VERTICAL MILLING ATTACHMENT

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Center of Excellence .
Production Manufacturing
Basic Training.
Basic Milling Gear Cutting.
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VERTICAL MILLING ATTACHMENT

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

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HIGH SPEED ATTACHMENT

• It is used to drive small milling cutters at
  high speed.
• It may be fitted on vertical or horizontal
  machine.
• It consists a housing contains step-up gearing
  and a small spindle.

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SLOTTING ATTACHMENT

• Its used for cutting at any angle in vertical
  plane to produce key ways , slots and corners.
• Its provide reciprocating drive for single
  point cutting tool.

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UNIVERSAL SPIRAL ATTACHMENT

• Its used to mill spirals with a plain milling
  machine.
• Its useful for cutting helical threads , gears ,
  worms and racks.

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RACK MILLING ATTACHMENT

• Its mounted between the face of column and outer
  support on a plain or universal milling machine.
• It consists a fixed housing and a spindle.
• A special rack indexing attachment used to move
  the work longitudinally with accurate spacing of
  teeth.

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CIRCULAR TABLE ATTACHMENT

• Its used for profile milling and many other
  circular operations in horizontal plane such as
  slotting and dovetailing.
• Its consists a base,a worm drive mechanism and a
  small circular work table.

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VERTICAL MILLING MACHINE

• PARTS
• Base
• Column
• Vertical head
• Spindle
• Table
• Saddle
• Knee

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HORIZONTAL MILLING MACHINE

• Axis of spindle is in horizontal plane and
  parallel to Its table.
• Generally cutters are mounted on long arbor.

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ELECTRICAL EQUIPMENT

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

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CUTTING FLUID EQUIPMENT

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

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HELICAL GEAR

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

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MITRE GEARING

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

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SPUR GEAR

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

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HERRINGBONE GEAR

• Its equivalent to two helical gears,one having a
  right hand and other a left hand helix.
• Its used in heavy duty machines like steel roll
  mills.

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BEVEL GEAR

• When two shafts are in same plane but at
  another,bevel gears an angle with one are used.
• Its a frustum of a cone having all elements of
  teeth intersecting at a point.

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SLOT DRILL CUTTER

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

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COLLET CHUCK

• The chuck is supplied with a set of spring
  collets in various sizes.

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COLLET CHUCK

• The cutter (d) is inserted into the collate and
  then the nut is tightened ,using the special
  spanner supplied with the chuck.

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COLLET CHUCK

• It is used to reduce the internal taper in the
  work spindle,so that it fits on required arbor or
  cutter.

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COLLET CHUCK

• This type of adapter with Morse taper and flat
  tong is used for holding taper shank and mill
  with tong.

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SELF-LOCKING CHUCK.

• The cutter is provided with pitch thread at the
  end of cutter shank.

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SLOT EQUAL TO CUTTER DIAMETER

• The side of the cutter which is traveling in same
  direction as the feed in climb milling.
• The work cant be pulled in to cutter because the
  resistance of opposite teeth which are
  up-milling.

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SLOT EQUAL TO CUTTER DIAMETER

• The direction of feed is against the direction of
  cutting edge of cutting mill.

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SLOT EQUAL TO CUTTER DIAMETER

• The common methods used to mount end mills in
  vertical milling machine are shown in these
  figures.

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DIRCTION OF HELIX OF CUTTER

• When the helix and cutter of opposite hand, the
  force will press the cutter in to spindle.
• Left hand helix right hand cut.

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END MILL CUTTER

• Its used for milling small faces and slots.

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PROFILE CUTTING

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

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INDEXABLE END MILL CUTTER

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

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STRAIGHT SHANK END MILL CUTTER

• Solid type of cutter in which straight shank are
  integral.

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TAPER SHANK END MILL CUTTER

• Taper shank type and helical flute type.
• Its fitted in MT-2 sleeve.

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PLAIN MILLING CUTTER

• Solid type of cutter made from a single piece of
  steel .
• Used for plain milling operation

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INSERTED TOOTH CUTTERS

• In large milling cutters the teeth are inserted
  in a body of less expansive material.
• The teeth are made from H.S.S or tungsten carbide.

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BRAZED-ON TIP CUTTERS

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

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DIRECTION OF ROTATION OF CUTTER

• Down milling
• Direction of rotation of cutter and work piece
  feed in same direction.

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METHOD OF MOUNTING THE CUTTER

• Arbor type cutter.
• Cutter mounted on arbor and arbor size selected
  as per cutter bore size.

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FACING TYPE CUTTER

• These cutters either bolted or attached directly
  to the spindle or secured on the stub arbor.

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SHANK TYPE CUTTER

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

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DIRECTION OF HELIX OF CUTTER

• Cutter axis is held vertically and the helix is
  towards the right side is called a right hand
  helix cutter.

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DIRECTION OF HELIX OF CUTTER

• Helix is towards the left side ,it is called a
  left hand helix cutter.

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DIRECTION OF HELIX OF CUTTER

• When a cutter has a helix and a cut of the same
  hand,this force will pull the cutter away form
  the spindle.

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VERTICAL MILLING MACHINE

• Position of spindle is vertical or 90º to the
  work table.
• Its suitable for boring pocket milling profile
  milling key way cutting.

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STATE THE USES OF ARBORS

• an extension of the machine.
• An arbor is consider as There are two types of
  arbor normally.

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USES OF ARBOR

• The outer end of the assembly is supported by the
  bushing.
• The arbor is designated 00
• by the taper number diameter and length.

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STUB ARBOR

• The arbors are hold with the machine.
• The arbors are of three types A,B,C as shown in
  picture.

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TYPES OF ARBORS

• Types A is used to mount the shell and mills and
  similar cutters.
• The cutter is tightened on the arbor using the
  screw.

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TYPES OF ARBOR

• It is used to mount large face milling cutters.
• The cutter is held on arbor by four screw(b), it
  has a slot(c),which fits over spindle (d).

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TYPES OF ARBOR

• It is a morse taper adaptor arbor used to hold
  drills, reamers, chucks etc.

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STRADDLE MILLING

• Plain side and face milling cutter used for slot
  cutting,and face milling and also used for
  straddle milling.

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STAGGERED TEETH SIDE MILLING CUTTER

• Cutters have alternate teeth with offside helix
  angles.
• Its used for milling deep and narrow slots or
  key ways.

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INTERLOCKING SIDE MILLING CUTTER

• It is formed out of two half side milling
  cutters or two staggered teeth side milling
  cutters.
• They are made to interlock to form one unit.

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ROUGH MILLING

• Before taking a finishing cut to bring the job in
  required dimension and surface finish.
• Amount of material left for a finishing cut
  called finishing allowance.

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ROUGH MILLING

• The object of rough milling is to remove excess
  material and not concerned with quality of
  surface finish.

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FEED,DEPTH OF CUT,CUTTING SPEED

• Rough milling done by using heavy feed a depth of
  cut of 3 to 6 mm and low cutting speed.

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FINISH MILLING

• The purpose of finish milling is to bring work
  piece to required dimension and surface finish.

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FINISH MILLING

• To achieve required accuracy and surface finish
  the smallest possible amount of material usually
  0.5 to 1mm material is removed.

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DIRECT INDEXING MACHANISM

• Its a rapid method
• Of indexing.
• It can be performed on a direct indexing head.
• Index plate has three circle of holes with
  20,30,36 respectively.

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HYPOID GEARS

• Modification of a bevel gear where the shaft are
  at right angle but they dont intersect as do
  the shaft for bevel gears.

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RACK GEARS

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

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DIRECT INDEDXING MECHANISM

• For center work,any suitable carrier may be used
  to engage the work piece with driving lug on the
  indexing head spindle .

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BASIC ELEMENTS OF SPUR GEAR

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

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BASIC ELEMENTS OF SPURGEAR

• Diametral pitch.
• Pressure angle

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WORM GEAR

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

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ANNULAR GEAR

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

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PRINCIPLE OF MILLING

• Cutter has a rotary movement and rotates at a
  high speed and removes metal at a very fast rate.
• Job can be fed manually or automatically.

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PRINCIPLE OF MILLING

• By milling we can produce flat horizontal,
  vertical, angular and formed surfaces.

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PLAIN\HORIZONTAL MILLING M\C

• Its covered in column and knee type of category.
• M\c haves horizontal spindle and cutter are
  mounted on horizontal arbor.
• Table muted in three direction- longitudinal,
  vertical and crosswise.

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SIMPLE INDEXING MECHANISM

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

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SECTOR ARMS

• Two sector arms fit on the face of the indexing
  plate.
• The arms can be set a part to cover a required
  number of holes between them.

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ANGULAR INDEXING

• Index for a certain number of degrees us when.
• Machining keyway, grooves flats. Located at
  angles of each other.

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DIRECT INDEXING

• Another type of index plate which is heaving a
  number of slots (24,30,36) on periphery of index
  plate.

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DIRECT INDEXING

• Indexing can performed by indexing head by
  disengaging worm from worm wheel.

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BROWN AND SHARP INDEX PLATE

• This system has three index plates and each plate
  has six circles of holes.
• Plate no 1 15,16,17,18,19,20.
• Plate no 2 21,23,27,29,31,33.
• Plate no 3 37,39,41,43,47,49.

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INDEX CRANK

• Its fitted to the end of the worm shaft.
• It carrier a spring loaded index pin to engage
  the hole in the plate.

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PRINCIPAL OF ANGULAR INDEXING

• If the crank is turned once,the spindle rotates
  1/40 of a turn and 1/40 of 360 is 360/40 9
  degrees.
• It follows that 1/9 turn of the crank will give a
  spindle movement of 1 degree.

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PRINCIPLE OF METAL CUTTING

• The common metal cutting process is carried out
  either by the use of single point multi point
  cutting tool.

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PRINCIPLE OF METAL CUTTING

• The important angle of cutting edge are
• Clearance angle(?)
• Rake angle (a)
• Tool angle (ß)

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CLERANCE ANGLE

• This is the clearance or relief provided behind
  the cutting edge.
• It prevents rubbing as well, thus reducing
  cutting force.

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RAKE ANGLE

• Angle given in front of the leading edge of tool.
• Its reduce the pressure of the chip on the tool
  face.
• Positive rake angles produce better finish at low
  speeds.

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RAKE ANGLE

• Zero and negative rake angle tools are stronger
  and have a long tool life.

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HALF SIDE MILLING CUTTER

• Cutters with teeth on one side only and used for
  heavy straddle milling and for machining one side
  only.

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PLAIN SIDE AND FACE MILLING CUTTER

• Side and face milling cutter with teeth on both
  sides used for slot cutting and face milling.

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UNIVERSAL MILLING MACHINE

• It is similar in construction to plain milling
  machine.
• But its table,a part from having movement in 3
  direction,can also be swiveled about horizontal
  axis.
• Maximum swiveling is 45 both in clock wise and
  anticlockwise directions

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PARTS OF MILLING MACHINE

• Base
• Column
• Knee
• Gear box
• Spindle
• Saddle
• Table
• Over arm brace
• Electrical equipment
• Cutting fluid equipment