| TEXTROOK OF MANUFACTURING TECHNOLOGY 9.9.6, Size of Boring Machines 4 The ste boring machine ven by eal boring machines, the (diameter), 11200 rom to 8600 mm, also have to be Eien. the aiameler ofthe spindle (78 mm to 360 ra) “dimensions of eoluman height and table size 9.10, MILLING MACHINES 9.10.1, Introduction which metal is removed by meons of @ revolving ing edge which removes metal from a workpiece 1d by various methods on the workable, and ransvereely or vertically. mally fed into a rotating cutting tool known ing machine the work ate ates longiudn ing procs, the work ter Equal ped inerainety ‘and machine the workpiece. Thi sescrcipen the workpies Fea sare owl t produce parts bang flat at well os curved shapes © Miling machines eet be produced on the ther machine tol, can be made on the milling machines This machine i perhaps next tthe lathe in importance. Milling Processes—Princple of Milling re are wo types of milling processes, namely 1 Up maillng (or conventions mig) proces 2 Down ming or clin miling) process. 1 Upmilling (or conventional milling) process. Refer to ig 992 the workpiece i fed velocity. Bach oth NV utr Depth tet ‘eaves the cut. The chip thickness {is zero increases fo maximum at the end of the eu ‘¢ Theaction ofthe cutter forces the workpiece land the table against the direction of ta +h as in heavy slotting operations, the cutter te ure since the cutting force is directed upward at in pouring colant om the is over with ot begin as soon as the cutter touches the work [MACHINE TOOLS AND MACHINING PROCESSES sor 2, Down milling (or climb milling) process : Refer to Fig. 9.93 In “down milling process” the workpiece is Seamed orate To aan (@ The cutting force tends to hold the work \T against the machine table, permitting lower clamping forces ‘This process produces better finish and lant can be fed easly. The chips are also disposed off conveniently and they do not interfere with the cutting. Thus the machined surface of the workpiece is not spoiled. i) Universal milling machine, (io) Ormniversal milling machine 2, Manufacturing or fixed bed type ) Pantograph, profiling and tracer controlled milling machine. 9.10.4. Horizontal Milling Machine Rofer to Fig. 9.94, The main parts of a horizontal milling machine (column and knee type) are briefly described below ives and pulley to give rotary sd to give automatic feed tothe je and table.[A TEXTBOOK OF MANUFACTURING TECHNOLOGY le coher Fig, 994. Horaootal milling machine 3. Knee fe Te supports the saddle, table, workpiece and other clamping devices. ‘moves on guideways of the column. 1s the deflection caused by the cutting forces on the workpiece. sade: {is mounted on the knee and can be moved by a handwheel or by power. . jounted on the saddle and can be moved by a handwheel or by power. ‘surface is machined accurately to hold the workpiece and otber holding devices. ‘the spindle head is vertical and the axis of the in Fig. 9.95. umn are integral castings. ldeways. The vertical milling ‘wiveling head spindle. spindle is perpendicular tothe work — In this machine both the ‘base’ and — The spindle head can be moved up and ai ‘machine may have fixed head, swiveling hea Fig, 9.95. Vertical miling machine. = The ‘saddle is mounted on a “knee which can be mould up and down over the guideways ‘column face. The aadale can be moved horizontally ether by band or by In this machine, the workpiece ean be moved both inthe vertical plane and on the horizon- used to machine grooves, slots and flat surfaces using end mill and ‘machine differs from the plain horizontal type in that its ical grooves to be milled (eg. The helical Ques of twist drs be rotated abi column fe ‘asis perpen tapered spiral grooves in reamers, teth on bevel gears and angular holes|h TEXTBOOK OF MANUFACTURING TECHNOLOGY 1 rotating cutter is in centre or neutral post lepth and then given a planetary motion either inside or outside ‘bomb ends. 9.10.12. Specifications of a Milling Machine Th rations of a column and knee type milling machine : 3, Maximum longitudinal movement and eross feed of the table, 4. Number of spindle speeds. 6, Power of the main drive motor. 9.10.13. Types Common types of 2, Side milling cutters. [MACHINE TOOLS AND MACHNG PROCESSES =n 9, Tealot milling cutter 10. Fly cutter. 9.10.14. Nomenclature of a Milling Cutter Fig. 9.97 shows the nomenclature of a milling cutter. x Land, Poste adal \\, ‘aie arg classified as follows 7. End milling 6. Gang milling 1, Plain or slab milling, Plain milling i used to. machine flat and horizontal surfaces (ig. 958). Here plain mulling cuter is used, which is held inthe arbor and rotated. The table is ‘moved upwards to give the roquired depth of eut.|k TEXTBOOK OF MANUFACTURING TECHNOLOGY siz angular milling, an angle milling cutter is used depending upon whether a single surface isto imultaneously. Angular mi cutter used may be a single or double bbe machined or fwo mutually inclined MACHINE TOOLS AND MACHINING PROCESSES S13 Pan iting “hi Fig 9102 Strada miling narrow slots, grooves the vertical spindle for in 2s ming. Fig 9.108.Talt mailing. & Tso fer to Fig, 9.105. In this milling operation, frst plain slot is ext on the workpiece by a ide and face milling cutter. Then the Tslot cutter is fed from the end of the Dove-tail milling. Refer Fig, recent dnt al angle The eter is pased fom ont end of te workpiece t he B: Qiu Fig. 9.106, Dove ailing Fig 9107 Saw mingsia | TEXTBOOK OF MANUFACTURING TECHNOLOGY 10, Saw milling, Refer to Fig. 9.10 operation of producing narrow grooves and slots on the workpiece. A sitting eaw is used railing. “IL Tovolute gear eutting. Gear milling operation, often referred as gear eulting, involves cutting of deren ypes of gears ov a milling machine. For this either an end mill euler ov a form relieved eut rev ernies the profile on its cutting teeth corresponding to the required profile ofthe gap between gear teeth. Fig, 9.108 shows involute gear cuting operation. Shape ofthe cutter teeth resembles the involute profile. Gear blank is indexed after cutting each tooth. rare ig 9108. lavolute gear cutting. 9.10.16. Cutting Speed, Feed and Depth of Cut Cutting speed. The ‘speed (V, for milling ie defined as the peripheral speed of the cutter. The cutting speed (V) is given by DN. v= SY nin (9.30) whore, = Diameter ofthe cutter, mm, and N= Cuttor speed in rp.m ection of eutting speed depends on the following factors if machine is defined as the movement of the workpiece leat which the workpiece is fed into the cutter [MACHINE TOOLS AND MACHINING PROCESSES sis ed) $= faed per rev * cutter epeed (p.m) or, (mm/min) = fx 2* (oa) where /,= feed rate per tooth, and Z = Namber of teeth on the cutter periphery — For rovgh milling, highest possible feed is employed while for Gnishing the feed is surface Gish required. ee! varies from 0.09 mu/tooth to 0.25 mmv/tooth. For milling feeda are one-third to one-half of these values. Depth of cut. In the milling proces, the depth of eu (4) is defined as the thickness of the layer of material removed in one pass of the workpiece under the cultr. — A depth of cut from 3 mm to 8 mm is common for roughing cuts and is less than 1.5, ‘mm for finishing cuts, 9.10.17. Material Removal Rate “Material removal rate (MRR)'is the volume of metal removed in wait time. For milling, [MR is given by. MRR = B d f, mm/min (9.32) where, B= Width of cu = Depth of eu, and P= Rate of feed Time (a) defied as the time required for one pass of width of cut B for Surface and is expressed in minutes. _Lengthof cut L___L. Mathematically, tn= Beedrate f feed 1 is for meking one pass across the length of surface. Ifthe width of cutter is h of aurface to be milled, only one pass will machine the whole suriace. if more than one pass is required, the above time is mult show milling operations being performs ain (0.33) Plain milling Let, Lj = Length of the job to machined, mm, to Fig 9.109, Then, (939 and, Approach, l= J@(D=@ mm (9.35)516 |A TEXTBOOK OF MANUFACTURING TECHNOLOGY ‘ig 9.108 Plain miling «~—____ '-__—,, etree emer Fig, 9.10 Face ming Face milling : Refer to Fig, 9.110. Appros, 05 (D-YDF-B*) mm (2.28) where, Be ob, mm "eThe ouerunlover {ter (1), depending upon the size of the machined furfoce, can by taken fom 1to 6 mm. ire the sumber of cuts and f the feed in mm per minut, then the machining tine, tq in minuton canbe elculated a lows Lxn 12 min (937) ae For finding out the foal flor time, handling time should be added to the actual machining time ealeulated above Example 9.22. Calculate the ‘end mill of 20 mm diameter having four {ooth is 0.1 mm and cutting speed is 38 half of the diameter of the eutter and a depth 1 for cutting 150 mm long keyway using HSS ‘The depth of heyway is 4.2 mm. Feed per sme approach and overtravel distance as im ean be cut in one pass. D_2% B22 219 mm ; No.of teeth, BaF = 10 mm; N Solution. Given : I, = 180 mm ; D= 20 mm ; t Z=4 ; Feed per tooth = 0.1 mm ; V,= 88 mimin ; d= 4.2 mm. Mschinigluting tn + Send (npn) athe oie "00 a) nD (» > oon soa 38 2 en = 605 epm, MACHINE TOOLS AND MACITNING PROCESSES si ‘Then, feed per min, [= Feed per tooth % No. of veeth % rpm. 20.14 x 606 = 242 main L= b+ (1, #4) = 160 10= 160 mm L_ 160 Machining Hine, = 7=15% = 0.66 min. (Ans) Example 9.23. A ste! workpiece is to milled. Metal removal rate is 25 em"lmin. Depth of cut and width of cut are 4.5 mm and 90 mm respectively. Caleulate the table fed. Solution. Given : MRR = 25 emY/min = 25 * 102 mm/min ; d= 45 mm ; B= 90 mm. Table feed, f (mm/min) : MRR = Dopth of eut (d) x width of cut (B) Rate of feed () 25% 109 =45%90%/ pa tint Now, Length of eu = 61.7 mmvmin. (Ans). required o mill aslo of 350 mm x 30 mm in a workpiece of 850 mm length ‘milling cutter of 120 mum diameter, 30 mm wide and Raving 20 teeth. The depth of cut is 6 mm, the feed per toth 1s 0.1 mm and cutting apeed is 24 mimin, Assume overtravel distance of 5mm. m8, Given ; Ly = 260 mm ; D= 120 mm ; Z= 20 teeth; d = 6 mm ; Feed per tooth Feed rate, /= Feed per tooth * No. of teeth % rpm. = 0. x 20 x 90°= 180 mmvmin ‘Also, Approach, 1,= J@D=O = (600-9 =26 om -{Bga. (8.359) Now, Length of eut, 38. < a.12 min. (Ans). Example 9.25. A plain surface 300 mm (long) * 100 me (wide) isto be face-milled on a vertical milling machine. The cutter has 18 teeth and feed per tooth is 0.2 mm. The spindle ‘peed is 120 rpm. Diameter of the eutter i 150 mm. The overiravel distance is 4 mm. Coleulate = 900 mm ; B= 100 mm ; No, of teeth in cutter, Z = 18 ; feed per pam; D= 150 mm; l,= 4 mm (Ban. 9.88), = 5 (190- /150"=100") = 19 am Feed rate, [= Feed per tooth * No. of teeth in eutter * rp.‘A TEXTAOOK OF MANUFACTURING TECHNOLOgy sis ea 18120 482 mimi 2 Eber 19430044 = 9.75 min Ans.) maT TF 432 sem ail [00 ne sc retegulr pas set 20 mt ier ofend aril: 20 mm ; umber of fas ‘Depth of eut = 3m. 1 oer thc operation tobe completed in single pas. (care) termine the cuting time forthe operat een eg) mn; D= 20 mm; Ne of Oates = 8 Fe 001 mae | = mm ‘Machining time, ty: D2. Cutter approach, he ge g 7mm Catter over travel, fy = 5 mm (83) pve 100%, Spindle sped Gin rpm), N= 22 1000 60 = Oe = 965 rpm = Feed per tooth No, of flutes % r.p.m. = 0.01 * 8 x 955 = 76.4 mm/min L_ tlt 10+100%5 = 1595 min. (ana) Table feed in mm/min * mG 164 2.10.18, Work Holding Devices The flowing devices are used for holding the workpiece to be machined: 1. Pit, strap clamps and pads. 2. Plain vice. 3, Swivel vce. 4¢ Universal vice. 5. Universal chuck 6 Rotary table 7. Dividing head 8 Various types of milling fixtures. 9.10.20, Milling Machine Attachments ‘A wide variety of standard attachments, as listed below, are available to increase the MACHINE TOOLS AND MACHINING Processes 319 tachment used on the milling ma ‘he circumferences of components for grooving oF ent and is, therefore, used for very precision index: Accuracy of the other types of dividing heads. ‘the dividing head drives the workpiece by means ofa jaw univer: 8 dog and live centre similar to a lathe. Fig. 9.11. Indexing mechanis (¢ With the Brown and sharpe milling machines the following index plates are available.oop, 20, 34, 97, 98, 39, 3 ler 2, eo 46,47, 49, 51, 68, i" ates from Cincinnat ‘4, 46, 79, 98.108, 89, 107, Many different cmstruction, the prineple on wi Shun bead the universal is much more ough they may va of the limitation ofthe ‘used. The attachment is comprised of the ine carries the dividing and driving mechanism. ‘holds the back centre, for work that has to be supported between cen. eo ng weet andar i earns tallow, the tont end bsing bored toa standard taper; coon ei ade tot ti taper. The outside ofthe spindle atthe ont eds or ang cen Mtjun for use when the work cannot be held between centres SEEDU RSG une ana ned the main casting is 9 worm ton ts ecumferece = Se Rlut inmate pil, and a ight angles tii another spindle passing through Sees tee Ou thc iner end ofthe spindle a sinleshread worm sed, wore ann ot len the outer end ist crank which carries sping loaded sane tee edced end af the plunger engages tothe hele of the di mii ange dacve has a bearing inthe main casting, and can be es con by gears connecting with another spindle running parallel wi Spindle and extending ot atthe bac of the bead ating into a 40-tovth worm-heelit requires 49 ss ne complete revolution of the main spindle. The by this means the civele can be divided ito ot) having 40 teeth umber of dths, Wher ‘means mustbe aplicd. For this purpose dividing o hole plats ae sup Carlier: some makers use only twn, while others use three plates. The hole pi 1 central hole to pass over the worm-epindl, and are attached tthe ann meeenideieiaeneeieetnieatt Fig 9.112 Universal dividing head Fig. 9.113 shows A sector has two a Fs ‘Tw index plate os anivernal dividing heed index plate of a universal is unnecessary to count individual holes inthe plate for each indexing movement 3. Optical dividing head ‘This type of dividing head is used for high precision operations, whe angular setting must not exceed 0.25 minute of arc Such heads have a hi hic is ead through the eyepice ofan opal sysem tu nthe ead Thee i Iredom from ptch ond backlash sor, To oly fears employed are anne sar wor a teeth morm-wheel char ny aed trate he einen fran ving pure 9.10.21. Methods of Indexing Common indering methods are 1 Rapid ordre inden. 2. Simple or pain inden. 8. Compound indering 4. Dferentil indexing 8. Angular indexing 1 Rapid or direct Indexing 0 Rapid or direct indexing is the simplest method of indexing and ts used enly on work that requires a small number divisions, such as square or hexagonal nuts etesx {in this indexing method, the si _A TEXTBOOK OF MANUFACTURING TECHNOLOgy. ja turned through a fiven angle without interp, ° ition of ming Fe nm ns the bale ‘Rested angle by rung the index erank ho Tlons and hols on one ofthe ole icles, fer inde pn is relocated isthe required hole. Ifthe muber of divisions on the job circumference needed is Nyy, then number of turns that the crank must be rotated for each indexing can be found from the following relationship. =2 238) Nas where ny, isthe number of crank rotations. ‘21. It is required to divide the periphery ofa job into 50 equal divisions. ind ment. Solution. Given : Ng, = 50 i = Lt Reguined crank movement ng = =" Selecting 15 holes circle on ey 12 leon 18 hls irl Example 9.28. It is required to divide the hery of a job isto 28 equal divisions. Find the indexing arrangement. aa eae oe Solution. Given : N = 28“ Required crank morenent = 2019.18 BT 3 axa Now, ae, 7 ‘That is foreach indexing we 21 hale cee ae dein me eed one complet rotation ofthe rank plus 9 mare holes sa MACHINE TOOLS AND MACHINING PROCESSES stages by using two diferent hole circles of one the crank in the urual way a in simple indexing, say, m, holes in 31 lockpin engaged in circle N, of the index plate. Let, Nay = No. of divisions needed Crank movement for each Tn order to obtain this mov 1s follows (@ Weite Ng, above and 40 below a straight line and factorize them. (i Select the two numbers representing two hole cirles in the same plate, Write these siren My ed Ma Gi et yb tember lb ned in My ae and mb he mamber thse tbe indeed nN, tle die ery a9 oy eal nd ee ain Ny hl cles Ble in, hl cil Solution Given : Nu, = 87 Steps: (0 87 (Lat a ~ 28| TEXTBOOK OF MANUFACTURING TecINGLogy su MACHINE TOOLS AND MACHINES PROCESSES ‘Now, —_Factorsof divisions FE eT " Faciors of 0% Factors of fir Fig. 9.115. Compound gear train — In the case of a compound gear train an idler is used when the indax plate ist» move ion in 29 hole circle forward and movement of crank and index ‘arcle backwards. (Ans.) ie Movement of ran plate bath by 11 hoes 4 iter! ‘Example 9.30. Obtain the indexing for 137 divisions. ‘Aubnush ompound inden ita convenient way to get any indexing required itis fay 0, Obtain Trane tence diferent indexing is used for that parpove which oy Seer Gee nae re out the compound indezing method vO " ‘The required indexing is 7 -~ 7 Which cannot be obtained with any ofthe index plate, Let us select a number slightly greater or smaller than the given number, such that the ‘selected number can be easily indexed through simple indexing. Let us select the new number as 140, 40 2 2%3_6 Simple indexing for 140 divisions = 335" F725 7 ay ‘ie 6 holes on 21 holes circle 6 6 iat Now, if the index crank is turned of a revolution 197 times, it will take : x 197 822 _ 493 = FE = 395, resolu revolutions. Obviousl lone complete turn ofthe jb it should make 40 complete ‘used as shown in Fige. 9 ‘and 8.115 respec: tively ‘© Thedirction ofthe movement ofthe index plat "il move inthe tone dos Of he indeing cont moet Fig. 9.114, Simple gear tain. Se ——|A TEXTBOOK OF MANUFACTURING TECHNOLOGY Driver 18_ 6 _8x8_ 6 Now, The gearing ratio, Doe" 357 Tx8 als Driven" 21 ‘An idle gear ie to be used since the index plate has 0 Example 9.81. Obtain indexing for 51 divisions Solution. Given : Ny, = 51 2.8 ebtained with any ofthe index pl ‘To roid indeing i 3" Mh eannot bob Hie mnove in the same direction (Ans), et us elect the new number = 50 Simple indexing = 42 =-4= £5438 - Le. 16 holes on 20 holes circle 4204 wox tM ows “Movement of crank for 81 division = 51 x = "04 = 40 ie sureuton moe than he eu 4 Tine ob et rg lt moron Drivers 4 2x2 _ 3224 Driven "5" 25x2° 40x20 i.e A compound gear train with an idler (ince the index plate is to move in opposite direction) is required. (Ans) . Example 9.32. Obtain indering for 78 divisions. Solution. Given : Ng, = 78 Gearing rato, Teresi nding a! wih ont be ied homo the ide pe the ow on = £.4,4%8_ 32 oe “0° 7" 1x3" 2 Ue 1a 21 sce Moreno oat 8 dhrisns nee : orn $-2eaf 2 ia 12-28 ca ttn ae 0 be lat hth lt movement Driver 12 1204 Dives 7 a a8 th lo dy) eid Genring ratio, wexing is used when i ‘angle at the centre ofthe circle upon In earlier discussions we have sen t sary to cut grooves or slots subtending a given 78 spaced. 40 crank rotations make the work rotate through MO Thr tr hon sta ek wil tate amy, 28D a0 2S IACHINE TOOLS AND MACHINING PROCESSES ou ‘Thus, crank movement = Anele seauieed Hamels 93%, Golevote te indi or 4% Solution. Indexing required = 42 «42 3-83 ‘This is equivalent to I rotations of the crank followed by 12 holes in the 18 hole cirele in plate No. 1. (Ans. Example 9.34, Calculate the indexing for 32° 20. 1 ah Solution. Indexing required = 2-92 = 516 i. 8 fall rotations of Example 9.35. 9.11, BROACHING MACHINES 9.4111. Broaching Brouching is a process of machining a surface with a special multipoint tool called a broach, whose teth remove the whole machining allowance in a single stroke ‘© Ibis an operation designed to produce high-precision forms and the complex tools are ‘expensive, The shapes produced may be fat surfaces but more often are holes of various forms or grooved components or the shat of gears. '¢ In this operation cutting speeds and feeds are low and adequate lubrication is essential — Although cutting speeds used in broaching is relatively low (2 to 15 m/min). The rods conjunction with automatic workpiece loading and unloading. '¢ Broaching machines are designed for machining external and internal surfaces of var ‘mass and large-ot production. These machines are distinguished from their exceptionally high output. They produce surfaces that are highly accurate in shape and size. Fig. 9.116, shows some typical internally broached shapes, Fig 8116. Sometypial internally broached shapes,(GAN ‘Machining time, ty, ¢ D_ 2 Cutter approwh, «= Be 1mm Cutter over wave = 5 mm (09) 100 V Spindle oped Ga rpm). N= 05% 360 im += 965 rpm. = R20 = Feed per toth * No. of utes * rp.m, = 001 x 8 « 955 = 764 mm/min ‘Table feed in mm/min hebjrh woeroes ea = 1.505 min. (Ans } ir = 1.508 ) for holding the workpiece to be machined : 1. Tolts strap clamps end pads 2. Plain vice. jated below, are available to increase the 9 xing Head lon of « work-part uniform amount, with or The main spindle tinding hed eve the workpiece by means ofa jaw univer ‘dog and live centre similar to a lathe To index lat dividing head consists of a number of holes with a crank and pin, ‘The rank drives the spindle and the live centre through a worm gear. which gon Consequently, a full rotation of the workpiece ia produced by 40 index crank. Further indexing is made poule by having the ing the periphery of the workpiece to any convenient number of divisions. orm wat » (@ With the Brown and sharpe milling machines the folowing index plates are available.1. TEXTBOOK OF MANUFACTURING TECHNOL 9 oY 8,19, 20 boles 15,160 31,28, 27, 28, 81,88, holes 3 3, 47, Plate no. 2 * pate 2 Side 1 34, 46, 79, 93, 109, ed 46 783, Pine 8:Sie 1 2842 72.80 e228 98,783, ‘but although they may vary in 2. and because of the limitation of the the two Jead slock= Tt cartes the dividing and driv Fe ae holds the back centre, fr work that has to be supported between cy , tres, when being milled nalheadeteck const of « main cating with the bearing, to asommodate the min nd ausiliory spindles Fhe min apundle shallow, the ont end being bored toa standard taper; the running ree om tent is made to Ut this taper, The outside ofthe spindle atthe font oar emerive chuck for use when the work cannot be held between He the main spindle and inside the main casting is a worm-wheel having 4 erence. Tmain spindle, end alright angles to it, is another spindle passing through re On the inner end ofthe spindle a single-thread worm is fixed, working “wbeel, while on the outer end is a crank. the plunger engages into the ho "The ange sleeve has «bearing in the main casting, and can be res arallel ie and extending out atthe back ofthe head. read worm engaging into a 40-tooth worm-wheel it require ts that revolver onthe armrspindle tthe erank ar. Thi also saves the coun the travel uackINE TOOLS AND MACHINING PROCESSES ing change wheels on the warms ‘on studs. ” ing is machined to Fit a rectangular block which is adjustabl the driving dog on the running centre and held by a set-screw. Fig, 9.112 shows a universal dividing heed, on spo index pate of universal dividing bead, ling head : it carries centric circles of ps forthe movement ofthe crank: arm, so ‘unnecessary to count individual holes in the plate for each indexing movement. viding head is used for high precision operations, when the error in 3t exceed 0.25 minute of are. Such bead: ve a highly accurate 9.10.21.8, Methods of Indexing Common indexing methods are 1. Rapid oF direct indexing. 2. Simple or plain indexing, 8. Compound indexing. il indexing. he simplest method of indexing and is used only on work that square or hexagonal nus eteTEXTBOOK OF MANUFACTURING TECHNOL Gg y be rotated to divide the peri B12 and 24 directly. Since the a) on of the index ple “ Plain indexing is: enolase when it ar — Say ee ni he ner antl ihr fn oh ay end ne nen i en om i Ton a ear a sre say mt i She nerd Cr ie mee (9.38) rank rotations. is required to divide the periphery of a job into 50 equal divisions. Find Solution. Given : Nyy = 50 Oa Reguted ernk movement, he = 5-5" 5 Selecting 15 holes circle on plate No. 1, we get, lie, 12 holes on 15 holes circle, (Ans.) fra is required to divide the periphery of @ job i:to 28 equal divisions ment iven N= 28 40_10_|3 Required crank movement n, = 42-1013 ep TT 33x39 Ta ach indexing we need one complete rotation of the crank plus 9 mare Mle No. 2). (Ans), me " ” [MACHINE TOOLS AND MACHINING PROCESSES 3, Compound indexing : ‘The compound indexing method is employed when the number of divisions required is outside the range that can be obtained by simple indezang . ‘The compound indexing is achieved in to stages by using two different hole circles of one index plate 1. By a movement of the crank in the umual way aa in simple indexing, say, my holes in hole circle Ny, with the lockpin engaged in ciele Ny of a farther movement by backward, through na, spar locking pin of the index plate so that it is fee to turn) Procedure : Let, Nay, = No. of divisions needed on the work A rank movement for each indexing = 4° ening = 5 In order to obtain this movement (since it cannot be obtained by simple indexing), proceed as follows Write Ny,, above and 40 below a straight line and factorize them. (it) Let mp, be the number of holes to be indexed in Ny, hole circle and na, be the number of holes to be indexed in Ny, hole cirle, ‘Then, etm (9.39) Now, find out ny, and ny by trial and error. ‘Then.the total indexing will be: ny, holes in Nh, hole circle = m, holes in Na, hole cirele by rotating the erank and indes plat Solution Given > N,, = 87 Steps: (9) 87=29%9 A= 2x 2x25 (Let Ny, = 29, and 88= 11 « 8 (Factors of second hole circle Ny)| TEXTBOOK OF MANUFACTURING TeCHNOLogy Factors of divisions required x factors of Now. icine af 40x Factors of iat hole cirle Ny, * 9x9 x0x2 __e9xx@x2)___ = Gated Dx 9x Dx ON 29° 33” 87 ie. Movement oferank by 28 holes in 29 hole circle forward and movement of erank and index plate both by 11 holes in 33 hole circle backwards. (Ans) 4 Differential indexing : ‘Although compound indesing is a convenient way to get any indexing required, itis ily ‘cumbersome to use in practice. Hence differential indexing is used for that purpose whic ‘ulomatic way fo carry out the compound indexing method. Differential indexing is also carried out is two stages certain direction. some-movement is added to the above crank movement ar is lost by rotating the plate inthe opposite direct pin, during diferential indexing should be taken out fo make the plat available (Brown and sharpe dividing hea: 32, 40, 44, 48, 56, 64, 72, 86 and 100. 1 shown in Figs. 9.114 and 9.116 respec- ‘© Thedirecton of he movement ofthe index lepends upon the gear train x late will move in the ‘same direction’. vo Bat OF the indexing crak movement, ig. 9.114. Simple gear rin. MACHINE TOOLS AND MACHINING PROCESSES fost nasa head pao ie 9.116. Compound gear train ind gear train an idler is used when the index plate is to move indexing for 137 divisions, Solution : Given : Nyy = 137 40 _ 40 ‘The required indexing is Gj“ gz whith cannot be oblained with any of the index 1 number slightly greater or amaller than the given number, such that the 7 times, i wil take : x 137 the index erank is dex crank is turned = lutions, whereas, or one complete turn ofthe job it should make 40 complete the job would not be, thus, indexed through exactly 137 equal divisions|k-TEXTHOOR OF MANUFACTURING TECHNOLoGy 26 Driver _18_ 6 6x8_ 48 Now, The groring rata, ven =z "7 "7x8 56 ce the index plate hos to move in the same direction (Ang), An idle gear isto be use Example 9.31. Obtain indexing for 51 divisions 51 40.49 sch cannot be obtained with any of the index plat, ‘The require indexing is, Solution. Given : Ne 404 ‘Simple indexing = 42-4 ‘ie 16 holes on 20 hoes circle = 204-40. 5 4 ‘Movement of crank for 51 division = 61 * = ta $ ecstatic one hn te ms Tis toe ot hoch pte sore Driven 5 25x2 40x24 fe A compound gear train with an idler (since the index plate is to move in opposite direction) is required, (Ans.) . Example 9.32. Obiain indexing for 78 divisions Solution, Given Nyy = Gearing ratio, ‘The required indexing is 4° which cannot be obtained with any of the index plate Lot us select the new number as 70 40_4_4x3_12 Simple indexing = T= 5 = 755 = 7s 2 fe 12 holes on 21 holes cirle Movement of erank for 78 divisions 5 12 ie 17-7 crank rotation are to be lost through the plate movement, Driver 12 1264 _ Driven 7" 7x4 "28 th no idler or two idler) ie required. Gearing ratio, eA simple gear train necessary to cut grooves or slots eubtending « giver ‘they are spaced. In earlier discussions we have seen that 40 crank rotations make the work rotate throug! 900. Terie, fr exch atone eras he wek wil ate tough 2 « o [MACHINE TOOLS AND MACHINING PROCESSES so ‘Thus, erank movement = Angle required © Example 9.33, Caleulaze the indexing for 42" Solution. Indexing required = “2 ‘This is equivalent to four ful circle in plate No. 1. (Ans.) Example 9.84, Caleulate the indexing for 32° 20 1 Solution. Indexing required = 3 i.e 3 full rotations of the erank followed bs Example 9.85. Calculate indenng na holes on 27 hole circle in plate No.2 (Ams.) 0. Solution. Indexing required = r= 20 4, 1 full rotation ofthe erank followed by 20 holes én the 27 hole circle in plate No.2 (Ans.) 9.11. BROACHING MACHINES brome aching is 0 process of machining a surface with @ special multipoint to called a ous contours in masa and large-lot production. These ts their exceptionally high out fare highly accurate in fand size. Fig. 8.116. shows some typical internally broached shapes. Fig. 9.116 Some spcal internally broached shape.