I'T'I

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• 
  I.T.I
• 
  RAJKOT

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CENTRE OF EXCELLENCEINDUSTRIAL TRAINING
INSTITUTERAJKOT

• PRODUCTION AND MANUFACTURING
• BASIC MILLING AND GEAR CUTTING
• P.M.B.T. 05
• Inst.- H.B.VASAVADA.

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TRADE INTRODUCTION

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SAFETY PREACAUTIONS

• Personal safety
• Workshop safety
• Machine safety
• Tools safety
• Work safety -

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First aids

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Manufacturing process

• Work process
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• Inspection
• Finish goods-
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• TESTED OK

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TYPES OF MILLING MACHINE
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(A) TYPES OF MILLING MACHINE

• Column VG knee type DL,L\U DXLG
• Manufacturing VYJF fixed bed type DL,L\U DXLG
• Planer type DL,L\U DXLG
• Special purpose DL,L\U DXLG

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(B) COLUMN AND KNEE TYPE MACHINE

• HAND DL,L\U DXLG
• PLANE DL,L\U DXLG
• UNIVERSAL DL,L\U DXLG
• OMNI VERSAL DL,L\U DXLG
• VERTICAL DL,L\U DXLG
• RAM TYPE DL,L\U DXLG

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(D)MANUFACTURING OR FIXED BED TYPE

• Simplex milling machine
• Duplex milling
• Triplex milling machine.

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(D) SPECIAL PURPOSE MILLING MACHINE

• Rotary table milling machine
• Drum type milling machine
• Planetary milling machine
• Pantograph milling machine
• Profiling machine
• Tracer control milling machine
• Gear hobbling machine
• Thread milling machine

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SIZE OF MILLING MACHINE

• Table working surface m.m 1400 x 330 mm
• Longitudinal traverse
  762 mm
• Cross wise traverse
  280 mm
• Vertical traverse
  430 mm
• Distance between spindle to over arm 155mm
• Spindle taper number
  ISO No40
• Arbor diameter
  25.4 mm
• No of cutting speed
  9
• Speed range 50 to
  1500 R.P.M.
• H.P of feed motor
  2 H.P
• H.P of main motor
  3 H.P
• Coolant motor
  0.10 H.P

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MAIN PARTS OF MILLING MACHINE

• Base
• Column or body
• Knee
• Saddle
• Table
• Over hanging arm
• Arm brassies
• Spindle
• Central bearings

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Parts of Milling Machine

• Over arm
  Arbor
• Column
• Main Motor
  Arm Brace
• Table
• Guide Ways
  Arbor Suporter
  
• 
  Saddle
• Base
  Jake
  

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ELECTRICAL EQUIPMENT

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

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CUTTING FLUID EQUIPMENT

• Its consists a pump ,piping and noses,a nozzle
  and shut-off valve and a tank in machine base.

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VERTICAL MILLING MACHINE

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WORK HOLDING DEVICES OF MILLING

• Vice ( plane swivel base universal )
• Angle plate v- Block
• T bolt clamp
• Special fixtures

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Machine vice

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• Angle Plate V-
  Block
• Special Fixtures

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MILLING CUTTER HOLDING DEVICES

• Arbor

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Cutter holding devices

• Collate chuck

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Cutter holding devices

• Stub arbor

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Cutter holding devices

• 85Z V08Z
• 8 VMO SM,8

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MILLING MACHINE ATTACHMENT

• Indexing head attachment
• Vertical milling attachment
• Rotary table attachment
• Slotting attachment
• Rack milling attachment

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UNIVERSAL SPIRAL ATTACHMENT

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• Its useful for cutting helical threads , gears ,
  worms and racks.

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HIGH SPEED ATTACHMENT

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VERTICAL MILLING ATTACHMENT

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

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Milling attachment

• Rack Milling attachment

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Milling attachment

• Circular table attachment

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ELEMENTS OF CUTTER

• Body
• Face
• Cutting space
• Fillet
• Land
• Linier cutting edge
• Out side diameter

• Root diameter
• Bore
• Shank
• Head
• Helix angle
• Rake angle
• Relief and clearance angle

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CLASSIFICATION OF MILLING CUTTERS

• According to construction of teeth.
• According to relief of cutter teeth.
• According to direction of rotation.
• According to method of holding the cutter.
• According to the direction of helix.
• According to use of cutter.

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ACCORDING TO CONSTRUCTION OF THE TEETH

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ACCORDING TO RELIEF OF CUTTER TEETH

• Profile relived cutter
• Form relived cutter

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ACCORDING TO DIRECTION OF ROTATION

• Right hand rotational cutter
• Left hand rotational cutter

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ACCORDING TO THE DIRECTION OF HELIX

• Straight or parallel teeth cutter
• Right hand helical cutter
• Left hand helical cutter
• Alternate helical teeth cutter

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ACCORDING TO METHOD OF HOLDING THE CUTTER

• Arbor type cutter
• Shank type cutter
• Facing type cutter
• Threaded bore type cutter

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ACCORDING TO USE OF CUTTER

• Standard milling cutter
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• Special milling cutter
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ANGLE CUTTERS

• Single angle cutter
• Double angular cutter

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• Shell end mill cutter
• End Mill Cutter

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END MILL CUTTER

• Its used for milling small faces and slots.

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FORM MILLING CUTTER

• single Corner rounding cutter -double corner
  rounding cutter
• Concave and convex cutter
• Gear cutter
• Gear hob cutter
• Tap and reamer fluting cutter
• Thread milling cutter

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SHANK TYPE CUTTER

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

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INDEXABLE END MILL CUTTER

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

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SLOT DRILL CUTTER

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

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BRAZED-ON TIP CUTTERS

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

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MILLING METHODS

• Conventional or up milling methods
• Climb or down milling methods

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Milling Method

• End Milling
• Straddle milling
• Gang Milling

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PROFILE CUTTING

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

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MILLING OPERATION

• Plain milling operations
• Side milling operations
• Angular milling operations
• Form milling operations
• Profile milling operations
• Saw milling operations
• Keyway milling operations
• Gear milling operations
• Helical milling operations
• Cam milling operations
• Thread milling operations

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Milling operation
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INDEXING HEAD

• Plain or simple indexing head
• Universal indexing head
• Optical indexing head
• Wide range indexing head

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PLAIN OR SIMPLE INDEXING HEAD

• Direct type
• Worm and worm wheel type

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UNIVERSAL INDEXING HEAD

• Body
• Worm wheel
• Worm
• Shaft
• Gears
• Index plate
• Index crank
• Latch - pin
• Tail stock
• Swivel block
• Sector

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BROWN AND SHARP INDEXING PLATE

• PLATE NO 1 15,16,17,18,19 and 20 Hole.
• PLATE NO 2 21,23,27,29,31 and 33 Hole.
• PLATE NO 3 37,39,41,43,47 and 49 Hole.

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CINCENATI INDEX PLATE
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VARIOUS METHOD OF INDEXING

• Direct indexing method
• Simple or plain indexing method
• Compound indexing method
• Differential indexing method
• Block indexing method
• Linear indexing method
• Angular indexing method

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Direct indexing

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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 .

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SIMPLE INDEXING MECHANISM

• Its used to obtain greater number of divisions
  that can not be obtained by direct indexing.
• Its carried out using 401 ratio of the worm and
  worm mechanism.

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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.

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GEAR AND GEAR CUTTING

• By Die casting Sand casting
• By molding
• By press or stamping
• By rolling
• By powder metallurgy
• By machining

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TYPES OF GEARS

• Spur gear
• Helical gear
• Bevel gear
• Hypoid gear
• Worm
• Internal gear

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SPUR GEAR

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

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BASIC ELEMENTS OF SPURGEAR

• Diametral pitch.
• Pressure angle

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BASIC ELEMENTS OF SPUR GEAR

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

75
ANGULAR GEAR

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

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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.

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WORM GEAR

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

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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.

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MITRE GEARING

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

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HELICAL GEAR

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

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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.

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RACK GEARS

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

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SPUR GEAR FORMULAE
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SPUR GEAR FORMULAE
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SELECTION OF CUTTER

• CUTTER NO 1 WILL CUT 135 TEETH TO A RACK
• CUTTER NO 2 WILL CUT 55 TEETH TO 134 TEETH
• CUTTER NO 3 WILL CUT 35 TEETH TO 54 TEETH
• CUTTER NO 4 WILL CUT 26 TEETH TO 34 TEETH
• CUTTER NO 5 WILL CUT 21 TEETH TO 25 TEETH
• CUTTER NO 6 WILL CUT 17 TEETH TO 20 TEETH
• CUTTER NO 7 WILL CUT 14 TEETH TO 16 TEETH
• CUTTER NO 8 WILL CUT 12 TEETH TO 13 TEETH

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HELICAL GEAR TERMS

• HELIX ANGLE
• REAL CIRCULAR HELIX
• PITCH
• NORMAL CIRCLE PITCH
• LEAD
• NORMAL DIAMETERAL PITCH
• NORMAL MODULE PITCH

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RULE AND FORMULA FOR HELICAL GEARS0
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RULE AND FORMULA FOR HELICAL GEARS0
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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.

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TYPES OF SHAPER

• According to ram driving mechanism.
• According to direction of cutting stroke.
• According to position of ram.
• According to construction of the table.

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ACCORDING TO RAM DRIVING MECHAINISM

• Crank drive
• Gear drive.
• Hydraulic drive.

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ACCORDING TO DIRECTION OF CUTTING STROKE

• PUSH CUT
• DRAW CUT.

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ACCORDING TO POSITION OF RAM

• Horizontal shaper
• Vertical shaper.
• Traveling head shaper
• Contour shaper

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ACCORDING TO CONSTRUCTION OF THE TABLE

• STANDERD SHAPER.
• UNIVERSAL SHAPER.

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• Base
• Column
• Cross rail
• Saddle
• Table
• Ram

• Tool head
• Clapper box
• Drive pinion
• Bull gear
• Rocker arm
• Link

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Shaper quick return mechanism
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TYPES OF SLOTTER

• Pusher slitter
• Production slitter
• Tool room slitter

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PARTS OF TOOL ROOM SLOTTER

• ROTARY TABLE
• RAM AND TOOL HEAD
• RAM DRIVING MICHINISM
• FEED MICHINISM

• BASE
• COLUMN
• SADDLE
• CROSS SLIDE

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RAM DRIVING MICHINISM

• SLOTED LINK GEAR MICHINSM
• WITH WORTH QUICK RETURN MICHINISM
• HYDRAULIC MICHINISM

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TYPES OF PLANER

• Standard or double housing planer
• Open side planer
• Pit planer
• Plate or edge planer
• Divided table Planer
• Miller and grinder planer

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PARTS OF PLANERS

• Stop dogs
• Belt shifting lever
• Elevating screw
• Controls
• Driving and feed mechanism

• Bed
• Table
• Housing or column
• Cross rail
• Saddle
• Tool head

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DRIVING MECHANISM OF PLANER

• Open or cross belt drive
• Reversible motor drive
• Screw drive
• Hydraulic drive

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FEED MECHANISM

• Hand feed
• Automatic feed

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SIZE OF PLANER

• Work holding devises
• Planer jack
• Planer center
• Special fixtures
• Planer gauge
• Planer operations