Center of Excellence .

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

 It’s used for cutting at

any angle in vertical
plane to produce key
ways , slots and
corners.
 It’s provide
reciprocating drive for
single point cutting
tool.
UNIVERSAL SPIRAL ATTACHMENT

 It’s used to mill spirals

with a plain milling
machine.
 It’s useful for cutting
helical threads , gears ,
worms and racks.
RACK MILLING ATTACHMENT

 It’s 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

 It’s used for profile milling and

many other circular operations
in horizontal plane such as
slotting and dovetailing.
 It’s consists a base,a worm drive
mechanism and a small circular
work table.
VERTICAL MILLING MACHINE

PARTS
1. Base
2. Column
3. Vertical head
4. Spindle
5. Table
6. Saddle
7. Knee
HORIZONTAL MILLING MACHINE

 Axis of spindle is in
horizontal plane and
parallel to It’s table.
 Generally cutters are
mounted on long arbor.
ELECTRICAL EQUIPMENT

 It’s usually grouped in

the column.
 It’s consists
fuses,motor breakers
and contactors.
CUTTING FLUID EQUIPMENT

 It’s consists a
pump ,piping
and noses,a
nozzle and shut-
off 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

90º 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

 It’s equivalent to two

helical gears,one
having a right hand
and other a left hand
helix.
 It’s 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.
 It’s 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.
 It’s 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 can’t 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
 It’s 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.
 It’s 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.
 It’s 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 it’s
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 90º to the
work table.
 It’s 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.
 It’s 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

 It’s 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 don’t
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
 It’s 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

 It’s used to obtain

greater number of
divisions that can
not be obtained by
direct indexing.
 It’s 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
 It’s 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(γ)
 Rake angle (α)
 Tool angle (β)
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.
 It’s 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