing
Indexing is obtained by the combination of 2 movements
Movement of the index crank similar to the simple indexing
Simultaneous movement of the index plate when the crank is turned
Rule for differential indexing
Gear ratio = (A – N) 40 / A where ‘A’ is the selected number which
can be indexed by plain indexing and the number is approximately
equal to N.
N is the required number of divisions to be indexed
In the ratio, the nr of fraction indicate driving gears on the index head
spindle and the dr indicate the driven gears on the index plate
Index crank movement = 40 / A
Index crank is to be moved by an amount for N number of times for
complete division of work
Ex. To index 83 divisions
Index crank movement in plain indexing: 40 / N = 40 / 83
Since there is no 83 hole circle, the number cannot be indexed by plain
indexing
Assume A = 86, a number close to 83 and indexed by plain indexing
Gear ratio: (A – N) 40 / A = (86 – 83) 40 / 86
= 3 x 40 / 86
= (72 / 24) x (40 / 86)
Drivers: 72, 40 and Driven: 24, 86
Index crank movement: 40 / 86 = 20 / 43
For complete indexing, the index will have to be moved by 20 holes in
43 hole circle for 83 times
As (A – N) is positive, the index plate should move in the same
direction as the crank
Angular Indexing
Angular indexing is the process of dividing the periphery of a work in
angular measurements and not by the number of divisions
Indexing method is similar to plain indexing
When the index crank is rotated by 40 number of revolutions the
spindle rotates through one complete revolution or by 360 deg.
One turn of crank will cause the spindle and work to rotate through
360 / 40 = 9 deg.
Rule
Index crank movement = Angular displacement of work in degrees / 9
= Angular displacement of work in minutes / 540
= Angular displacement of work in Sec. / 32400
Ex. Index an angle of 19˚40’
= (19 x 60) + 40 = 1180’
Index crank movement = 1180’ / 540’ = 2 5/27
Index crank should be moved two complete turns and 5 holes of 27
hole circle.
Grinding
- Metal cutting operation performed by means of a rotating abrasive
wheel
- Used to finish workpiece with high surface quality & dimensional
accuracy
Oxy-chloride bonding
- abrasive grains mixed with magnesium oxide and magnesium
chloride
- mixing of bond and abrasive is performed as in the case of vitrified
bonded wheel
- used for making wheel segments
Grinding wheel selection factor
1. Material
- This influences the selection of abrasive, grain size, grade, structure
and bond
- Al2O3 recommended for material with high tensile strength
- SiC recommended for material with low tensile strength
- Fine grain is used for hard and brittle material
- Coarse grain is used for soft ductile material
- Hard wheel for soft materials
- Soft wheel for hard materials
- Close spacing required for hard and brittle materials
- Wide spacing required for soft and ductile materials
2. Amount of stock to be removed
- Involves accuracy and finish
- Coarse grain used for fast cutting and fine grain for fine finish
- Wide spacing for rapid removal and close for fine finish
3. Wheel speed
- influences the selection of grade and bond
- higher the wheel speed with respect to work speed the softer the
wheel should be.
Recommended wheel speed for different type of grinding:
Cylindrical 1500-2000 m/min.
Surface 1200-1500 m/min.
Internal 600-1800 m/min.
Tool and cutter 1500-2000 m/min.
Centreless 1500-1800 m/min.
4. Work speed
- Higher the work speed with respect to wheel speed harder the wheel
should be
Working speed for different material
Roughing finishing
C.I 60 m/min. 120 m/min.
Al 30 m/min. 60 m/min.
Soft steel 9 m/min. 15 m/min.
Hard steel 20 m/min. 30 m/min.
Wearing of Grinding wheel
Glazing
- Condition in which the face or cutting edge takes a glass-like
appearance (i.e.) the cutting points of the abrasives have become
dull and worm down
Loading of wheel
- Cutting face of the wheel has particles of the metal being ground
adhering to it (i.e.) the openings / pores of the wheel face being
filled up with metal powder
Reconditioning of grinding wheel
- Dressing removes loading and break away the glazed surface so that
the sharp abrasive particles are ready for grinding.
Dressing can be done by using :
Star dresser
Diamond dresser
Star Dresser
- Common type of wheel dresser
- Consist of number of hardened steel wheels with points on their
periphery
- Dresser is held against the face of the revolving wheel and moved
across the face to dress the whole surface
Diamond dresser
- Single crystal diamond tip is used as tool for dressing
- Tip will be inserted in a holder in such a way that the tip alone is
projected outward
- Holder is provided with a magnetic stand which can be placed on
the table of the grinding machine
- Dresser is held against the face of the revolving wheel and moved
across the face.