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Production & Manufacturing

Basic Training.

Basic Milling & Gear Cutting.

VERTICAL MILLING ATTACHMENT

This attachment mounted on column of universal Milling machine. Which consists housing spindle head and bevel drive gears

HIGH SPEED ATTACHMENT

It is used to drive small milling cutters at high speed. It may be fitted on vertical or horizontal machine. It consists a housing contains step-up gearing and a small spindle.

SLOTTING ATTACHMENT

Its used for cutting at any angle in vertical plane to produce key ways , slots and corners. Its provide reciprocating drive for single point cutting tool.

UNIVERSAL SPIRAL ATTACHMENT

Its used to mill spirals with a plain milling machine. Its useful for cutting helical threads , gears , worms and racks.

RACK MILLING ATTACHMENT

Its mounted between the face of column and outer support on a plain or universal milling machine. It consists a fixed housing and a spindle. A special rack indexing attachment used to move the work longitudinally with accurate spacing of teeth.

CIRCULAR TABLE ATTACHMENT

Its used for profile milling and many other circular operations in horizontal plane such as slotting and dovetailing. Its consists a base,a worm drive mechanism and a small circular work table.

VERTICAL MILLING MACHINE

PARTS
1. 2. 3. 4. 5. 6.
7.

Base Column Vertical head Spindle Table Saddle

Knee

HORIZONTAL MILLING MACHINE

Axis of spindle is in horizontal plane and parallel to Its table. Generally cutters are mounted on long arbor.

ELECTRICAL EQUIPMENT

Its usually grouped in the column. Its consists fuses,motor breakers and contactors.

CUTTING FLUID EQUIPMENT

Its consists a pump ,piping and noses,a nozzle and shutoff valve and a tank in machine base.

HELICAL GEAR

Elements of teeth are twisted or helical. Used for connecting shaft at an angle in same or different planes. Smooth acting gearing.

MITRE GEARING

When the shafts are at 90 and two bevel gears are of same size, known as miter gears.

SPUR GEAR

Teeth element parallel to rotating shafts are known as spur gear. Used to transmit power and motion through parallel shafts.

HERRINGBONE GEAR

Its equivalent to two helical gears,one having a right hand and other a left hand helix. Its used in heavy duty machines like steel roll mills.

BEVEL GEAR

When two shafts are in same plane but at another,bevel gears an angle with one are used. Its a frustum of a cone having all elements of teeth intersecting at a point.

SLOT DRILL CUTTER

Two flute type, which meet at the cutting end. Its used for plunge milling like key ways etc.

COLLET CHUCK

The chuck is supplied with a set of spring collets in various sizes.

COLLET CHUCK

The cutter (d) is inserted into the collate and then the nut is tightened ,using the special spanner supplied with the chuck.

COLLET CHUCK

It is used to reduce the internal taper in the work spindle,so that it fits on required arbor or cutter.

COLLET CHUCK

This type of adapter with Morse taper and flat tong is used for holding taper shank and mill with tong.

SELF-LOCKING CHUCK.

The cutter is provided with pitch thread at the end of cutter shank.

SLOT EQUAL TO CUTTER DIAMETER

The side of the cutter which is traveling in same direction as the feed in climb milling.

The work cant be pulled in to cutter because the resistance of opposite teeth which are
up-milling.

SLOT EQUAL TO CUTTER DIAMETER

The direction of feed is against the direction of cutting edge of cutting mill.

SLOT EQUAL TO CUTTER DIAMETER

The common methods used to mount end mills in vertical milling machine are shown in these figures.

DIRCTION OF HELIX OF CUTTER

When the helix and cutter of opposite hand, the force will press the cutter in to spindle. Left hand helix right hand cut.

END MILL CUTTER

Its used for milling small faces and slots.

PROFILE CUTTING

In vertical milling machine with rotary table attachment. This end mill cutter performed profile cutting operation.

INDEXABLE END MILL CUTTER

Some end mill have index able inserts which can be replaced when worm out.

STRAIGHT SHANK END MILL CUTTER

Solid type of cutter in which straight shank are integral.

TAPER SHANK END MILL CUTTER

Taper shank type and helical flute type. Its fitted in MT-2 sleeve.

PLAIN MILLING CUTTER

Solid type of cutter made from a single piece of steel . Used for plain milling operation

INSERTED TOOTH CUTTERS

In large milling cutters the teeth are inserted in a body of less expansive material. The teeth are made from H.S.S or tungsten carbide.

BRAZED-ON TIP CUTTERS

Carbide tips are brazed on a solid cutter body. Its also known as tipped solid cutters.

DIRECTION OF ROTATION OF CUTTER

Down milling Direction of rotation of cutter and work piece feed in same direction.

METHOD OF MOUNTING THE CUTTER

Arbor type cutter. Cutter mounted on arbor and arbor size selected as per cutter bore size.

FACING TYPE CUTTER

These cutters either bolted or attached directly to the spindle or secured on the stub arbor.

SHANK TYPE CUTTER

Cutter with straight or taper shank with its body. Collate chuck or adapters are used for holding this cutter.

DIRECTION OF HELIX OF CUTTER

Cutter axis is held vertically and the helix is towards the right side is called a right hand helix cutter.

DIRECTION OF HELIX OF CUTTER

Helix is towards the left side ,it is called a left hand helix cutter.

DIRECTION OF HELIX OF CUTTER

When a cutter has a helix and a cut of the same hand,this force will pull the cutter away form the spindle.

VERTICAL MILLING MACHINE

Position of spindle is vertical or 90 to the work table. Its suitable for boring pocket milling profile milling& key way cutting.

STATE THE USES OF ARBORS

an extension of the machine. An arbor is consider as There are two types of arbor normally.

USES OF ARBOR

The outer end of the assembly is supported by the bushing. The arbor is designated 00 by the taper number diameter and length.

STUB ARBOR

The arbors are hold with the machine. The arbors are of three types A,B,C as shown in picture.

TYPES OF ARBORS

Types A is used to mount the shell and mills and similar cutters. The cutter is tightened on the arbor using the screw.

TYPES OF ARBOR

It is used to mount large face milling cutters. The cutter is held on arbor by four screw(b), it has a slot(c),which fits over spindle (d).

TYPES OF ARBOR

It is a morse taper adaptor arbor used to hold drills, reamers, chucks etc.

STRADDLE MILLING

Plain side and face milling cutter used for slot cutting,and face milling and also used for straddle milling.

STAGGERED TEETH SIDE MILLING CUTTER

Cutters have alternate teeth with offside helix angles. Its used for milling deep and narrow slots or key ways.

INTERLOCKING SIDE MILLING CUTTER

It is formed out of two half side milling cutters or two staggered teeth side milling cutters. They are made to interlock to form one unit.

ROUGH MILLING

Before taking a finishing cut to bring the job in required dimension and surface finish. Amount of material left for a finishing cut called finishing allowance.

ROUGH MILLING

The object of rough milling is to remove excess material and not concerned with quality of surface finish.

FEED,DEPTH OF CUT,CUTTING SPEED

Rough milling done by using heavy feed a depth of cut of 3 to 6 mm and low cutting speed.

FINISH MILLING

The purpose of finish milling is to bring work piece to required dimension and surface finish.

FINISH MILLING

To achieve required accuracy and surface finish the smallest possible amount of material usually 0.5 to 1mm material is removed.

DIRECT INDEXING MACHANISM

Its a rapid method Of indexing. It can be performed on a direct indexing head. Index plate has three circle of holes with 20,30,36 respectively.

HYPOID GEARS

Modification of a bevel gear where the shaft are at right angle but they dont intersect as do the shaft for bevel gears.

RACK GEARS

Rack gears are straight and have no curvature. Used for feeding mechanism and reciprocating drives.

DIRECT INDEDXING MECHANISM

For center work,any suitable carrier may be used to engage the work piece with driving lug on the indexing head spindle .

BASIC ELEMENTS OF SPUR GEAR

Pitch circle. Circular pitch. Pitch circle diameter. Addendum circle. Root circle. Addendum. Dedendum . Hand. Clearance. Working depth. Flank of tooth.

BASIC ELEMENTS OF SPURGEAR

Diametral pitch. Pressure angle

WORM GEAR

When a large speed reduction is desired worm gear are used. Worm will always be the driver & used for teeth mechanism.s

ANNULAR GEAR

A gear with internal teeth is known as annular gear are used in automobiles.

PRINCIPLE OF MILLING

Cutter has a rotary movement and rotates at a high speed and removes metal at a very fast rate. Job can be fed manually or automatically.

PRINCIPLE OF MILLING

By milling we can produce flat horizontal, vertical, angular and formed surfaces.

PLAIN\HORIZONTAL MILLING M\C

Its covered in column and knee type of category. M\c haves horizontal spindle and cutter are mounted on horizontal arbor. Table muted in three direction- longitudinal, vertical and crosswise.

SIMPLE INDEXING MECHANISM

Its used to obtain greater number of divisions that can not be obtained by direct indexing. Its carried out using 40:1 ratio of the worm and worm mechanism.

SECTOR ARMS

Two sector arms fit on the face of the indexing plate. The arms can be set a part to cover a required number of holes between them.

ANGULAR INDEXING

Index for a certain number of degrees us when. Machining keyway, grooves flats. Located at angles of each other.

DIRECT INDEXING

Another type of index plate which is heaving a number of slots (24,30,36) on periphery of index plate.

DIRECT INDEXING

Indexing can performed by indexing head by disengaging worm from worm wheel.

BROWN AND SHARP INDEX PLATE

This system has three index plates and each plate has six circles of holes. Plate no 1: 15,16,17,18,19,20. Plate no 2: 21,23,27,29,31,33. Plate no 3: 37,39,41,43,47,49.

INDEX CRANK

Its fitted to the end of the worm shaft. It carrier a spring loaded index pin to engage the hole in the plate.

PRINCIPAL OF ANGULAR INDEXING

If the crank is turned once,the spindle rotates 1/40 of a turn and 1/40 of 360 is
360/40 =9 degrees. It follows that 1/9 turn of the crank will give a spindle movement of 1 degree.

PRINCIPLE OF METAL CUTTING

The common metal cutting process is carried out either by the use of single point multi point cutting tool.

PRINCIPLE OF METAL CUTTING

The important angle of cutting edge are Clearance angle() Rake angle () Tool angle ()

CLERANCE ANGLE

This is the clearance or relief provided behind the cutting edge. It prevents rubbing as well, thus reducing cutting force.

RAKE ANGLE

Angle given in front of the leading edge of tool. Its reduce the pressure of the chip on the tool face. Positive rake angles produce better finish at low speeds.

RAKE ANGLE

Zero and negative rake angle tools are stronger and have a long tool life.

HALF SIDE MILLING CUTTER

Cutters with teeth on one side only and used for heavy straddle milling and for machining one side only.

PLAIN SIDE AND FACE MILLING CUTTER

Side and face milling cutter with teeth on both sides used for slot cutting and face milling.

UNIVERSAL MILLING MACHINE

It is similar in construction to plain milling machine. But its table,a part from having movement in 3 direction,can also be swiveled about horizontal axis. Maximum swiveling is 45 both in clock wise and anticlockwise directions

PARTS OF MILLING MACHINE

Base Column Knee Gear box Spindle Saddle Table Over arm brace Electrical equipment Cutting fluid equipment