MILLING WORK

MODULES
 MILLING MACHINE

LEARNING OUTCOMES:

LO [Link] MACHINES AND ACCESSORIES

LO 2. MILLING CUTTERS
LO [Link] Speeds, Feeds, and Depth of Cut
LO [Link] MACHINE SET UP
LO 5. MILLING OPERATION
LO 6. THE INDEXING OR DIVIDING HEAD
LO [Link]
LO [Link] CUTTING
LO 9. HELICAL MILLING
LO 10. CARM , RACK , WORM AND CLUTCH MILLING.
LO [Link] VERTICAL MILLING MACHINE CONSTRUCTION AND OPERATIION
LO [Link] MILLING OPERATIION
 LESSON 1
MILLING MACHINES AND ACCESSORIES

MILLING MACHINES

Milling is the machining process of using rotary cutters to remove material from a
workpiece advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a
wide variety of different operations and machines, on scales from small individual parts to
large, heavy-duty gang milling operations. It is one of the most commonly used processes in
industry and machine shops today for machining parts to precise sizes and shapes.

HORIZONTAL MILLING MACHINES

In order to meet many different industrial requirements, milling machines are made in
a wide variety of types and sizes. They are classified under the following headings:
1. Manufacturing type, in which the cutter height is controlled by vertical movement of the
headstock.
2. Special type, designed for specific milling operatiions.
3. Knee-and-column type, in which the relationship between the cutter height and the
work is controlled by vertical movement of the table.

MANUFACTURING-TYPE MILLING MACHINE

Manufacturing-type milling machines are used primarily for quantity production of
identical parts. This type of machine may be either semiautomatic or fully automatic and is of
simplebut sturdy construction.
Some of the more common manufacturing-type milling machines are:
• The plain manufacturing type has one horizontal spindle and one headstock. This
machine is sometimes equipped with a reciprocating table cycle, which permits feeding
and rapid traversing in both directions. On this type of machine, reciprocal milling is
possible. Identical fixtures may be mounted on each end of the table. While work is
being machined at one end, a new piece is being loaded into the fixture at the other
end.

• The small plain automatic knee-and-column type is similar to the plain horizontal mill. It
is used for milling small or medium-sized parts in different quantities. The table is
operated by power and controlled automatically by trip dogs mounted on the front of
the table.
 • The tracer-controlled milling machine has a hydraulic or electriacal circuit designed to
automatically control the relative position if the cutter and the workpiece by a tracer
stylus riding on a cam, template, or model. This machine is used for efficient, accurate
reproduction of curved or irregular surfaces. If the tracer is disengaged it can be used
for standard milling operatiions

SPECIAL-TYPE MILLING MACHINES

Special-type milling machines are designed for individual milling operatiions and are
used for only one particular type of job. They may be completely automatic and are used for
production purposes when hundereds or thousands of similar pieces are to be machined.

MACHINING CENTERS
A special type of machine which is finding wide application in the industrial world is the
horizontal numerical control machining center. This is machine is capable of handling a wide
variety if work such as straight and contour milling, drilling, reaming, tapping, and boring all in
one step.

KNEE-AND-COLUMN-TYPE MILLING MACHINES

Machines in this class fall into three categories:
1. Plain horizontal milling machines
2. Universal horizontal milling machine
3. Vertical milling machine
UNIVERSAL HORIZONTAL MILLING MACHINES
The universal horizontal milling machine is essential for advanced machine shop work.
The difference between this machine and the plain horizontal will be deal with in this unit.
The only difference between this mill and the plain horizontal machine is the addition of
a table swivel housing between the table and the saddle. This housing permits the table to be
swiveled 45° in ether direction in a horizontal plane for such operations as the milling of
helical grooves in twist drills , milling cutters and gears.

PARTS OF THE MILLING MACHINE

• The base of the machine is Grey iron casting accurately machined on its top and
bottom surface and serves as a foundation member for all the other parts which rest
upon it. It carries the column at its one end. In some machines, the bage is hollowed
and working as a reservoir for cutting fluid.
• The column is the main supporting frame mounted vertically on the bage. The column
is box shaped. Heavily ribbed inside and houses all the driving mechanisms for the
spindle and table feed. The front vertical face of the column is accurately machined
and is provided with dovetail guide ways of supporting knee. The top of the column is
finished to hold an over-arm that extends outward at the front of the machine.
• The knee is the rigid gray iron casting that slides up and down on the vertical way of
the column face. The adjustment of height is effected by elevating screw on the base
that also supports the knee. The knee houses the feed mechanism of the table, and in
different controls to operate it. The top face of the knee forms slid way for the saddle to
provide cross travel of the table.
• The saddle is placed on the top of the knee, which slides on guide ways set exactly at
90 to column face. A cross feed screw near the top of the knee engages a nut of the
 bottom of the saddle to move it horizontally, by hand or power, to apply cross feed. The
top of the saddle is accurately machined to provide guide ways for the table.
• The table rest on ways on the saddle and travels longitudinally. The top of the table is
accurately finished and T-slots are provided for clamping the work and other fixtures on
it. A lead screw under the table engages a nut on the saddle to move the table
horizontally by hand or power. The longitudinal travel of the table may be limited by
fixing trip dogs on the side of the table. In universal machines, the table may also be
swiveled horizontally. For this purpose the table is mounted on a circular bage which in
its turn is mounted on the saddle. The circular bage is graduated in the degree.
• An arbor is considered as an extension of the machine spindle on which cutters are
securely mounted and rotated. The arbors are made with taper shanks for proper
alignments with machine spindles having taper hole on their nose. The taper shank of
the arbor conforms to the Morse taper or self release taper whose value is 7:24. The
arbor may be supported at the farthest end from the over hanging arm or may be of
cantilever type which is called stub arbor.
• A swivel table housing, fastened to the saddle on a universal milling machine, enable
the table to be swiveled 45° to either side of the centerline.
• The overwarm provides for correct alignment and support of the arbor and various
positions, depending on the length of the arvor and the position of the cutter.
• The elevating screw is controlled by hand or an automatic feed. It gives an upward or
downward movement to the knee and the table.
• The spindle speed dial is set by a carnk that is turned to regulate the spindle speed.
On some milling machines the spindle speed changes ar made by means if two levers.

BACKLASH ELIMINATOR
A feature on most milling machines is the addition of a backlash eliminator. This device,
when engaged, eliminates the backlash ( play) between the nut and the table lead screw
permitting the operatiion of climb (down) milling.

MILLING MACHINE ACCESSORIES

A wide variety of accessories, which greatly increase its versatility and productivity, are
available for the milling machine. These accessories may be classed as fixtures or as
attachments.

Three Classes of Milling Machine Attachments

1. Designed to hold special attachment that increase versatility of machine
• Vertical, high-speed, universal, rack milling, slotting
2. Designed to hold standard cutters
 • Arbors, collets, and adapters
3. Designed to hold workpiece
• Vise, rotary, indexing (dividing) head

Vertical Milling Attachment

The vertical milling attachment, which may be mounted on the face of the column or
the overarm, enables a plain or universal milling machine to be used as a vertical milling
machine. Angular surfaces made by swiveling head, parallel to face of column up to 45º either
side of vertical , Used for face milling, end milling, drilling, boring and T-slot milling .

Rack Milling Attachment

The rack milling attachment and the rack indexing attachment are used to mill longer
gear rocks ( flat gears) than could be cut with the standard horizontal milling machine. These
attachments will be discussed later in the section with gear-cutting accessories.

Slotting Attachment
The slotthing attachment converts the rotary motion of the spindle into reciprocating
motion for cutting keyways, splines, templates, and irregularly shaped surfaces. The length of
the stroke is controlled by an adjustable crank. The tool side may be swiveled to any angle in
a plane parallel to the face of the column, making the slotting attachment especially valuable
in die work.

Arbor, collets, and adapters

Arbors, used for mounting the milling cutter, are inserted and held in the main spindle
by a draw bolt or a special quick-change adapter.
Shell-end mill arbors may fit into the main spindle or the spindle of the vertical
attachment. These devices permit face milling to be done either horizontally or vertically.
Collets adapters are use for mounting drills or other taperd-shank tools in the main
spindle of the machine or the vertical milling attachment.
A quick-change adapter, mounted in the spindle, permits such operatiions as drilling,
boring, and milling with out a change in the setup of the workpiece.
 Universal vise Plain Vise Swivel base Vise

Vises
Milling machine vises are the most widely work-holding devices for milling: they
manufactured in three style.
• The plain vise may be bolted to the table so that its jaws are parallel or at right
angles to the axis of the spindle.
• The swivel base vise is similar to the plain vise,expect that it ha a swivel base
which enables the vise to be siveled through 360° in a horizontal plane.
• The universal vises may be siveled through 360° in a horizontal plane and may
be tilted from 0 to 90°in a vertical plane. It is used chiefy by toolmakers,
moldmakers, and diemakers, since it permits the setting of compound angles for
milling.

Indexing or Dividing Head

The indexing or dividing head is a very useful accesory permitting the cutting of bolt
heads, gear teeth, ratchets, and so on. When connected to the lead scew of the milling
machine, it will revolve the work as required to cut helical gears and flutes in drills, reamers ,
and other tools the dividing head will be fully discussed later in the section.
REVIEW QUESTIONS

HORIZONTAL MILLING MACHIN

1. Name six operations that can be performed on a milling machine.

MANUFACURING-TYPE MILLING MACHINE

2. List four features of a manufacturing-type milling machine.

KNEE-AND-COLUMN-MILLING MACHINE

3. What is the difference between a plain horizontal and a univeersal horizontal milling
machine?
4. What is the purpose of the backlash eliminator?

MILLING MACHINE ACCESSORIES AND ATTACHMENTS

5. What is the purpose of a fixture?

6. List three milling machine attachments and give example of each.
7. Describe tge purpose of the following devices:
a. Vertical milling attachment
b. Rack milling attachment
c. Slotting attachment
8. Name three methods of holding cutters on a milling machine.
9. What are the features of the:
a. Plain vise
b. Swivel base vise
c. Universal vise
 LESSON 2
MILLING CUTTERS

Milling cutters are usually made of high-speed steel and are available in a great variety
of shapes and sizes for various purposes. You should know the names of the most common
classifications of cutters, their uses, and, in a general way, the sizes best suited to the work at
hand.

SIDE MILLING CUTTERS

Side milling cutters are essentially plain milling cutters with the addition of teeth on one
or both sides. A plain side milling cutter has teeth on both sides and on the periphery. When
teeth are added to one side only, the cutter is called a half-side milling cutter and is identified
as being either a right-hand or left-hand cutter. Side milling cutters are generally used for
slotting and straddle milling. Interlocking tooth side milling cutters and staggered tooth side
milling cutters are used for cutting relatively wide slots with accuracy (Figure 8-6). Interlocking
tooth side milling cutters can be repeatedly sharpened without changing the width of the slot
they will machine. After sharpening, a washer is placed between the two cutters to
compensate for the ground off metal. The staggered tooth cutter is the most washer is placed
between the two cutters to compensate for efficient type for milling slots where the depth
exceeds the width.

[Link]

FACE MILLING
Face milling is the milling of surfaces that are perpendicular to the cutter axis. Face
milling produces flat surfaces and machines work to the required length. In face milling, the
feed can be either horizontal or vertical. In face milling, the teeth on the periphery of the cutter
do practically all of the cutting. However, when the cutter is properly ground, the face teeth
actually remove a small amount of stock which is left as a result of the springing of the
workpiece or cutter, thereby producing a finer finish. It is important in face milling to have the
cutter securely mounted and to see that all end play or sloppiness in the machine spindle is
eliminated During face milling operations, the workpiece should be fed against the milling
cutter so that the pressure of the cut is downward, thereby holding the piece against the
[Link] possible, the edge of the workpiece should be in line with the center of the
cutter. This position of the workpiece in relation to the cutter will help eliminate slippage.

ANGULAR CUTTERS
Ang gular cutters have teeth that are neither parallel nor perpendicular to the cutting
axis. They are used for milling angular surfaces, such as grooves, serrations, chamfer, and
reaner teeth. They nay be divided into two groups.
1. Single-angle milling cutters have teeth on the angular surface and may or may not
have teeth on the flat side. The included angle between the flat face and the conical
face desigantes the cutters, such as 45 or 60°
2. Double-angle milling cutters have two intersecting angular surfaces with cutting teeth
on both. When these cutters have equal angles on both sides of the line at a right
angle to the axis (symmetrical), they are desiganted by the size of the included angle.
When the angles formed with this line ar not the same (unsymmetrical), thje cutters are
desiganted by specifying the angle on either side of the plane or line, such as 12 to 48°
double-angle milling cutter.

Concave and Convex Milling Cutters

Concave and convex milling cutters are formed tooth cutters shaped to produce
concave and convex contours of 1/2 circle or less. The size of the cutter is specified by the
diameter of the circular form the cutter produces.

END MILLING CUTTER

The end milling cutter, also called an end mill, has teeth on the end as well as the
periphery. The smaller end milling cutters have shanks for chuck mounting or direct spindle
mounting. End milling cutters may have straight or spiral flutes. Spiral flute end milling cutters
are classified as lefthand or right-hand cutters depending on the direction of rotation of the
flutes. If they are small cutters, they may have either a straight or tapered shank. The most
common end milling cutter is the spiral flute cutter containing four flutes. Two-flute end milling
cutters sometimes referred to as two-lip end mill cutters, are used for milling slots and
keyways where no drilled hole is provided for starting the cut. These cutters drill their own
starting holes. Straight flute end milling cutters are generally used for milling both soft or
tough materials, while spiral flute cutters are used mostly for cutting steel. Large end milling
cutters (normally over 2 inches in diameter) (Figure 8-10) are called shell end mills and are
recessed on the face to receive a screw or nut for mounting on a separate shank or mounting
on an arbor, like plain milling cutters. The teeth are usually helical and the cutter is used
particularly for face milling operations requiring the facing of two surfaces at right angles to
each other

T-SLOT CUTTER
The T-slot milling cutter is used to machine T-slot grooves in worktables, fixtures, and
other holding devices. The cutter has a plain or side milling cutter mounted to the end of a
narrow shank. The throat of the T-slot is first milled with a side or end milling cutter and the
headspace is then milled with the T-slot milling cutter

METAL SAWS
Metal-slitting saws are basically thin plain milling cutters with sides relieved or “dished”
to prevent rubbing or binding when in ise. Slitting saws are made in widths from 1/32 to 3/16
in. ( 0.8 mm to 5 mm). Because of their thin cross section, they should be operated at
approximately one-quarter to one-eighth of the feed per tooth used for other cutters.

Woodruff Keyslot Milling Cutters

The Woodruff keyslot milling cutter is made in straight tapered-shank, and arbor-
mounted types. See Figure 8-7. The most common cutters of this type, under 1 1/2 inches in
diameter, are provided with a shank. They have teeth on the periphery and slightly concave
sides to provide clearance. These cutters are used for milling semicylindrical keyways in
shafts.
DOVETAIL CUTTER
The dovetail cutter is similar to a single-angle milling cutter with an integral shank.
Some dovetail cutters are manufactured with an internal thread and are mounterd on a
special threaded shank.

FLY CUTTER
The flycutter is a single-pointed cutting tool with the cutting end ground to the desired
shape. It is mounted in a special adapter or arbor. Since all the cutting is done with one tool ,
a fine feed must be used . Flycutters are used in experimental work and where the high-cost
of a specially shaped cutter would not be warranted.
REVIEW QUESTIONS

1. Name two materials which are used to make milling cutters.

2. Name five elements that may be added to iron or steel to produce high-speed steel,
abd state the purpose of each additive.

3. Discuss the advantages and disadvantages of cemented carbide tools.

4. Describe three types of plain milling cutters and explain their uses.

5. Describe three types of side milling cutter and state where each is used.

6. List two ways in which formed cutter differ from plain milling cutters.

7. What advantage does a two-flute end mill have?

 LESSON 3
Cutting Speeds, Feeds,
and Depth of Cut

CUTTING SPEEDS
One of the most important factors affecting the efficiency of a milling operation is cutter
speed. The cutting speed of a metal may be defined as the speed, in surface feet per minute
(sf/min) or meters per minute (m/min) at which the metal may be machined efficienctly. When
the work is machined in a lathe, it must be turned at a specific number of revolutions per
minute (r/min), depending on its diamater to achieve the proper cutting speed. When work is
machined in a milling machine, the cutter must be revolved at a specific number of r/min,
depending on its diameter, to achieve the proper cutting speed.

INCH CALCULATIONS
To get optimum use from a cutter, the proper speed at which the cutter shiuld be
revolved must be determined. When cutting machine steel, a high-speed steel cutter would
have to achieve a surface speed if about 90ft/min (27m/min) since the diameter of the cutter
affects this speed, it is necessary to consider its diameter in the calculation. The following
example illustrates how the formula is developed.

Calculate speed required to revolve a 3-in. diameter

high-speed steel milling cutter for cutting machine
steel (90 sf/min).

simplify formula
 Milling Machine Cutting Speeds
Material High-Speed Steel Cutter Carbide Cutter
Ft/min M/min Ft/min M/min
Machine Steel 70-100 21-30 150-250 45-75
Tool steel 60-70 18-20 125-200 40-60
Cast iron 50-80 15-25 125-200 40-60
Bronze 65-120 20-35 200-400 60-120
Aluminum 500-1000 150-300 1000-2000 300-600

METRIC CALCULATIONS
The r/min at which the milling machine should be set when using metric measurements
is as follows:

r/min = CS(m) x 1000

π X D (mm)

= CS X 1000
3.1416 X D

Since only a few machines are equipped with variable speed drives, which allow them
to be set to the exact calculated speed, a simplified formula can be used to calculate r/min.
The π (3.1416) on the bottom line of the formula will divide into the 1000 of the top line
approximately 320 times. This result in a simplified formula , which is close enough for most
milling operations:
r/min = CS (m) x 320
D (mm)

Face Mills Helical Mills Slotting and Mills End mills Form-relieved Cutters Circular Saws

Material in. mm in. mm in. mm in mm in mmm in mm

Alloy steel .006 0.15 .005 0.12 .004 0.1 0.010 0.25 0.006 0.15 0.005 0.13

Aluminum .022 0.55 .018 0.45 .013 0.33 0.010 0.25 0.006 0.15 0.005 0.13

Brass and bronze (medium) .014 0.35 .011 0.28 .008 0.2 0.008 0.20 0.005 0.13
0.003 0.08

Cast iron (medium) .013 0.33 .010 0.25 .007 0.18 0.008 0.20 0.005 0.13 0.004 0.10
METRIC CALCULATIONS
Calculate the feed in millimeters per minutefor a 75-mm diameter, six-tooth helical
carbidemilling cutter when machining cast-iron (CS 60)

First, calculate proper r/min for cutter:

CSx320 60𝑥320 19,200

𝑟/min = = = = 256
𝐷 755 75

Feed(in/min) = N x CPT x r/min

= 6 x .025 x 256
= 384 mm/min

Directions of Feed
One final consideration concerning feed is the directions in which the work is fed into
the cutter. The most commonly used method of feeding is to feed the work against the
rotation direction of the cutter ( convetional or up milling) . However, if the machine is
equipped with a backflash eliminator, certain types of work can best be milled by climb milling.

Conventional Climbing

Advantages of Climb Milling

• Increased tool life (up to 50%)
-Chips pile up behind or to left of cutter
• Less costly fixtures required
-Forces workpiece down so simpler holding devices required
• Improved surface finishes
-Chips less likely to be carried into workpiece
• Less edge breakout
-Thickness of chip tends to get smaller as nears edge of workpiece, less chance of
breaking
• Easier chip removal
-Chips fall behind cutter
• Lower power requirements
-Cutter with higher rake angle can be used so approximately 20% less power required
Disadvantage of Climb Milling
• Method cannot be used unless machine has backlash eliminator and table gibs
tightened
Cannot be used for machining castings or hot-rolled steel
• Hard outer scale will damage cutter

DEPTH OF CUT
Where a smooth , accurate finish is desired, it is good milling practice to take a
roughing and finishing cut. Roughing cuts should be deep, with a feed as heavy as the work
and the machine will permit. Heavier cuts may be taken with helical cutters having fewer
teeth, since they are stronger and have a greater chip clearance than cutters with more teeth.

REVIEW QUESTIONS

1. Name three factors that affect the efficiency of a milling operations.

2. List six factors which must be considered when selecting the proper r/min for milling.

3. At what maximun speed should a 3½ in. cemented carbide milling cutter revolve to
machine cast iron?

4. At what r/min should a 115 mm high-speed steel cutter revolve to machine a piece of
tool steel?

5. What rules should be obeserved to obtain best result when using milling cutters?

6. Name three factores which determine milling feed.

7. Define chip per tooth.

8. Calculate the feed (in/min) fir ab eight- toothh , 3 in diameter cemen ted carbide face
milling cutter to cut cast iron.

9. What is considered to be a proper roughing cut?

10. Why is very light cut not desirable as a finish cut?

11. List seven main causes of milling cutter failure and state how each can be minimized.
 LESSON 4
MILLING MACHINE SETUPS

MILLING MACHINE SAFETY

1. Do not grip a workpiece with grease or oil on it.

Grip all workpieces firmly.
Do not attempt to hold workpieces that are too awkward or too difficult to hold.
Do not hold workpieces that are too heavy for the machine.
Know how to hold workpieces properly when lifting.
2. Be sure to clean oil or grease from hand tools, levers and handles.
Be sure there is enough texture on the surface of the hand tool or lever handle for proper safe
hand contact.
3. Grip hand tools and lever handles firmly.
Always choose the proper hand tool and appropriate grip position on the lever handle.
Do not use hand tools or lever handles in an awkward position.
Do not apply excessive force.
4. Always use the recommended gripping position to grasp hand tools and lever handles.
5. Do not allow tools to be caught in the milling cutter or other holding device.
6. Do not use broken, chipped or defective tools.
7. Be sure the workpiece is securely held in the vice, chuck or other holding device.
8. Beware of irregular shaped workpieces.
9. Beware of large burrs on workpieces.
10. Always select the correct tool for the job.
11. Do not run the machine unattended.
12. Do not use tools without handles.
13. Always support the workpiece as necessary.
 14. Correctly locate tool in socket heads and screw slots.
15. Beware of obstructions that prevent complete tightening of screws – ensure screw is
tight.
16. Do not rush work.
17. Never substitute the wrong size tools if the correct sized tool is not available or cannot
be located in the shop.
18. Do not place hand or body in path of moving objects.
Beware of moving milling parts that can fall.
Be aware of where you are moving your hand or body in relationship to the milling machine.
Be aware of hands or other parts of the body that may in position to be hit by a cutting tool or
workpiece.
19. Beware of accidentally moving levers, clutches (when applicable) or turning the power
on.
20. Know the function of each and every control.
21. Never place a hand on the tool to stop the rotation of the spindle.

MILLING MACHINE SETUPS

To prolong the life of a milling amchine and its accessories and to produce accurate
work, the following actions should be taken when milling machine setups are being made.
1. Prior to mounting any accessory or attachment, check to see that both the machine
surface and the accessory are free from dirt and chips.
2. Dot not place the tools, cutters, or parts on the milling machine table. Place them on a
piece of masonite, board, or a bech kept for this purpose to prevent damaging the table
or machined surfaces.
3. When mounting cutters, be sure to use keys on all but slitting saws.
4. Check that the arbor spacers and bushings are clean and free from burrs.
5. When tightening the arbor nut, take care to make it only hand tight with a wrench.
NEVER USE A HAMMER ON THE NUT OR HOLDING DEVICE ON ANY MACHINE.
The use of a hammer and wrench to tighten nuts will strip the threads and bend or
damage the accessory or part.
6. When is mounted in a vise, tighten the vise securely by hand and tap it into place with
a LEAD OR SOFT-FACED HAMMER.

Hints On Milling
As in most machining operations optimum performance is controlled by the following:

(1) Rigidity of set up, use the most robust tool. Where this cannot be done, feeds and
speeds must be reduced. Avoid large overhang of shank cutters. Adequately clamp
cutter for both movement and chatter.

(2) Speeds, feeds and lubrication, consult the charts and adapt to suit workshop
conditions, no coolant requires a reduction to the speed by up to 50%.

(3) Tool maintenance. Check tool shanks, machine chucks and arbor for dirt. Scoring or
damage before mounting the tool. Tools with these faults will run eccentrically giving
poor finish, inaccuracy, and poor tool life.
ARBORS
Milling machine arbors are made in various lengths and in standard diameters of
7/8,1,1 1/4, and 1 1/2 inch. The shank is made to fit the taper hole in the spindle while the
other end is threaded.

NOTE: The threaded end may have left or right-handed threads.

The milling machine spindle may be self-holding or selfreleasing. The self-holding taper
is held in the spindle by the high wedging force. The spindle taper in most milling machines is
self-releasing; tooling must be held in place by a draw bolt extending through the center of the
spindle.
Arbors are supplied with one of three tapers to fit the milling machine spindle: the
Standard Milling Machine taper, the Brown and Sharpe taper, and the Brown and Sharpe
taper with tang

(Figure 8-10).

The Standard Milling Machine Taper is used on most machines of recent manufacture.
See Figure 8-11. These tapers are identified by the number 30, 40, 50, or 60. Number 50 is
the most commonly used size on all modern machines. The Brown and Sharpe taper is found
mostly on older machines. Adapters or collets are used to adapt these tapers to fit machines
whose spindles have Standard Milling Machine tapers. The Brown and Sharpe taper with tang
is used on some older machines. The tang engages a slot in the spindle to assist in driving
the arbor,

Standard Milling Machine Arbor

The standard milling machine arbor has a tapered, cylindrical shaft with a standard
milling taper on the driving end and a threaded portion on the opposite end to receive the
arbor nut. One or more milling cutters may be placed on the straight cylindrical portion of the
arbor and held in position by sleeves and the arbor nut. The standard milling machine arbor is
usually splined and keys are used to lock each cutter to the arbor shaft. These arbors are
supplied in three styles, various lengths and, standard diameters.
The most common way to fasten the arbor in the milling machine spindle is to use a
draw bar. The bar threads into the taper shank of the arbor to draw the taper into the spindle
and hold it in place. Arbors secured in this manner are removed by backing out the draw bar
and tapping the end of the bar to loosen the taper.
 The end of the arbor opposite the taper is supported by the arbor supports of the
milling machine. One or more supports reused depending on the length of the arbor and the
degree of rigidity required. The end may be supported by a lathe center bearing against the
arbor nut or by a bearing surface 0f the arbor fitting inside a bushing of the arbor support.

The arbor may also be firmly supported as it turns in the arbor support bearing
suspended from the over-arm (Figure 8-12).
Typical milling arbors are illustrated in Figure 8-13. Listed on the next page are several
types of Style C arbors.
Style A has a cylindrical pilot on the end that runs in a bronze bearing in the arbor
support. This style is mostly used on small milling machines or when maximum arbor support
clearance is required.
Style B is characterized by one or more bearing collars that can be positioned to any
part of the arbor. This allows the bearing support to be positioned close to the cutter, to-obtain
rigid setups in heavy duty milling operations).
Style C arbors are used to mount the smaller size milling cutters, such as end mills that
cannot be bolted directly on the spindle nose. Use the shortest arbor possible for the work.

Screw Arbor
Screw arbors are used to hold small cutters that have threaded holes. See Figure 8-14.
These arbors have a taper next to the threaded portion to provide alignment and support for
tools that require a nut to hold them against a taper surface. A right-hand threaded arbor must
be used for righthand cutters while a left-hand threaded arbor is used to mount left-hand
cutters.
Screw arbors are used to hold small cutters that have threaded holes. These arbors
have a taper next to the threaded portion to provide alignment and support for tools that
require a nut to hold them against a taper surface. A right-hand threaded arbor must be used
for right-hand cutters while a left-hand threaded arbor is used to mount left-hand cutters.
MOUNTING AND REMOVING A MILLING MACHINE ARBOR
The milling arbor is ised to hold the cutter during the machine operation. When
mounting or removing an arbor, follow the proper procedure in order to preserve the
accuracy of the machine . An improperly mounted arbor may damage the taper surfaces of
the arbor or machine spindle, cause the arbor to bend, or make the cutter run out of true.

TO MOUNT AN ARBOR
1. Clean the tapered hole in the spindle and the taper on the arbor using a clean
cloth.
2. Check to make sure that there are cuttings or burrs in the taper which would
prevent the arbor from running true.
3. Check the bearing bushing and remove any burrs using a honing stone.
4. Place the tapered end of the arbor in the spindle and align the spindle driving
lugs with the arbor slots.
5. Place the right hand on the draw-in bar approximately 1 in. ( 25mm)
6. tigthen the draw in bar lock nut securely against the back of the spindle.

TO REMOVE AN ARBOR
1. Remove the milling machine cutter.
2. Loosen the lock nut on the draw-on bar approximately two turns.
3. With a soft-hand hammer, sharply strike the end of the draw-in bar until the arbor taper
is fee.
4. With one hand, hold the arbor and unscrew the draw-in bar from the arbor with the
other hand.
5. Carefully remove the arbor from the tapered spindle so as not to damage the spindle or
arbor taperes.
6. Leave the draw-in bar in the spindle for further use.
7. Store the arbor in a suitable rack to prevent it from being damaged or bent.
REVIEW QUESTIONS

1. Why is the proper setup of the machine important?

2. What can happen if an excessively heavy cut is taken or too fast a feed used?

3. How far should the hands be kept from a revolving cutter?

4. What is the purpose of an arbor?

5. How is the arbor held securely in the machine spindle ?

6. How is the outer end of the arbor supported?

7. How should the arbor be stored when it is not in the machine?

8. In which direction should the cutter teeth point when it is mounted on a arbor?

9. Why should the arbor support be in place before attempting to remove a cutter from
the arbor?

10. Why is the alignment so important to most milling operations?

11. Why must the indicator be mounted on the table and not the column or the arbor when
aligning a universal table?

12. By means of suitable sketches, show how the vise may be aligned:
a. parallel to the line of longitudinal table travel
b. at right angles to the milling machine column
 LESSON 5
MILLING OPERATIONS

The milling machine is one of the most versatile machine tools found in industry. The
wide variety of operations which can be perforemed depends on the type of machined used,
the cutter used and the attachmentys and accessories available for the milling machine. The
two basic types of milling are:
1. Plain milling, where the surface cut is parallel to the periphery of the cutter . These
surfaces may either be flat or formed.
2. Face milling, where the surface cut is at right angles to the axis of the cutter.

Setup
The success of any milling operation depends, Before setting up a job, be sure that the
to a great extent, upon judgment in setting up the job, workpiece, the table, the taper in the
spindle, selecting the proper milling cutter, and holding the cutter by the best means under the
circumstances Some fundamental practices have been proved by experience to be necessary
for and the arbor or cutter shank are all clean and good results on all jobs. Some of these
practices are mentioned be low...
 • Before setting up a job, be sure that the workpiece, table, the taper in the spindle, and
the arbor or cutter shank are free from chips, nicks, or burrs.
• Do not select a milling cutter of larger diameter than is necessary.
• Check the machine to see if it is in good running order and properly lubricated, and that
it moves freely, but not too freely in all directions
• Consider direction of rotation. Many cutters can be reversed on the arbor, so be sure
you know whether the spindle is to rotate clockwise or counterclockwise.
• Feed the workpiece in a direction opposite the rotation of the milling cutter
(conventional milling).
• Do not change feeds or speeds while the milling machine is in operation.
• When using clamps to secure a workpiece, be sure that they are tight and that the
piece is held so it will not spring or vibrate under cut.
• Use a recommended cutting oil liberally.
• Use good judgment and common sense in planning every job, and profit from previous
mistakes.
• Set up every job as close to the milling machine spindle as circumstances will permit.

1. Raise the work within ¼ in (6mm) of the cutter and directly under it.
2. Hold a long piece of thin paper on the surface of the work.
3. Start the cutter rotating.
4. With the left hand on the elevating screw handle , move the work up slowly until the
cutter grips the paper.
5. Stop the spindle.
6. Move the machine table so that the the cutter just clears the end of the workpiece.
7. Raise the knee 0.002 in ( 0.05mm) for paper thickness.
8. Set the graduated collar on the elevating screw hand to zero (0). Do not move the
elavating scew handle.
9. Move the work clear of the cutter and raise the table to the desired depth of cut.

MILLING A FLAT SURFACE

One of the most common operations perforemed on a milling machine is that of
machining a flat surface. Flat surfaces are generally machined on a workpiece with a helical
milling cutter. The work may be held in a vise or clamped to a table. Proceed as follows:
1. remove all burrs from all edges of the work with a mill file.
2. Clean the vise and workpiece.
3. Align the vise to the column face of the milling machine, using a dial indicator.
4. Set the work in the vise, using parallels and paper feelers under each corner to make
sure that the work is seated on the parallels.
5. Tighten the vise securely by hand . DO NOT USE A HAMMER ON THE VISE
WRENCH.
6. Tap the work lightly at the four corners with a soft-faced hammer until the paper feelers
are tight betweem the work and the parallels.
7. Select a plain helical cutter wider than the work to be machined.
8. Mount the cutter on the arbor for conventional milling.
9. Set the proper speed for the size of cutter and the type of work material.
10. Set the feed to approximately 0.003 to 0.005 (0.08 to 0.13mm) chip per tooth (CPT)
11. Start the cutter and raise the work, using a paper feeler between the cutter and the
 work.
12. Stop the spindle when the cutter just cuts the paper.
13. Raise the knee 0.002 in.(0.05mm) for paper thickness.
14. Set the graduated collar on the elevating screw hand-wheel to zero.
15. Move the work clear of the cutter and set the depth of cut using the graduated collar.
16. For roughing cuts use a depth of not less than 1/8 in. (3mm) and 0.010 to 0.025 in
(0.25 to 0.63 mm) for finish cuts.
17. Set the table dogs for the length of cut.
18. Engage the feed and cut side 1.
19. set up and cut the remaining sides as required.

FACE MILLING
Face milling is the process of producing a flat vertical surface at right angles to the
cutter axis. The cutters used for face milling are generally inserted-tooth cutters or shell end
mills. Face milling cutters are made in sizes of 6 in (150mm) diameter and over; cutter less
than 6 in (150mm) diameter are usually called shell end mills.
1. When face milling a large surface, use an inserted-tooth cutter and moubnt it into the
spindle of the machine.
2. When milling smaller surfaces, the face milling cutter should be about 1 in. (25mm)
larfger than the width of the workpiece.
3. Set the speeds abd feeds for the type of cutter and the material being cut.
4. Set up the work on the milling machine, being sure that the work-holding clamps do not
interfere with the cutting action.
5. Use cutting fluid if the cutter material or work will allow.
6. Take as large a roughing cut as possible to bring the surface close to within 1/32 to
1/16 (0.80 to 1.5 mm) of the finish size.
7. Set the depth of the finish cut and machine the surface to size.
8. After completing the operation, clean and sotre the cutter and clamping equipment in
their proper places.

SIDE MILLING
Side milling is often used to machine a vertical surface on the sides or the ends of a
workpiece.
Proceed as follows:
1. Set up the work in a vise and on parallels
2. Tighten the vise securely by hand . DO NOT USE A HAMMER ON THE VISE
WRENCH.
3. Tap the work lightly at the four corners with a softfaced hammer until the paper
feeleres are tighten between the work parallels.
4. Mount a side milling cutter as close to the spindle bearing as possible to provied
maximun rigidity when milling.
5. Set the proper speed and feed for the cutter being used.
6. Start the machine and move the table until the top corner of the work just touches the
revolving cutter. Make sure that the cutter is rotating in the proper directions.
7. Set the corssfeed graduated collar to zero.
8. With the table handwheel, move the work clear of the cutter.
9. Set the required depth of cut with corssfeed handle.
10. Lock the saddle to prevent movement during the cut.
11. Take the cut across the surface.
CENTERING A CUTTER TO MILL A SLOT
1. Locatethe cutter as close to the center of the work as possible.
2. Using a steal square and rule or a gage block, adjust the work to the center by using
the crossfeed screw dial.
3. Lock the saddle to prevent movement during the cut.
4. Move the work clear of the cutter and set the depth of cut.
5. Proceed to cut the slot using the same methods as for milling a flat surface.

STRADDLE MILLING
Straddle milling involves the use of two side milling cutter to machibne the opposite
sides of a workpiece parallel in one cut. The cutters are separated on the arbor by a spacer of
the required length so that the distance between the inside faces of the cutters is equal to the
desired size.
1. Select two sharp side milling cutterm preferably staggered tooh, of the suitable sizes.
2. Mount the cutters, with suitable arbor spacers, as close to the column as the work will
permit.
3. Mount the arbor support as close to the cutters as possible to provide rigidity fot the
cutters and arbor.
4. Center the cutters on the workpiece in the proper location.
5. Tighten the saddle lock to prevent any movement during a cut.
6. Set the cutter to the work surface.
7. Move the table so that the cutter clears the end of the workpiece.
8. Set the depth of cut required and tigthen the knee clamp.
9. Set the proper speeds and feeds for the cutter size and the tpe of work material; check
ctutter rotation.
10. Use a good supply of cutting fluid and complete the straddle milling operation in one
cut.

GANG MILLING
Gang milling is a fast method of milling used a gread deal in production work. It is
performed by using two or more cutter on the arbor to produce the desired shaped
1. Select cutter whicj are as close as possible to the same size and the same number of
theeth. This will allow maximum speeds and feeds to be used.
2. Mount the correct cutters on the arboer as close to the machine column as possible.
3. Fasten the arbor support as close to the cutters as the work will permit.
4. Set the spindle speed to suit the largest-diameter cutter.
5. Be sure that the work is fastened securely and that the workholding devices will not
come in contact with the cutters.
6. Use a food flow of cutting fluid to assist the cutting action and produce a good surface
finish.
SAWING AND SLITTING
Metal-slitting saws may be used for milling narrows slots and for cutting off work. Plain
slitting saws, because of their thin corss section, are rather fragile cutting tools, and if they are
not used carefull they will break easily.
1. Never key a slitting saws on the arbor unless it is mounted in a special flanged
mounting collar. If the slitting saw is keyed and jams in the work, it will rotate cutting
through the key, making it difficult to remove the broken saw.
2. When selecting a slitting saw, choose one with the smallest diameter that will permit
 adequate clearance between the arbor collars or supports and the clamping bolts,
holding device, or workpiece.
3. Mount the saw close to the column face and have the outer arbor support as close as
possible to the saw.
4. Always use a sharp cutter.
5. Be sure that the table gibs are drawn up to eliminate any play between the table and
the saddle.
6. Operate saws at approximately one-quarter to one-eighth the feed per tooth used for
side milling cutters.
7. When sawing or slitting fairly long or deep slots, it is advisable to climb-mill to prevent
the cutter from crowding sideways and breaking. The table should be fed carefully by
hand and the backflash eliminator engaged.
REVIEW QUESTIONS

SETTING CUTTER TO WORK

1. Why shouyld a long, thin piece of paper be used for setting a cutter to the work
suraface?
2. What should be done when the knee is moved beyond the desired amount?

MILLING A FLAT SURFACE

3. List the steps required to set work in a vise for milling.

4. Explain how the cutter should be set to the surface of the work.

FACE MILLING

5. Describe the process of face milling.

6. How large should a face milling cutter be in relation to the width of the work?

SIDE MILLING

7. For what purpose is side milling often used?

8. How should the work be set up in a vise for side milling?
9. Why should the table saddle be locked before machining?
10. Explaine how a cutter can be aligned with the center of a round workpice.

STRADDLE AND GANG MILLING

11. What is the difference between straddle and gang milling?

12. Why sohuld the arbor support be mounted as close to the cutters as possible

SAWING AND SLITTING

13. list five of the most important precautions for sawing slitting
 LESSON 6
THE INDEXING OR DIVIDING HEAD

INDEXING
Indexing is the operation of dividing the periphery of a workpiece into any number of
equal parts. For example if we want to make a hexagonal bolt. Head of the bolt is given
hexagonal shape. We do indexing to divide circular workpiece into six equal parts and then all
the six parts are milled to an identical flat surface. If we want to cut „n‟ number of teeth in a
gear blank. The circumference of gear blank is divided into „n‟ number of equal parts and
teeth are made by milling operation one by one. The main component used in indexing
operation is universal dividing head

INDEX HEAD PARTS

• Headstock with index plates
• Headstock change gears
• Quadrant
• Universal Chuck
• Footstock
• Center rest

INDEX HEAD PARTS

Swiveling block
• Mounted in base enables headstock to be tilted from 5º below horizontal to 10º beyond
vertical
Spindle
• Mounted in swiveling block with 40-tooth worm wheel, meshes with worm
Worm
• Right angle to spindle, connected to index crank
Direct indexing plate
 • Engaged by pin and attached to front of spindle

Universal Dividing Head

It is most popular and common type of indexing arrangement. As indicated by its name
“universal”, it can be used to do all types of indexing on a milling machine. Universal dividing
head can set the workpiece in vertical, horizontal, or in inclined position relative to the
worktable in addition to working principle is explained below with the help of illustration in
Figure 1.15. The worm gear has 40 teeth and the worm has simple thread. Crank is directly
attached with the worm. If we revolve crank by 40 revolutions the spindle attached with worm
gear will revolve by only one revolution and one complete turn of the crank will revolve the
spindle only by 1/40th revolution (turn). In order to turn the crank precisely a fraction of a
revolution, an indexing plate is used. An indexing plate is like a circular disc having concentric
rings of different number of equally spaced holes. Normally indexing plate is kept stationary
by a lock pin. A spring loaded pin is fixed to the crank which can be fixed into any hole of
indexing plate. The turning movement of the workpiece is stably controlled by the movement
of crank as explained below
 If the pin is moved by one hole on the indexing plate in the circle of 20 holes,
the spindle will revolve by 1/40 x 1/20 = 1/600 the turn of revolution.

Direct Indexing
It is also named as rapid indexing. For this direct indexing plate is used which has 24
equally spaced holes in a circle. It is possible to divide the surface of workpiece into any
number of equal divisions out of 2, 3, 4, 56, 8, 12, 24 parts. These all numbers are the factors
of 24.
In this case fist of all worm and worm wheel is disengaged. We find number of holes by
which spring loaded pin is to be moved. If we want to divide the surface
into 6 parts than number of holes by which pin is to be moved 24/N = for 6 parts N=6

So number of holes 26/6 =4 holes thatis after completing one pair of milling

whole surface of workpiece we have to move the pin by 4 holes before next milling
operation, thats to be done for 5 number of times for making hexagonal bolt.

Slots Direct indexing divisions

24 2 3 4 _ 6 8 _ __ 12 __ __ 24 __
__
30 2 3 _ 5 6 _ _ 10 __ 15 __ __ 30
__
36 2 3 4 _ 6 _ 9 __ 12 __ 18 __ __
36

Simple Indexing
It is also named as plain indexing. It over comes the major limitation of direct indexing
that is possibility of dividing circumference of workpiece into some fixed number of divisions.
In this case worm and worm gear is first engaged. So one Milling complete turn of indexing
crank revolves the workpiece by 1/40 th revolution.

Three indexing plates are used. These plates have concentric circles of holes with their
different numbers as described below :

Plate #1 15 16 17 18 19 20
Plate #2 21 23 27 29 31 33
Plate #3 37 39 41 43 47 49
These are the standard indexing plates followed by all machine tool manufacturers.

Indexing Procedure
• Divide 40 by the number of divisions to be done on the circumference of workpiece.
This Give movement of indexing crank.

Indexing crank movement 40/N

 N is the number of divisions to be made on the circumference of workpiece.

• If the above number is a whole number, then crank is rotated by that much number of
revolutions after each milling operations, till the completion of the work. For example, if
we want to divide the circumference into 10 number of parts

Indexing crank movement 40/10 =4 revolution

That is the indexing crank is given 4 revolutions after each of milling operation for 9
more milling operations

• If indexing crank movement calculated by 40/N is not whole number, it is simplified and
then expressed as a whole number and a fraction.

• The fractional part of the above number is further processed by multiplying its
denominator and numerator by a suitable common number so that the denominator will
turn to a number equal to any number of holes available on the any of indexing plates.
• That particular holes circle is selected for the movement of crank pin.
• The numerator of the process fraction stands for the number of holes to be moved by
the indexing crank in the selected hole circle in addition to complete turns of indexing
crank equal to whole number part of 40/N .
• Let us do the indexing to cut 30 teeth on a spur gear blank that means we need to
divide the circumference of gear blank into 30 identical, parts. Crank movement is
calculated s given below.
Crank movement =40/N = 40/30
Here, N = 30.
=1 10/30 = 1 1/3

Let us multiply both numerator and denominator by 5.

=1 5/15
Denominator becomes „15‟ so we will select 15 hole circle of plate 1.

Compound Indexing
The word compound indexing is an indicative of compound movements of indexing
crank and then plate along with crank. In this case indexing plate is normally held stationary
by a lock pin, first we rotate the indexing crank through a required number of holes in a
selected hole circle, then crank is fixed through pin. It is followed by another movement by
disengaging the rear lock pin, the indexing plate along with indexing crank is rotated in
forward or backward direction through predetermined holes in a selected hole circle, then lock
pin is reengaged. Following steps are to be followed for compound indexing operation.

INDEX PLATE AND SECTOR ARMS

The index plate is a circular plate provided with a series of equally spaced holes into
which the index crank pin engages. The sector arms fit on the front if thus okate abd may be
set to any portion of a complete turn
 INDEX PLATE HOLE CIRCLES
BROWN AND SHARPE
PLATE 1 15-16-17-18-19-20
PLATE 2 21-23-27-29-31-33
PLATE 3 37-39-41-43-47-49
CINCINNATI STANDARD PLATE
ONE SIDE 24-25-28-30-34-37-38-39-41-42-43
OTHER SIDE 46-47-49-51-53-54-57-58-59-62--66

Cutting Seven Flutes

1. Mount B&S Plate 2 index plate on dividing head
2. Loosen index crank nut and set index pin into hole on 21-hole circle
3. Tighten index crank nut and check to see that the pin enters hole easily
4. Loosen setscrew on sector arm
5. Place narrow edge of left arm against index pin
6. Count 15 holes on 21-hole circle
• Do not include hole in which index crank pin is engaged.
7. Move right sector arm slightly beyond fifteenth hole and tighten sector arm setscrew
8. Align cutter with work piece
9. Start machine and set cutter to top of work by using paper feeler
10. Move table so cutter clears end of work
11. Tighten friction lock on dividing head before making each cut and loosen lock when
indexing for spaces
12. Set depth of cut and take first cut
13. After first flute has been cut, return table to original starting position
14. Withdraw index pin and turn crank clockwise five full turns plus the 15 holes indicated
right sector arm
• Release index pin between 14th and 15th holes and gently tap until it drops into 15th
hole
15. Turn sector arm farthest from pin clockwise until it is against index pin
16. Lock dividing head; continue machining and indexing for remaining flutes

ANGULAR INDEXING
1. Setup for simple indexing may be used
• Must calculate indexing with angular distance between divisions instead number of
divisions
2. One complete turn of index crank turns work 1/40 of a turn
• 1/40 of 360º equals 9 degrees

Calculate indexing for 45º

 5 complete turns

Calculate indexing for 60º

6 full turns plus 12 holes on 18 hole circle

Angular Indexing

Calculate indexing for 24'

Divide 24'/540' = 4/90
4/90 = 1/22.5
1 hole on a 22.5 hole circle

The nearest is a 23 hole circle. Indexing would be 1 hole on a 23 hole circle with a slight error
(approximately 1/2 minute). A need for higher accuracy requires differential indexing.

Calculate indexing for 24º30'

• First, convert angle into minutes
(24 x 60') = 1440' now add 30' = 1470'
Convert 9° to minutes 9°x60 = 540'
Divide 1470'/540' = 2 13/18

2 full turns and 13 holes on 18 hole circle

Differential Indexing

• Used when 40/N cannot be reduced to a factor of one of the available hole circles
• Index plate must be revolved either forward or backward part of a turn while index
crank turned to attain proper spacing (indexing)
• Change of rotation effected by idler gear or gears in gear train

Differential Method
• Number chosen close to required divisions that can be indexed by simple indexing
• Example: Assume index crank has to be rotated 1/9th of a turn and only 8-hole circle
• Crank moved 1/9th, index pin contacts plate at spot before first hole
• Exact position would be the difference between 1/8th and 1/9th of a revolution of the
crank
Differential Method cont.

one-seventy-second of a turn short of first hole

Since there is no hole at this point, it is necessary to cause plate to rotate backward by
means of change gears one-seventy-second of a turn of pin will engage in hole.

REVIEW QUESTIONS

INDEXING OR DIVIDING HEAD

1. Name four parts of a dividing head set.

2. Name of four methods of indexing that may be performed using the dividing head.
3. For what purpose us direct indexing used?

SIMPLE INDEXING

4. Explain how the ration of 40:1 is determined on a standard dividing head.

5. Caluculate the sunoke indexing, using a brown and sharpe dividing head, for the
following divisions: 37,41,22,34, and 120.
6. What procedure should be followed in order to set the sector arms for 12 holes on an
18-hole cirlce?

ANGULAR INDEXING

7. Explain the principle of angular indexing.

8. Calculate the indexing, using a cincinnati dividing head, for the following angles: 21°,
37°, 24°30' .

DIFFERENTIAL INDEXING

9. for what purpose is differential indexing used?

10. What is meant by positive rotation and negative rotation of the index plate?

WIDE-RANGE DIVIDING HEAD

11. How does the wide-range dividing head differ from a standard dividing head?
12. What two ratios are found in a widre-range dividing head?
13. Calculate the indexing for (a) 1000 and b() 1200 dividing head.
14. Calculate the angular indexing for the following , using a wide-range dividing head:
20°45' , 25°15'32” .
LINEAR GRADUATING

15. how are the dividing head and the milling machined geared for linear graduating.
16. What indexing would be required to move the table 0.003in. When using equal gearing
on the dividing head and the lead screw?

LESSON 7
GEARS

Gears are widely used in various mechanisms and devices to transmit power and
motion positively (without slip) between parallel, intersecting ( axis) or non-intersecting non
parallel shafts,
• without change in the direction of rotation
• with change in the direction of rotation
• without change of speed (of rotation)
• with change in speed at any desired ratio

Gears are basically wheels having, on its periphery, equispaced teeth which are so
designed that those wheels transmit, without slip, rotary motion smoothly and uniformly with
minimum friction and wear at the mating tooth – profiles. To achieve those favourable
conditions, most of the gears have their tooth form based on involute curve, which can simply
be defined as Locus of a point on a straight line which is rolled on the periphery of a circle or
Locus of the end point of a stretched string while its unwinding over a cylinder as indicated in
Fig. 7.2.1

General Applications Of Gears

 Gears of various type, size and material are widely used in several machines and
systems requiring positive and stepped drive. The major applications are :
• Speed gear box, feed gear box and some other kinematic units of machine tools
• Speed drives in textile, jute and similar machineries
• Gear boxes of automobiles
• Speed and / or feed drives of several metal forming machines
• Machineries for mining, tea processing etc.
• Large and heavy duty gear boxes used in cement industries, sugar industries, cranes,
conveyors etc.
• Precision equipments, clocks and watches • Industrial robots and toys.

Types Of Gears and their Characteristic

(a) According to configuration (Fig. 7.2.2)

• External gear
• Internal gear
GEAR TERMINOLOGY
A knowledge of the more common gear terms is desirable to understand gearing and to
make the calculations necessary to cut a gear. Most of these terms are applicable to either
inch or metric gearing, although the method of calculating dimension may differ. These
methods , as applicable to inch and metric gear-cutting.
SPUR GEAR TERMINOLOGY
The following terms (see fig. 14-2) describe gears and gear teeth. The symbols in
parentheses are standard gear nomenclature symbols used and taught at MR schools.

• OUTSIDE CIRCLE (OC): The circle formed by the tops of the gear teeth
• OUTSIDE DIAMETER (OD): The diameter to which you will turn the blank or the
overall diameter of the gear
• PITCH CIRCLE (PC): The contact point of mating gears, the basis of all tooth
dimensions, or an imaginary circle one addendum distance down the tooth
• PITCH DIAMETER (PD): The diameter of the pitch circle. In parallel shaft gears, you
can determine the pitch diameter directly from the center-to-center distance and the
number of teeth.
• ROOT CIRCLE (RC): The circle formed by the bottoms of the gear teeth
• ROOT DIAMETER (RD): The distance through the center of the gear from one side of
the root circle to the opposite side
• ADDENDUM (ADD): The height of the part of the tooth that extends outside the pitch
circle
• CIRCULAR PITCH (CP): The distance from a point on one tooth to a corresponding
point on the next tooth measured on the pitch circle
• CIRCULAR THICKNESS (CT): One-half of the circular pitch, or the length of the arc
between the two sides of a gear tooth on the pitch circle.
• CLEARANCE (CL): The space between the top of the tooth of one gear and the
bottom of the tooth of its mating gear
• DEDENDUM (DED): The depth of the tooth inside the pitch circle, or the radial
distance between the root circle and the pitch circle
• WHOLE DEPTH (WD): The radial depth between the circle that bounds the top of the
gear teeth and the circle that bounds the bottom of the gear teeth
• WORKING DEPTH (WKD): The whole depth minus the clearance, or the depth of
engagement of two mating gears; the sum of their addendums
• CHORDAL THICKNESS (tc): The thickness of the tooth measured at the pitch circle or
the section of the tooth that you measure to see if the gear is cut correctly
• CHORDAL ADDENDUM (ac): The distance from the top of a gear tooth to the chordal
thickness line at the pitch circle (used to set gear tooth vernier calipers to measure
tooth thickness)
• DIAMETRAL PITCH (DP): The most important calculation because it regulates the
tooth size, or the number of teeth on the gear divided by the number of inches of pitch
diameter
• NUMBER OF TEETH (NT): The actual number of teeth of the gear
• BACKLASH (B): The difference between the tooth thickness and the tooth space of
engaged gear teeth at the pitch circle
REVIEW QUESTIONS

1. List six types of gears, and state where each may be used.

2. Define the follosing gear terms, and state the formula used to determine each. Used
the formulas involving diametral pputech, not circular pitch, where applicable.
a. Pitch diameter e. Clearance
b. Diameter pitch f. Outside diameter
c. Addendum g. Number of teeth
d. Dedendum

3. Calculate the pitch diameter, outside diameter, and whole depth of tooth for the
following gears.
a. 8 DP with 36 teeth
b. 12 DP with 81 teeth
c. 16 DP with 100 teeth
d. 6 DP having 23 teeth
e. 4 DP having 54 teeth
 LESSON 8
GEAR CUTTING

Most gears cut on a milling machine are generally used to repaire or replace a gear
which has been broken or lost or is no longer carried in inventory. Industry generally mass
produces gears on special machines which have been designed for this purpose.

INVOLUTE GEAR CUTTERS

Gear cutters are an example of formed cutters. This type of cutter is sharpened on the
face and ensures exact duplication of the shape of the teeh, regardless of how far back the
face of the tooth has been ground.
 INVOLUTE GEAR CUTTERS
CUTTER NUMBER RANGE
1 135 teeth to a rack
1½ 80 to 134 teeth
2 55 to 134 teeth
2½ 42 to 54 teeth
3 35 to 54 teeth
3½ 30 to 34 teeth
4 26 to 34 teeth
4½ 23 to 25 teeth
5 21 to 25 teeth
5½ 19 and 20 teeth
6 17 to 20 teeth
6½ 15 and 16 teeth
7 14 to 16 teeth
7½ 13 teeth
8 12 and 13 teeth

TO CUT A SPUR GEAR

1. Calculate all the necessary gear data

a. Outside diameter = N + 2
DP
= 54
8
= 6.750 in.

b. Whole depth of tooth = 2.157

DP
= 2.157
8
= 0.2697 in.
 c. Cutter number = 3 (35 to 54 teeth)
d. Indexing (using Cincinnati standard plate)

=40
N
= 40
52
= 10/10 x 3/3 = 30 holes on the 39-hole circle
2. Turn the gear blank to the proper outside diameter.
3. press the gear blank firmly onto the mandrel.
4. Mount the index head and footstock, and check the alignment of the index centers.
5. Set the dividing head so that the index pin fits into a hole on the 39-hole circle and the
sector arms are set for 30 holes.
6. Mount the mandrel (and workpiece), with the large end toward the indexing head,
between the index centers.
7. Move the table close to the column to keep the setup as rigid as possible.
8. Mount a 8 DP#3 cutter on the milling machine arbor over the approximate center of the
gear. Be sure to have the cutter rotating in the direction of the indexing.
9. LOCK THE CROSS SLIDE.
10. Start the milling cutter and run the work under the cutter.
11. Raise the table until the cutter just touches the work. This can be done by using a
chalk mark on the gear blank or a piece of paper between the gear blank and the cutter
to indicate when the cutter is just touching the work.
12. Set the graduated feed collar on the vertical feed to zero.
13. Move the work clear of the cutter by means of the longitudinal feed handle and raise
the table to about two thrids the depth of the tooth (0.180in) then lock the knee clamp.
14. Slightly notch all gear teeth on the end of the work to check for correct indexing.
15. Rough out the first tooth and set the automatic feed trop dog after the cutter is clear of
the work.
16. Return the table to the starting position.
17. Cut the remaining teeth and return the table to the starting position.
18. Loosen the knee clamp, raise the table to the full depth of 0.270 in . And lock the knee
clamp.
19. Finish-cut all teeth.

Metric Module Gear Cutters

Module Milling Cutters Numbers
Size (mm) Cutter No. For Cutting
0.50 3.50
0.75 3.75 1 12-13 teeth
1.00 4.00 2 14-16 teeth
1.25 4.50 3 17-20 teeth
1.50 5.00 4 21-25 teeth
1.75 5.00 5 26-34 teeth
2.00 6.00 6 35-54 teeth
2.25 6.50 7 55-134teeth
2.50 7.00 8 135 teeth to rac
 2.75 8.00
3.00 9.00
3.25 10.00

GEAR TOOTH MEASUREMENT

To ensure that the gear teeh are of the proper dimensions they sould be measured with
a gear tooth vernier caliper. The caliper should be set to the correcter addendu, , a dimension
which may be found in most handbooks.
Gear size may also be accurately checked by measuring over wires or pins of a
specific diameter, which have been placed in two diametrically opposite tooth spaces of the
gear.
The wire or pin size to be used is determined as follows:
1. For external inch spur gears the wire or pin size is equal to 1.728 diveded by the
diametral pitch of the gear.
2. For internal inch spur gears, the wire size is equalto 1.4 divided by the diameter pitch
of the gear.
3. Metric module geras are measured using a wire size equal to 1.728 multiplied by
module of the gear. The measurement over the wires should equal the value shown in
the handbook table multiplied by module.
EXAMPLE
Determine the wire size and the measurement iver the wires for a 10-DP external gear
having 28 teeth and a 14.50° pressure angle.
Wire size = 1.728
10
= 0.1728 in.
By reffering to handbook tables, the size over the wires for a gear having 28 teeth and a
14.50° pressure angle should be 30.4374 in. divided by the DP. Therefore the measurement
over the wires should be
30.4374
10
=3.0437 in.
If the measurement is larger than this size, the PD is too large and the depth of cut will
gave to be increased. If it is less than the determined size, the gear is undersize. Gears
having an odd number of teeth are calculated in a similar manner but using the proper tables
of these gears.
REVIEW QUESTIONS

1. What cutter numbers should be used to cut the following gears?

a. 8 DP-36 teeth c. 16 DP-100 teeth
b. 12 DP-81 teeth d. 6 DP-23 teeth

2. Describe two methods of centering the gear blank with the cutter for machining a spur
gear.

3. What precautions should be observed when mounting the gear blank between the
index head and centers?

4. What is the purpose of notching before gear teeth are cut?

 5. Compare the terms module and pitch diameter.

6. How does the metric module and pitch diameter. How does the metric module
numbering system for gear cutter differ from the for diameter pitch system?

7. For a 40-tooth spur gear, 240mm pitch dianeter, calculate:

a. Module e. Dedendum
b. Circular pitch f. Whole depth
c. Outside diameter g. Cutter number
d. Addendum

GEAR TOOTH MEASUREMENT

8. state two methods of measuring gear teeth.

9. How is the wire size determined
a. External gears?
b. Internal gears?

LESSON 9
HELICAL MILLING

A helix may be defined as a regular curved path. such as is formed by winding a cord
around the surface of a cylinder. Helical parts most commonly cut on the milling machine
include helical gears. spiral flute milling cutters, twist drills. and helical cam grooves. When
milling a helix. a universal index head is used to rotate the workpiece at the proper rate of
speed while the piece is fed against the cutter. A train of gears between the table feed screw
and the index head serves to rotate the workpiece the required amount for a given
longitudinal movement of the table. Milling helical parts requires the use of special formed
milling cutters and doubleangle milling cutters, The calculations and formulas necessary to
compute proper worktable angles, gear adjustments. and cutter angles and positions for
helical milling are beyond the scope of this manual,
HELICAL TERMS
The term spiral is often used incorreclty in place of a helix
• A helical is a theoretical line or path generated on a cylindrical surface by cutting tool
which is fed lenghwise at a uniform rate . The flutes on a drill or the threads on a bolt
are examples of helices.
• A spiral is the path generated by a point moving at a fixed rate of advance along the
surface of a rotating cone or plane. Threads on awood screw and pipe threads are
examples of conical spirals. Watch springs and scroll threads on a universal lathe
chuck are examples of a plane or flat spiral.

In order to cut either an inch or metric helix, any two of the following must be known :
1. The lead of the helix, which is longtidunal distance the helix advances axially in one
complete revolution of the work.
2. The angle of the helix, which is formed by the intersection of the helix with the axis of
the workpiece.
3. The diameter (and circumference ) of the workpiece.

Incomparing two different helices, it will be noticed that the greater the angle with the
centerline, the shorter will be the lead. However, if the diameter is increased but the helix
angle remains the same, the greater will be the lead. Thus it is evident that the lead of a helux
varies with :
1. The diameter of the work
2. The angle of the helix.

CUTTING A HELIX
1. Swing the table in the proper direction to the angle of the helix to ensure that a groove
of the same contour as the cutter is produced.
2. The work must rotate one turn while the table travels lengthwise the distance equal to
the lead. This is achieved by installing the proper change gears between the worm
shaft on the dividing head and on the milling machine lead screw.

DETERMINING THE HELIX ANGLE

To ensure that a groove of the same contour as the cutter is produced, the table must
be swung to the angle of the helix .
 Tangent of helix angle= circumference of work
lead of helix

= 3.1416 x diameter (D)

lead of helix

EXAMPLE (inch)
To what angle must the milling machine table swiveled to cut a helix having a lead of
10.882 in. on a piece of work 2 in. in diameter.

Tangent of helix angle = 3.1416 x D

lead of helix

= 3.1416 x 2
10.882
= 6.2832
10.882
=0.57739
helix angle =30°
After the helix angle has been calculated , it is necessary to determine the direction in
which to swivel the table to produce the proper hand of helix (that is, right or left hand)

EXAMPLE (metric)
To what angle must a milling machine table be swiveled to cut a helix having a lead of
450mm on a workpiece 40mm in diameter.

Tangent of helix angle = 3.1416 D(mm)

lead of helix (mm)

=3.1416
450
= 0.2792
helix angle = 15°36'
REVIEW QUESTION

HELICAL MILLING

1. Define:
a. Helix c. Lead
b. Spiral d. Angle of helix
2. Make a sketch to illustrate the relationship between the lead, circumference, and helix
angles.
3. List two factors which affect the lead of a helix.
4. To what angle must the table be swung to cut the following helicles?
a. Lead 10.290 in., diameter of workpiece 3¼ in.
b. Lead 12.000 in., diameter of workpiece 2¾ in.
c. Lead = 600 mm, work diameter= 100 mm
d. Lead = 232 mm, work diameter= 25 mm.
5. How many a right- and left-handed helix be recognized and in which direction should
the table be swiveled for each?
6. a. Calculate the change gears to cut the following leads:
1. 6.000 in.
2. 7.500 in.
3. 9.600 in.
b. The lead screw of a milling machine has a pitch of 5mm. The available chage gears are
24,24,28,32,36,40,44,48,56,64,72,86,100. Calculate the change gears required for leads of
800 mm and 560 mm.
7. It is required to make a helical milling cutter having the following specifications.

Diameter: 3.475
Helix: left-hand
Rake angle: 5°positive
Depth of flute: 0.5 in.
Material : tool steel
Number of teeth: 7
Helix angle: 20°
Angle of flute: 55°
Length: 3 in.

Calculate:
a. indexing
b. lead
[Link] gears required
 LESSON 10
CAM, RACK, WORM AND
CLUTCH MILLING

CAMS AND CAM MILLING

A cam is a device generally applied to a machine to change rotary motion into straight-
line or reciprocating motion and to transmit this motion to other parts of the machone through
a follower. The cam shaft on an automobile engine incorporates several cams, which control
the opening and closing of the intake and exhaust valves.

CAMS USED TO IMPART MOTION

Cam used to impart motion are generally found on machines and may be of two types:
the positive and the non-postive
Positive-type cams, such as the cylindrical and grooved plate, control the follower at all
times. That is, the follower remains engaged in the groove on the face or the periphery of the
cam and uses no other menas to maintain this engagement.
Example of the nonpositve-types cams are the plate, toe and wiper, and crown. In the
nonpositve types, the cam pushes the follower in a given direction and depends on some
external force, such as gravity or springs, to keep the follower bearing against the cam
surface
Followers may be of several types:
• The roller type has the least frictional drag and requires little or no lubrication.
• The taperd roller type is ised with grooved plate or cylindrical cams.
• The flat, or plunger, type is used to transmit large forces and requires lubrication.
• The knife-edge, or pointed, type is used on more intricate cams as it permits sharp
contours to be followed more readily than with a roller cam.

CAM MOTIONS
There are three standard types of motions imparted by cams to followers and machine
parts:
1. Uniform motion
2. Harmonic motion
3. Uniformly accelerated and decelerated motion

The uniform-motion cam moves the follower at the same rate from the beginning to the
end of the stroke. Since the movement goes from zero to full speed instantaneously and ends
in the same abrupt way , there is a distinct shock at the beginning and the end of the stroke.
The harmonic-motion cam provides a smooth start and stop to the cyle. It Is used when
uniformity of motion is not essenstial and where high speeds are required.
The uniformly accelerated and decelerated cam moves the follower slowly at first ,
then accelerates or decelerates at a uniform rate. It then gradually decreases in speed,
permitting the follower to come to a slow stop before reversal takes place. This type is
considered the smoothest of the tthree motions and is used on high-speed machines.
RADIAL CAM TERMS
A lobe is a projecting part of the cam which imparts a reciprocal motion to the follower.
Cams may have one or several lobes, depending on the application to the machine.
The rise is the distance one love will raise or lower rhe follower as the cam revolves.
The lead is the total travel which would be imparted to the follower in one revolution of
a uniform-rise cam, having only one love in 360°
The uniform rise is the rise generated on a cam whicj moves inward at an even rate
around the cam, assuming the shape of an archimendes spiral. This is caused by unifrom
feed and rotaion of the work when a cam is being machined.

CAM MILLING
In the majority of plate cams which do not have a uniform rise the cam must be laid out
and machined by incremental cuts. By this method, the blank is rotated through an angular
increment and the cut is taken to the layout line or a predetermined point.
Uniform-rise cams may be produced in the milling machine with a vertical head, by the
combined unifrom rotation of the cam blank, held in the spindle of a dividing head, and the
unifrom feed of the table.
When cam is machined by this method, the work and vertical head are usally swung at
an angle so that the axis of the work and the axis of the mill are parallel .

Calculations Requred
From the drawing determine the lead of the lobe or lobes of cams; that is, determine
the amount of rise of each lobe if it were continued for the full circumference of the cam.
If the space occupied by the lobe is indicated in degrees on the drawing, the lead
would be calculated as follows:

Lead= rise of lobe in inches X 360

number of degrees of circumference
occupied by the hole

However, if the circumference is diveded into 100 equal parts, it will be necessary to caltulate
the lead as follows:

Lead= rise of lobe in inches x 100

percent of circumference
occupied by the hole

RACK MILLING
A rack, in conjuction with a gear (pinion), is used to convert rotary motion into
lingitudinal motion. Racks are found on lathes, drill presses, and many other machine in a
shop. A rack may be considered as a spur gear which has been straightened out so that the
teeth are all in one [Link] the pitch line of a racks is the distance of one addendum
(1/DP) below the top of the tooth.
The pitch of a rack is measured in linear (circular) pitch, which is obtained by dividing
3.1416 by the diametral pitch that is :

Rack pitch = 3.1416

DP
RACK INDEXING ATTACHMENT
When cutting a rack using the rack milling attachment , the table is often moved
(indexed) for each tooth by means of the rack indexing attachment. This consits of an
indexing plate with two diametrically opposed notches and a locking pin.
This attachment permits the indexing of all diametral pitches from 4 to 32, as well as all
circular pitches from 4 to 32 , as well as all circular pitches from 1/8 in to ¾ in. varying by
sixteenths. The following table movements can also be produced : 1/7 , 1/6, 1/5, 2/7, 1/3, and
2/5 in.

WORMS AND WORM GEAR

Worms and worm gears are used when a great ratio reduction is required between the
driving and driven shaft. A worm is a cylinder on which is cut a single- or multiple-start acme-
type thread. The angle of this thread ranges from a 14.5 to 30° pressure angle.

TO MILL A WORM
Worms are often cut on a milling machine with a rack milling attachment and a thread
milling cutter. The setup of the cutter is similar to that for rack milling. The work is held
between index centers and is rotated by suitable gears between the worm shaft and the lead
screw of the milling machine.

PROCEDURE
1. Calculate all dimensions of the thread, that is, lead, pitch, depth, and angle of thread.
2. Mount the worm blank between the dividing head centers located at the end of milling
machine table.
3. Determine the proper gears for the lead, and mount them so that they connect the
worm shaft and the lead screw.
4. Disengage the index plate locking device.
5. Mount the proper thread milling cutter on the rack milling attachment.
6. Swing the rack milling attachment to the required helix angle of the worm thread and in
the proper direction for the lead of the worm.
7. Center thre work under the cutter.
8. Raise the work up to the cutter.
9. Move the work clear of the cutter, and ruase the table to thre required depth of thread.
10. Cut the thread using the automatic feed or by turning the index crank handle to feed
the table manually.

CLUTCHES
Positive-drive clutches are used extensively to drive or disconnect gears and shafts in
machine gearboxes. The headstock on most lathes use clutches, machine on the hubs of
gears, to engage or disengage gears to provide different spindle speeds.
Three forms of positive-drive clutches.
The straight tooth clutch permits rotation in either direction. This type is more difficult
to engagae since the mating teeth and grooves must be in perfect alignment before
engagement is possible.
The inclined-tooth clutch provieds and easier means of engaging or disengaging the
driving and driven members because of an 8 o 9° angle machined on the faces of the teeth.
The sawtooth clutch permits drive in only one direction but is more easily engaged than
the other two types of clutches. The angle of the teeth in thus tyoe is generally 60°
REVIEW QUESTIONS

CAMS AND CAM MILLING

1. Define a cam.
2. Name four types of cams.
3. Name four types of followers and state how each is used.
4. List three cam motions, and describe the type of motion which is imparted to the
follower in one revolution of the cam.
5. In a single-lobe cam and a double-lobe cam, what is the relationship of the lead to the
rise?
6. Calculate:
a. Lead of cam
b. The change gears required to produce this lead
c. The angle at which to swing the dividing head
d. the angle at which to swing the vertical head for each of the following examples of uniform
rise:
1. a single-lobe cam having a rise of 0.125 in. in °
2. a two-lobe cam, each lobe having a rise of 0.187 in. in 180°
3. a three-lobe cam, each lobe having a rise of 0.200 in. in 120°

RACK MILLING

7. Define rack and state its purpose.

8. A 10-DP gear is in mesh with a rack. The gear has 42 teeth. The rack is 1 in. thick
from the top of the tooth to the center bottom of the rack. Calculate the distance from
the center of the gear to the bottom of the rack.
9. Calculate the linear pitch of a 5-pith rack, an 8-pitch rack, and a 14-pitch rack.

WORMS AND WORM GEARS

10. Define worm and worm gear, and describe ther use.
11. Describe briefly how a worm is cut on a milling machine.

CLUTCHES

12. List three types of clutches, and state the application of each.
13. Why are clutches with an odd number of teeth perferred to twose with an ever number
teeth?
14. After the outside surface if 1 a 3-in. Diameter ( or 76-mm) clutch blank has been
touched up to a ½ in. (or 13—mm), how far must the table be move over when cutting:
a. A clutch having five teeth?
b. A clutch having six teeth?
 LESSON 11
THE VERTICAL MILLING MACHINE
CONSTRUCTION AND OPERATIION

TYPES OF VERTICAL MILLING MACHINE

The standard vertical milling machine has all the construction has all the construction
features of a plain horizontal milling machine, expect that the cutter spindle is mounted in a
vertical position. The spindle head on most vertical milling machines may be swiveled, which
readily permits the machining of angular surfaces. The spindle on most vertical milling
machines have a short travel, which facilities step milling and the drilling and boring holes.

RAM-TYPE MILLING MACHINE

The ram-type milling machine is characterized by a spindle mounted to a movable housing
on the column to permit positioning the milling cutter forward or rearward in a horizontal
plane. Two popular ram-type milling machines are the universal milling machine and the
swivel cutter head ram-type milling machine.

PARTS OF THE RAM-TYPE VERTICAL MILLING

• The base is made of ribbed cast iron. It may contain a coolant reservoir.
• The column is often cast in integrally with the base. The,machined face of the column
provides the ways for vertical movement of the knee.
• The overwarm is round, or of the ram type. It may be adjustable toward or away from
the column to increase the capacity of the machine.
• The head is attachment to the end of the arm. Provision is made to swivel the head in
 one plane.
• The knee moves up and down on the face of the column and supports the saddle and
the table. The knee in this type of machine does not contain the gears for the
automatic feed as in the horizontal milling machine and the standard vertical milling
machine.

ALIGNING THE VERTICAL HEAD

Proper alignment of the head is of the utmost importance when machining holes or
when face milling. If the head is not at an angle of 90° tot the table, the holes will not be
square with the work surface when the cutting tool is fed by hand or automatically. When face
milling, the machined surface will be stepped if the head is not square with the table. Although
all heads are graduated in degrees and some have vernier devices used for setting the head ,
it is wise to check the spindle alignment.
REVIEW QUESTIONS

1. Why has the vertical machine been so readily accepted by industry?

2. Name six operations which can be performed in a vertical mill.
3. Describe:
a. A standard vertical mill
b. A ram-type vertical mill
4. State the purpose of the following parts:
a. Column
b. Overarm
c. Head
d. Knee

ALIGNING THE VERTICAL HEAD AND VISE

5. why is it necessary to align the vertical head square with the table?
6. Describe briefy how the vertical head may be aligned with the table surface.
7. Why is it important that the vise be aligned with the tavle travel?
8. Describe one method of aligning the vise parallel to the table travel.

MACHINING A FLAT SURFACE

9. What precautions should be observed before machining a flat surface?
10. What type of cutter should be used to machine a large surface?
11. How can the edge of a flat piece be machine square with a flat finished surface?

MACHINING A BLOCK SQUARE AND PARALLEL

12. How should the work be set in a vise to machine side 1?
13. how should the work be set in a vise to machine side 2?
14. draw a sketch of the work setup required for machining side 3 and side 4.

MACHINING ANGULAR CENTER

15. describe briefly two methods of machining angular surfaces.

CUTTING SLOTS AND KEYWAYS

16. What type of cutter should be used to cut slots or keyways having one or twoo blind
ends.
17. How can round work be held for machining slots and keyways?
18. Explain one method of aligning the end mill with the center of a shaft.
19. How may the depth of a keyway be measured?
20. Calculat the measurement for a ½-in.-wide key seat from the botton if a 2-in.-diamaeter
shaft to the botton if the keyseat (½ x ½ key)
21. Describe a woodruff key an state its purpose.
22. Explain the marking 810 found on a woodruff key cutter.
23. Explain how to center a woodruff key cutter with in a shaft
 LESSON 12
SPECIAL MILLING OPERATIION

Explanatory names, such as sawing, slotting, gear cutting, and so forth have been
given to special operations. Routing is a term applied to milling an irregular outline while
controlling the workpiece movement by hand feed. Grooving reamers and taps is called
fluting. Gang milling is the term applied to an operation in which two or more milling cutters
are used together on one arbor. Straddle milling is the term given to an operation in which two
milling cutters are used to straddle the workpiece and mill both sides at the same time.

Using a Rotary Table

A rotary table can be used to make arcs and circles. For example, the circular T-slot in
the swivel base for a vise can be made using a rotary table. Rotary tables can also be used
for indexing, where a workpiece must be rotated an exact amount between operations. You
can make gears on a milling machine using a rotary table. Dividing plates make indexing with
a rotary table easier.
REVIEW QUESTIONS

ROTARY TABLE

1. For what purpose may a rotary table be used?

2. Describe briefly the construction of a rotary table.
3. What is the purpose of the hole in the center of a rotary table?
4. Wwhat common ratios are found on rotary tables?
5. Describe briefly how a rotary tabke may be centered with the vertical mill spindle.
6. Explain how a number of indentical parts, having a hole in the center, can be aligned
on a rotary table.