Talks about milling and gear generation methods

1. Module - 3
A. Milling
B. Gear Generation
a. Types of Milling Machine
b. Up milling x Down milling
c. Milling Cutters
d. Milling Operations
e. Indexing
a) Gear forming & Gear generating
b) Gear generating principle
c) Gear generating methods
d) Gear finishing methods
e) Bevel gear generator

2. Milling Machine
“Milling machine removes material,
when the work piece is fed into a rotating
multi-point cutting tool”
Rotating Multi-point cutting tool

7. Block Diagram and main parts of a
milling machine
(Column & Knee Type milling machine)

8. BASE
COLUMN
OVER ARM
KNEE
Table
Milling Cutter
ARBOR

9. BASE
COLUMN
KNEE
Table
OVER ARM
Milling Cutter
ARBOR
 Base
 Column
 Knee
 Table
 Over Arm
 Spindle
 Arbor
MOVI
E

10. Main Classification
of
Milling Machines

11. HORIZONTAL type VERTICAL type
Vertical ARBOR
Milling cutter
Milling cutter
Horizontal ARBOR
Main Classification of Milling
Machines

12. UNIT - 3
A. Milling
B. Gear Generation
a. Types of Milling Machine
b. Up milling x Down milling
c. Milling Cutters
d. Milling Operations
e. Indexing
a) Gear forming & Gear generating
b) Gear generating principle
c) Gear generating methods
d) Gear finishing methods
e) Bevel gear generator

13. Types of Milling
Machine

14. Types of Milling Machine
1. Column and Knee type Milling machine
2. Fixed Bed type or Manufacturing Type
3. Planer Type
4. Special Type
BASE
COLUMN
OVER ARM
KNEE
Table
Milling
Cutter
ARBOR

15. Types of Milling Machine
1. Column and Knee type Milling machine
2. Fixed Bed type or Manufacturing Type
3. Planer Type
4. Special Type
Refer any text book related to machine tools

16. UNIT - 3
A. Milling
B. Gear Generation
a. Types of Milling Machine
b. Up milling x Down milling
c. Milling Cutters
d. Milling Operations
e. Indexing
a) Gear forming & Gear generating
b) Gear generating principle
c) Gear generating methods
d) Gear finishing methods
e) Bevel gear generator

17. Main Classification of Milling
Processes
1. Peripheral Milling
a. Down Milling
b. Up Milling
2. Face Milling
The surface
generated will be
parallel
to the cutter axis
The surface
generated will be
perpendicula
r to the cutter axis
Movie-1
Movie-2
Movie-1(a)
Movie-2(a)

19. Main Classification of Milling
Processes
1. Peripheral Milling
a. Down Milling
b. Up Milling
2. Face Milling

20. DOWN-Milling Vs UP-Milling
DOWN-Milling UP-Milling

21. Work piece
Rotating Multipoint cutting tool
Down-Milling or Climb Milling

22. Work piece
Rotating Multipoint cutting tool
UP-Milling or Conventional Milling

23. DOWN-Milling Vs UP-Milling
DOWN-Milling UP-Milling
1
Work piece & Cutter moves
in the same direction
Work piece & Cutter moves
in the opposite direction
2 Chip thickness MAX to MIN Chip thickness MIN to MAX
3 Cutting Force MAX to MIN Cutting force MIN to MAX
4
Cutting force acts
DOWNWARDS
Cutting force acts
UPWARDS
5
Cutting force seats the work
piece
Cutting force tries to lift the
work piece

24. DOWN-Milling Vs UP-Milling
DOWN-Milling UP-Milling
1
Work piece & Cutter moves
in the same direction
Work piece & Cutter moves
in the opposite direction
2 Chip thickness MAX to MIN Chip thickness MIN to MAX
3 Cutting Force MAX to MIN Cutting force MIN to MAX
4
Cutting force acts
DOWNWARDS
Cutting force acts
UPWARDS
5
Cutting force seats the work
piece
Cutting force tries to lift the
work piece

25. DOWN-Milling Vs UP-Milling
DOWN-Milling UP-Milling
1
Work piece & Cutter moves
in the same direction
Work piece & Cutter moves
in the opposite direction
2 Chip thickness MAX to MIN Chip thickness MIN to MAX
3 Cutting Force MAX to MIN Cutting force MIN to MAX
4
Cutting force acts
DOWNWARDS
Cutting force acts
UPWARDS
5
Cutting force seats the work
piece
Cutting force tries to lift the
work piece

26. UNIT - 3
A. Milling
B. Gear Generation
a. Types of Milling Machine
b. Up milling x Down milling
c. Milling Cutters
d. Milling Operations
e. Indexing
a) Gear forming & Gear generating
b) Gear generating principle
c) Gear generating methods
d) Gear finishing methods
e) Bevel gear generator

27. Types of Milling
Cutters

28. According to Purpose of use of Cutter:
(a)Standard Milling Cutters : Conventional cutters
(b)Special Milling Cutters: Designed to perform special
operations
Types of Milling Cutters

29. Types of Standard Milling Cutters

30. Plain Milling Cutter
Cylindrical in shape having teeth on their
circumference
Used to produce flat surfaces
parallel to axis of rotation
Fig: Plain milling cutter and its elements

31. Plain Milling Cutter
Fig: Plain milling cutter and its elements

32. Depending on size and application: Light duty, heavy
duty and helical plain milling cutters

33. Used to remove metal from the side of work piece
Have teeth on the periphery and on its sides

34. Types of Side Milling Cutters
1.Plain side milling cutters: Have straight
circumferential teeth
2.Staggered teeth side milling cutter : Have
alternate teeth with opposite helix angle providing
more chip space

35. Have small width
Used for parting off or slotting operations

36. Types of Metal Slitting Saw
Metal Slitting Saw
1. Plain milling slitting saw
2. Staggered teeth slitting
saw

37. Have conical surfaces with cutting edge over them
Used to machine angles other than 90°

39. Used for cutting slots and small holes
Have teeth on their end as well as on periphery

40. Used to produce “T” shaped slots in the work piece

41. Used for making
Woodruff key slots

42. Wood ruff key

43. Used to make contoured surfaces
Cutters are single point cutting tools

44. Fly cutter
https://www.youtube.com/watch?v=-sLHcFanDpg

46. Convex Milling cutters:
Have profile outwards at their circumference and
used to generate concave semi circular surface on
the work piece
Concave Milling cutters:
Have teeth profile curve in wards on their
circumference. These are used to generate convex
semi circular surfaces

47. Used to make grooves and flutes in taps or reamers

48. Tap and Reamer
cutter

49. Different sizes of Taps

52. 513-516, P.C. Sharma

53. UNIT - 3
A. Milling
B. Gear Generation
a. Types of Milling Machine
b. Up milling x Down milling
c. Milling Cutters
d. Milling Operations
e. Indexing
a) Gear forming & Gear generating
b) Gear generating principle
c) Gear generating methods
d) Gear finishing methods
e) Bevel gear generator

54. Milling Machine Operations

55. Milling Machine Operations
1. Plain Milling
2. Face Milling
3. Straddle Milling
4. Angular Milling
5. Gang Milling
6. Form Milling
7. Profile Milling
8. End Milling
9. Saw Milling
10. Key way Milling
11. T- Slot Milling
12. Gear Cutting
13. Cam Milling
14. Thread milling

56. Milling Machine Operations
1. Plain Milling
2. Face Milling
3. Straddle Milling
4. Angular Milling
5. Gang Milling
6. Form Milling
7. Profile Milling
8. End Milling
9. Saw Milling
10. Key way Milling
11. Slot Milling
12. Gear Cutting
13. Cam Milling
14. Thread milling
Work Piece
Milling
Cutter
Work Piece
Milling
Cutter
https://

57. Milling Machine Operations
1. Plain Milling
2. Face Milling
3. Straddle Milling
4. Angular Milling
5. Gang Milling
6. Form Milling
7. Profile Milling
8. End Milling
9. Saw Milling
10. Key way Milling
11. Slot Milling
12. Gear Cutting
13. Cam Milling
14. Thread milling
Work Piece
Milling
cutter
https://www.youtube.com/watch?
v=9OkBMA43qzg

58. Milling Machine Operations
1. Plain Milling
2. Face Milling
3. Straddle Milling
4. Angular Milling
5. Gang Milling
6. Form Milling
7. Profile Milling
8. End Milling
9. Saw Milling
10. Key way Milling
11. Slot Milling
12. Gear Cutting
13. Cam Milling
14. Thread milling
Straddle milling cutter
https://www.youtube.com/watch?v=8Io8n7XBI3I

59. Milling Machine Operations
1. Plain Milling
2. Face Milling
3. Straddle Milling
4. Angular Milling
5. Gang Milling
6. Form Milling
7. Profile Milling
8. End Milling
9. Saw Milling
10. Key way Milling
11. Slot Milling
12. Gear Cutting
13. Cam Milling
14. Thread milling
Angular Milling Cutter
Work piece

60. Milling Machine Operations
1. Plain Milling
2. Face Milling
3. Straddle Milling
4. Angular Milling
5. Gang Milling
6. Form Milling
7. Profile Milling
8. End Milling
9. Saw Milling
10. Key way Milling
11. Slot Milling
12. Gear Cutting
13. Cam Milling
14. Thread milling

61. Milling Machine Operations
1. Plain Milling
2. Face Milling
3. Straddle Milling
4. Angular Milling
5. Gang Milling
6. Form Milling
7. Profile Milling
8. End Milling
9. Saw Milling
10. Key way Milling
11. Slot Milling
12. Gear Cutting
13. Cam Milling
14. Thread milling

62. Milling Machine Operations
1. Plain Milling
2. Face Milling
3. Straddle Milling
4. Angular Milling
5. Gang Milling
6. Form Milling
7. Profile Milling
8. End Milling
9. Saw Milling
10. Key way Milling
11. Slot Milling
12. Gear Cutting
13. Cam Milling
14. Thread milling
https://www.youtube.com/watch?v=tK0RuMtdMjw

63. Milling Machine Operations
1. Plain Milling
2. Face Milling
3. Straddle Milling
4. Angular Milling
5. Gang Milling
6. Form Milling
7. Profile Milling
8. End Milling
9. Saw Milling
10. Key way Milling
11. Slot Milling
12. Gear Cutting
13. Cam Milling
14. Thread milling
END
MILL
END
MILL
Work
piece
SLO
T
Movie

64. Milling Machine Operations
1. Plain Milling
2. Face Milling
3. Straddle Milling
4. Angular Milling
5. Gang Milling
6. Form Milling
7. Profile Milling
8. End Milling
9. Saw Milling
10. Key way Milling
11. Slot Milling
12. Gear Cutting
13. Cam Milling
14. Thread milling
Max. Thickness = 5mm
Work piece
Saw milling cutter
(5mm)

65. Milling Machine Operations
1. Plain Milling
2. Face Milling
3. Straddle Milling
4. Angular Milling
5. Gang Milling
6. Form Milling
7. Profile Milling
8. End Milling
9. Saw Milling
10. Key way Milling
11. T- Slot Milling
12. Gear Cutting
13. Cam Milling
14. Thread milling
Movie

66. Milling Machine Operations
1. Plain Milling
2. Face Milling
3. Straddle Milling
4. Angular Milling
5. Gang Milling
6. Form Milling
7. Profile Milling
8. End Milling
9. Saw Milling
10. Key way Milling
11. T - Slot Milling
12. Gear Cutting
13. Cam Milling
14. Thread milling
Movie-1
Movie-2

67. Milling Machine Operations
1. Plain Milling
2. Face Milling
3. Straddle Milling
4. Angular Milling
5. Gang Milling
6. Form Milling
7. Profile Milling
8. End Milling
9. Saw Milling
10. Key way Milling
11. T - Slot Milling
12. Gear Cutting
13. Cam Milling
14. Thread milling
Movie -1
Movie -2
Thread milling
cutter
https://www.youtube.com/watch?v=FEy_Uq2Q8eM

68. Milling Machine Operations
1. Plain Milling
2. Face Milling
3. Straddle Milling
4. Angular Milling
5. Gang Milling
6. Form Milling
7. Profile Milling
8. End Milling
9. Saw Milling
10. Key way Milling
11. T - Slot Milling
12. Gear Cutting
13. Cam Milling
14. Thread milling
Refer any text book
For more details and line diagrams
Refer page number
437 to 444, H.C &
S.K.B

69. UNIT - 3
A. Milling
B. Gear Generation
a. Types of Milling Machine
b. Up milling x Down milling
c. Milling Cutters
d. Milling Operations
e. Indexing
a) Gear forming & Gear generating
b) Gear generating principle
c) Gear generating methods
d) Gear finishing methods
e) Bevel gear generator

70. INDEXING
(main application in Gear
manufacturing)

71. INDEXING
It’s the process of dividing the periphery of a
circular work piece in to any number of equal parts

72. INDEXING
Gear
Blank
Gear milling cutter

73. INDEXING
Gear
Blank

74. INDEXING
Gear
Blank

75. INDEXING
GearBlank

76. INDEXING
GearBlank

77. INDEXING
GearBlank

78. INDEXING
24 teeth
GearBlank

79. INDEXING
24 teeth
GearBlank

80. INDEXING
24 teeth
GearBlank

81. INDEXING
24 teeth
GearBlank

82. INDEXING
24 teeth
GearBlank

83. INDEXING
24 teeth
GearBlank
MOVIE

84. INDEXING
It’s the process of dividing the periphery of a
circular work piece in to any number of equal parts

85. Indexing Head and Index plate

86. Indexing Methods

87. Indexing Methods
1. Direct or Rapid indexing
2. Plain or Simple indexing
3. Compound indexing
4. Differential indexing
5. Angular indexing

88. Types of GEAR
SPUR
HELICAL
DOUBLE HELICAL
(Herringbone)
SPROCKETBEVEL WORM & WORM GEAR
RACK & PINION

89. • Using Milling Machine,
Shaping machine etc..
Indexing Mechanisms………….
## Simple indexing mechanism
(most commonly used)
Gear Forming
Worm gear
(40Teeth)
Worm
Worm & worm gear mechanism
Movie
(commonly used as a speed reduction mechanism)

90. Indexing Methods
1. Direct or Rapid indexing
2. Plain or Simple indexing
3. Compound indexing
4. Differential indexing
5. Angular indexing

91. Indexing Methods
1. Direct or Rapid indexing
2. Plain or Simple indexing
3. Compound indexing
4. Differential indexing
5. Angular indexing

92. SIMPLE INDEXING
WORM & WORM GEAR INDEXING PLATES

93. SIMPLE INDEXING
WORM & WORM GEAR
INDEXING PLATES
MOVIE – Simple indexing

94. Plain or simple indexing (using worm and worm gear)
Number of gear teeth = 12
Required indexing
movement
=
40
N
Where N = Number of teeth
40
12
Here N=12
= 3
4
12
Indexing plate
having 12 hole circle

95. Plain or simple indexing (using worm and worm gear)
Number of gear teeth = 12
40
12
Here N=12
= 3
5
15
10
3
=
50
15
=

96. Plain or simple indexing (using worm and worm gear)
Number of gear teeth = 37
40
37
Here N=37
= 1
3
37

97. Plain or simple indexing (using worm and worm gear)
Number of gear teeth = 32
40
32
Here N=32
=
5
4
25
20
= 1
5
20
=

98. Gear Generating
1. Gear generating principle
2. Gear generating methods
3. Gear finishing methods
4. Bevel gear generator

99. Gear generating principle
Two gears of the same module will mesh together
Meshing gears
Module = pitch circle diameter / no. of teeth

100. GEAR - 1
GEAR - 2

101. Gear - 1 Gear - 2
Movie -1
(Meshing of gears)

102. Gear Generating
1. Gear generating principle
2. Gear generating methods
3. Gear finishing methods
4. Bevel gear generator

103. Gear generating methods
a) Gear hobbing process
b) Pinion cutter generating process
c) Rack cutter generating process
Automated “INDEXING”
is mandatory
Relative movement between the tool and the work piece

104. Gear HOB

105. Animated movie – basics of
gear hobbing
Movie
“The Hob and Gear blank”
interacts like a
_______________assembly“Worm & Worm gear”

106. Gear generating methods
a) Gear hobbing process
b) Pinion cutter generating process
c) Rack cutter generating process
Automated “INDEXING”
is mandatory

107. PINIO
N
Cutter
Gear Blank
(work
piece)
PINION
Slow Rotation
Both the “cutter” and the “gear blank” interacts like a ________________
Fast
Reciprocation
pair of Spur gears
Movie

108. Gear generating methods
a) Gear hobbing process
b) Pinion cutter generating process
c) Rack cutter generating process
Automated “INDEXING”
is mandatory

109. Pinion
Rack
(Gear with infinite radius)
Rack & Pinion converts rotary motion to reciprocating
motion
Gear generation by RACK cutter – animated movie
Movie –
Rack & Pinion

110. Gear generating methods
a) Gear hobbing process
b) Pinion cutter generating process
c) Rack cutter generating process
Automated “INDEXING”
is mandatory
Blank
Flat DIE - 2 (Rack type)
Flat DIE – 1 (Rack type)
Gear Rolling method

111. Gear Generating
1. Gear generating principle
2. Gear generating methods
3. Gear finishing methods
4. Bevel gear generator

112. www.ignou.ac.in/upload/gear.pdf
For details on “Gear Finishing methods”,
visit the following web site
Gear shaving cutter

114. Gear Generating
1. Gear generating principle
2. Gear generating methods
3. Gear finishing methods
4. Bevel gear generator
Movie

115. UNIT - 3
A. Milling
B. Gear Generation
a. Types of Milling Machine
b. Up milling x Down milling
c. Milling Cutters
d. Milling Operations
e. Indexing
a) Gear forming & Gear generating
b) Gear generating principle
c) Gear generating methods
d) Gear finishing methods
e) Bevel gear generator
completed