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Milling and gear generation
- 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 machineremoves material, when the work piece is fed into a rotating multi-point cutting tool” Rotating Multi-point cutting tool
- 7. Block Diagram andmain parts of a milling machine (Column & Knee Type milling machine)
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- 9. BASE COLUMN KNEE Table OVER ARM Milling Cutter ARBOR Base Column Knee Table Over Arm Spindle Arbor MOVI E
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- 11. HORIZONTAL type VERTICALtype 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
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- 14. Types of MillingMachine 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 MillingMachine 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 ofMilling 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 ofMilling Processes 1. Peripheral Milling a. Down Milling b. Up Milling 2. Face Milling
- 20. DOWN-Milling Vs UP-Milling DOWN-MillingUP-Milling
- 21. Work piece Rotating Multipointcutting tool Down-Milling or Climb Milling
- 22. Work piece Rotating Multipointcutting tool UP-Milling or Conventional Milling
- 23. DOWN-Milling Vs UP-Milling DOWN-MillingUP-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-MillingUP-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-MillingUP-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
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- 28. According to Purposeof 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 StandardMilling Cutters
- 30. Plain Milling Cutter Cylindricalin 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 sizeand application: Light duty, heavy duty and helical plain milling cutters
- 33. Used to removemetal from the side of work piece Have teeth on the periphery and on its sides
- 34. Types of SideMilling 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 Usedfor parting off or slotting operations
- 36. Types of MetalSlitting Saw Metal Slitting Saw 1. Plain milling slitting saw 2. Staggered teeth slitting saw
- 37. Have conical surfaceswith cutting edge over them Used to machine angles other than 90°
- 39. Used for cuttingslots 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 Woodruffkey slots
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- 43. Used to makecontoured surfaces Cutters are single point cutting tools
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- 46. Convex Milling cutters: Haveprofile 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 makegrooves and flutes in taps or reamers
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- 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
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- 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 inGear manufacturing)
- 71. INDEXING It’s the processof dividing the periphery of a circular work piece in to any number of equal parts
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- 84. INDEXING It’s the processof dividing the periphery of a circular work piece in to any number of equal parts
- 85. Indexing Head andIndex plate
- 86.
- 87. Indexing Methods 1. Director Rapid indexing 2. Plain or Simple indexing 3. Compound indexing 4. Differential indexing 5. Angular indexing
- 88. Types of GEAR SPUR HELICAL DOUBLEHELICAL (Herringbone) SPROCKETBEVEL WORM & WORM GEAR RACK & PINION
- 89. • Using MillingMachine, 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. Director Rapid indexing 2. Plain or Simple indexing 3. Compound indexing 4. Differential indexing 5. Angular indexing
- 91. Indexing Methods 1. Director 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 simpleindexing (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 simpleindexing (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 simpleindexing (using worm and worm gear) Number of gear teeth = 37 40 37 Here N=37 = 1 3 37
- 97. Plain or simpleindexing (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. Geargenerating principle 2. Gear generating methods 3. Gear finishing methods 4. Bevel gear generator
- 99. Gear generating principle Twogears of the same module will mesh together Meshing gears Module = pitch circle diameter / no. of teeth
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- 101. Gear - 1Gear - 2 Movie -1 (Meshing of gears)
- 102. Gear Generating 1. Geargenerating 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
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- 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 Boththe “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 infiniteradius) 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. Geargenerating 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. Geargenerating 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