“Heaven’s Light is our guide”

Rajshahi University of Engineering & Technology

Department of Mechanical Engineering

A report on

Study of milling machine and cutting a spur gear.

Subject: Machine tool-ІІ Lab Submitted by: Self

Course no: ME- 4808 Name: Md.Hafizur Rahman
Date of exp: 25.04.11 Class: 4th year, 8th sem.
Date of sub: 10.05.11 Roll no: 062072
Group: B1 (2) Session: 2006-07
Milling Machine
Milling machines are very versatile. They are usually used to machine flat surfaces, but can also
produce irregular surfaces. They can also be used to drill, bore, cut gears, and produce slots. The type
of milling machine most commonly found in student shops is a knee type milling machine with a
swiveling head. Although there are several other types of milling machines, this document will focus
only on the horizontal milling machine. A milling machine removes metal by rotating a multi-toothed
cutter that is fed into the moving work piece.

Over Arm

Column

Spindle

Arbor

Index

Table

Motor

Base
Fig: Nomenclature of Plain Milling Machine

Types of milling:
1. Conventional Milling: Milling in which the cutter and feed move in opposite directions from the
point of contact.

2. Climb Milling/Down Milling: The Milling Cutter and the work piece move in the same direction.

Sizes of milling machine:

The size of the milling machine can be determined by –
1. The amount of the table
2. The amount of the horse power.
3. The model.
4. The type.
Column and Knee type Universal Milling Machine:

The column and Knee type Universal Milling Machine is the most commonly found schools and
industrial shops. It is called this name the spindle is fixed in the column. The table can be adjusted
longitudinally, transversely and vertically.
Main parts of a milling machine:

1. Base

2. Spindle

3. Over arm

4. Table

5. Saddle

6. Knee

7. Column

Base:
Base is the foundation of the Milling machine. It is a heavy rigid casting, made in one piece. It is the
backbone of the milling machine. It holds or supports all the other parts of the milling machine.

Spindle:
The spindle holds and drives the various cutting tools. It is a shaft mounted on bearings supported by
the column. The spindle is driven by an electric motor through a train of gears all mounted within the
column. The front end of the spindle has a tapered hole and driving keys for locating and driving
various cutting tools, chucks, and arbors.
Over arm:
The over arm is mounted on the top of the column and guided in perfect alignment by the machined
dovetailed surfaces. It supports the arbor and is adjustable and can be tightened in any position. Some
machines have two rounds over arm.

Table:
The table holds the work piece. It rest on the dovetailed guides of the saddle. T slots are machined
along the length of the top surface of the table. They are used to align the job or the fixture, which
holds the job. Bolts fit loosely in the T slots and are used to clamp the job, vise, or fixture to the table

Saddle:
The saddle supports the table. It is supported and guided by the accurately machined surfaces of the
knee.

Knee:
The knee supports the saddle. The feed-change gearing is enclosed within the knee. The knee can be
raised or lowered on the column face. It is supported and can be adjusted by the elevating screw.

Column:
The column is the main casting, which supports all the other parts of the machine. The front of the
column, the column face, is machined to provide an accurate guide for the vertical travel of the knee.

Attachment of milling machine:

Universal milling attachment:

A universal milling attachment as it name implies, is fully universal because its spindle may be set at
any angle in both planes. The spindle speed is faster than the regular spindle. It may be 1.6 or 3.5
times as fast as the regular spindle.
 Rotary attachment:
It is used on a variety of circular milling such as circular T-slots, segment outlines, and so forth, and on
many tool and die making jobs that require splinting, slotting, or irregular form milling. In addition to
the hand feed unit, rotary attachments are also available as power fed units.

Slotting attachment:
It is largely used in tool making, such as forming box tools for screw machines, making templates, and
splinting keyways. The working parts consist of a tool slide, driven from the machine spindle by an
adjustable crank that allows the stroke to be set for different lengths. The attachment may be set at
any angle between zero to and 90◦.

Rack milling attachment:

It I used for cutting teeth in racks. It can also be used in connection with the universal spiral-index
centers for cutting worms, on universal milling machines, and for other miscellaneous operations. The
cutter is mounted on the end of a spindle that extends through the attachment case parallel to the
table T slots.

Work holding devices: There are many different devices for holding the work piece to be machined.
They are
1). Plain vice: It is the handiest and most common work holding device. It can be fastened to the table
with the jaws either parallel or at the right angle to the T slot.
2).Swivel vice: It is same as the plain vise but only difference that its top part can be turned in
complete circle.
3).Universal chuck: It is used for holding the round work piece.
4). Dividing head: It is used for holding and turning the job so that a number of equally spaced
divisions or cuts can be around it.

Working Principle:
1. At first cutting tool necessary stock material has been collected.
2. Then the work piece has been attached to mandrel & cutting tool (involute spur gear cutter) was
clamped to arbor.
3. After that the machine was switched ON.
4. The total no of teeth to be cut on the W/P was then identified.
5. Then through indexing the first tooth was cut on W/P.
6. After that by making one revolution of index handle the location for 2nd tooth was determined.
7. Similar way the location of gear cutter for the rest teeth was determined.
8. Finally 40 teeth were cut on the periphery of the W/P & a spur gear was obtained.

Flow Diagram for motor 1:

by by
Motor-
pull
1 shaft
Pulley beltt
Pulley leverby Gear box
engage
Spindle Cutter

Flow Diagram for motor 2:

by engage engage
Motor-
st 2
Sha 1 lever Gear box lever
fed rod lever By led screw table
Flow Diagram for motor 3:

By pump
Motor 3 By pipe Coolant on the job

Feed:
Feed is the rate at which the work piece advances under the cutter. There are three ways feed is
controlled:
1. Manual feed.
2. Inches per revolution of the spindle or cutter.
3. Inches per minute (imp).

The feed (F) in inches per minute can be found as follows:

F = maximum metal removal in3 per minute/depth of cut*width of cut

Spur gear cutting calculation:

I = 40/N Let, N=40
I=40/40 =1
OD = (N+2)/DP
WD = 2.157/DP
Where, N = No. of teeth.
DP = Diametral pitch.
WD = Whole depth.
I = Rotation of index crank pin.
OD = Outside diameter of the gear blank.

Indexing:

Indexing in reference to motion is moving (or being moved) into a new position or location quickly
and easily but also precisely. After a machine part has been indexed, its location is known to within a
few hundredths of a millimeter (thousandths of an inch), or often even to within a few thousandths of
a millimeter (ten-thousandths of an inch), despite the fact that no elaborate measuring or layout was
needed to establish that location. Indexing is a necessary kind of motion in many areas of mechanical
engineering and machining. A part that indexes, or can be indexed, is said to be indexable.

Usually when the word indexing is used, it refers specifically to rotation. That is, indexing is most
often the quick and easy but precise rotation of a machine part through a certain known number of
degrees. However, the swapping of one part for another, or other controlled movements, is also
sometimes referred to as indexing, even if rotation is not the focus.
Precautions:
1. We ensured that machine is switched off at main switch.
2. Made sure that machine has been lubricated & is cleaned & is free from all metal chips, with
particular attention to sideways.
3. We selected suitable work-holding device. Mount the work piece so that the surface to be cut is
over the centre of the table. Check that work piece is secure. Removed all unwanted items from
table.
4. Mount cutters after thoroughly cleaning the bore, keyway & boss faces ensuring that cutter is
clear of the surface of the work piece.
5. Fixed all safety guard.
6. Set controls for depth of cut, speed of cutter & rate of feed.
7. Adjusted the position of cutting fluid nozzle when coolant is required.
8. Switch on machine check its running.