Machining Processes- Milling, Broaching and Gear Manufacturing

1. Shri. Shamrao Patil (Yadravkar) Educational & Charitable Trust’s
Sharad Institute of Technology, College of Engineering Yadrav- (Ichalkaranji)
(Approved by AICTE, New Delhi, Recognized by Government of Maharashtra & Affiliated to DBATU, Lonere)
Accredited by NAAC ‘A’ Grade and NBA, ISO 9001:2015 Certified Institute
Recognized u/s 2(f) and 12(B) of the UGC Act 1956
An Autonomous Institute
Machining Processes: Milling,
Broaching and Gear
Manufacturing
Mr. S M Ghanvat
ME (CAD/CAM/CAE)
Assistant Professor
Mechanical Department

2. Introduction

3. Milling and Milling Machines
Peripheral Milling
Some basic types of milling cutters and milling operations. la) Peripheral
milling. (b) Face milling. (c) End milling.
(a) Schematic illustration of conventional milling and climb milling

4. Milling Parameters
(a) Face-milling operation, showing action of an insert; (b) climb milling; (c)
conventional milling; (d) dimensions in face milling. The width of cut, w, is not
necessarily the same as the cutter radius.

6. Face Milling
A face-milling cutter with indexable inserts.

7. Schematic illustration of the effect of insert shape on feed marks on a face milled surface: (a)
small corner radius, (b) corner flat on insert, and (C) Wiper, consisting of a small radius
followed by a large radius, resulting in smoother feed marks. id) Feed marks due to various
insert shapes.

8. Terminology for a face-milling cutter.
The effect of the lead angle on the undeformed
chip thickness in face milling.

9. End Milling
Ball nose end mills

10. Other Milling Operations and Milling Cutters
Cutters for (a) straddle milling, (b) form milling, (c)
slotting, and (d) slitting with a milling cutter.

11. (a) T-slot cutting with a milling cutter. (b) A shell mill

12. Toolholders
Milling Process Capabilities

14. Design and Operating Guidelines for Milling

15. Milling Machines
Schematic illustration of (al a horizontal-spindle column-and-knee-type milling machine
and (b) vertical-spindle column-and-knee-type milling machine.

16. Schematic illustration of a bed-type milling machine.

17. A computer numerical-control (CNC) vertical-spindle milling machine.

18. Planing and Shaping

19. Broaching and Broaching Machines
(a) Typical parts made by internal broaching. (b) Parts made by surface
broaching. (c) Vertical broaching machine.

20. Gear Manufacturing by Machining
Nomenclature for an involute spur gear.

21. Form Cutting
(a) Producing gear teeth on a blank by form cutting. (b) Schematic illustration of gear
generating with a pinion-shaped gear cutter. (c) and (d) Gear generating in a gear shaper
using a pinion-shaped cutter. (e) Gear generating with rack-shaped cutter

22. Gear Generating
(a) Schematic illustration of gear cutting with a hob. (b) Production of a
worm gear by hobbing

23. Cutting Bevel Gears
(a) Cutting a straight bevel-gear blank with two cutters. (b) Cutting a helical
bevel gear.

24. Gear-finishing Processes
Finishing gears by grinding: (a) form grinding with shaped grinding
Wheels; (b) grinding by generating, using two Wheels.

25. Design Considerations and Economics of Gear Machining
Gear manufacturing cost as a function of gear quality. The
numbers along the vertical lines indicate tolerances.