MACHINING SCIENCE
AND
METROLOGY
(BME402)
Course Coordinator
Sundaresh S
SYLLABUS AND SCHEME
Course Code BME402 SEMESTER IV
Teaching Hours/Week (L:T:P) 3:0:2 CIE Marks 50
Total Number of Lecture Hours 40 hours of theory+ 10 Lab slots SEE Marks 50
Examination Pattern (SEE) Theory Exam Hours 03
Course objectives:
1. To enrich the knowledge pertaining to relative motion and mechanics required for various machine tools.
2. To introduce students to different machine tools to produce components having different shapes and sizes.
3. To develop the knowledge on mechanics of machining process and effect of various parameters on
machining.
4. To understand the basic principles of measurements
5. To enrich the knowledge pertaining to gauge, comparator, and angular measurement.
Module – 2
Milling Machines: Up milling & down milling, classification of milling machines, various
Shapes produced on different milling operations, calculation of machining time. Types of milling cutters and
milling cutter nomenclature.
Milling indexing: Need of indexing Simple, compound and differential indexing. Numerical problems on
indexing.
Shaping, Slotting and Planning Machines Tools: Driving mechanisms of shaper, slotter and planer. Parts
produced on shaping and planning machines, calculation of machining time on shaping machine.
Drilling Machines: Classification, constructional features of radial drilling machine and drilling operations, types
of drill bits and drill bit nomenclature. Abrasive machining: Grinding wheel characteristics, types of grinding
operations, grinding wheel specification and selection.
Self-study: Construction of Column and Knee type and Vertical milling machine (08 Hours)
Self-study: Studies on Chip breakers.
MILLING METHODS
Up or Conventional Milling
➢The work is fed into the rotation of the
cutter.
➢Chip thickness is minimum at the start of the
cut.
➢The chip is so light that the cutter has a
tendency to slide over the work .
➢This alternate sliding leaves marks on the
milled surface.
Down or Climb Milling
➢The work is fed in the same
direction as the rotation of the
cutter.
➢Chip thickness is maximum at the
start of the cut.
➢There is no sliding action and
hence better surface finish.
NOMENCLATURE OF MILLING CUTTER
INDEXING
➢ The operation of rotating the job through the required angle between two
successive cuts is called indexing.
➢ Required in many milling operations such as in milling gear teeth, splines,
grooves, slots, hexagonal or square heads of bolts and nuts etc.
➢ Accomplished with the help of indexing head or dividing head.
Methods of Indexing
1. Direct Indexing
2. Simple or Plain Indexing
3. Compound Indexing
4. Differential Indexing
5. Angular Indexing
Simple or Plain Indexing
➢ Carried out using any of the indexing plates in conjunction with the worm.
➢ Possible to obtain relatively simple divisions.
➢ For example, suppose we want to have 6 equal divisions to be made
𝟒𝟎 𝟐𝟎 2
The rotation of the index crank = = =6
𝟔 𝟑 3
This means that the index crank should be rotated 6 full turns followed by two-thirds of a
rotation. The fraction of rotation required to be obtained with the help of index plates as given
above. This can be done as follows, using any of the Brown and Sharp Plates.
1. Plate no.1: 10 Holes in 15 hole circle/ 12 holes in 18 hole circle.
2. Plate no.2: 14 holes in 21 hole circle/18 holes in 27 hole circle/22 holes in 33 hole circle.
3. Plate no.3: 26 holes in 39 hole circle.
Compound Indexing
➢ Used when the available capacity of the index plates is not sufficient to do a
given indexing job.
➢ Majority of the indexing job could be completed.
➢ In this method, first the crank is moved in the usual fashion in the forward
direction, then the further motion is added or subtracted by rotating the index
plate after locking the plate with the plunger. Hence the name compound
indexing.
➢ For example, suppose 27 teeth are to be cut on a gear blank,
𝟒𝟎 𝟏𝟖 𝟐𝟐 𝟔 𝟐𝟐 𝟏𝟐 𝟐𝟐
Then rotation of the index crank T = = + = + = +
𝑵 𝟐𝟕 𝟐𝟕 𝟗 𝟐𝟕 𝟏𝟖 𝟐𝟕
Thus for each tooth, rotate the worm by 12 holes of 18 hole circle with the help of crank and then
rotate the index plate by 22 holes of 27 hole circle.
Differential Indexing
➢ In this case, index plate is unlocked and connected to a train of gears, which
receive their motion from the worm gear spindle.
➢ As the handle is turned, the index plate also turns, but at a different rate.
➢ Its movement depends on these gears used to drive it.
➢ After the gears are set up, the operation is similar to simple indexing.
➢ The work may be rotated by fraction of revolution with the usual indexing plates.
➢ The following equation is used for calculating the necessary gears to be placed between the
𝐃𝐫𝐢𝐯𝐞𝐫 𝟒𝟎
spindle and the worm shaft, = (P– N) x
𝐃𝐫𝐢𝐯𝐞𝐧 𝐏
Where P = Approximate number of divisions, N = Actual number of divisons.
𝟒𝟎
and the crank movement T =
𝐏
➢ The above following equation gives the gear ratio to be placed on the spindle(driver) and the
worm shaft(driven). The arrangement of gears may be simple or compound train depending
upon the suitability.
➢ If (P – N) is positive, then rotate the index plate in the direction in which crank is rotated. If it is
negative, then rotate the index plate in opposite direction to that of the crank.
Axis: It is the longitudinal center line of the drill running through the centres of the tang
and the chisel edge.
Body: It is the part of the drill from its extreme point to the commencement of the neck,
if present. Otherwise, it is the part extending up to the commencement of the shank.
Helical grooves are cut on the body of the drill.
Shank: It is the part of the drill by which it is held and driven. It is found just above the
body of the drill. The shank may be straight or taper. The shank of the drill can be fitted
directly into the spindle or by a tool holding device.
Tang: The flattened end of the taper shank is known as tang. It is meant to fit into a slot in
the spindle or socket. It ensures a positive drive of the drill.
Neck: It is the part of the drill, which is diametrically undercut between the body and the
shank of the drill. The size of the drill is marked on the neck.
Point: It is the sharpened end of the drill. It is shaped to produce lips, faces, flanks and
chisel edge.
Land: It is the cylindrically ground surface on the leading edges of the drill flutes
adjacent to the body clearance surface. The alignment of the drill is maintained by the land.
The hole is maintained straight and to the right size.