1. PRESENTED BY SUBMITTED TO ANUJ KUMAR SRIVASTAVA Mr. DEEPAK SHARMA ME-1 3 rd YEAR COORDINATOR AND FACCULTY ROLL NO- 1214340035 IMSEC MILLING

2.  DEFINITION  MILLING CUTTING MECHANISM  MILLING OPERATION  TOOL NOMENCLATURE  TYPES OF MILLING MACHINES  WORK HOLDING DEVICES  INDEXING CONTENT

3.  MILLING IS DEFINED AS THE PROCESS OF CUTTING,SHAPING &FINISHING A PIECE OF METAL BY USING A ROTATING MULTIPOINT CUTTING TOOL CALLED CUTTER  THE CUTTERS ARE GENERALLY MADE OF “HSS”  THE CUTTING ACTION ARE GENERALLY FAST.  USED TO PRODUCED COMPLEX SHAPES. MILLING

4.  Peripheral milling a)Up milling b)Down milling  Face milling  End milling MILLING CUTTING MECHANISM

5.  Milled surfaces is generated by teeth located on the periphery of cutter body.  Axis of cutter rotation is parallel to workpiece. Two types a)Up milling b)Down milling PERIPHERAL MILLING

6. UP MILLING  Known as conventional Milling.  Direction of cutter opposes feed motion.  Chip thickness minimum at beginning and max.at end

7. ADVANTAGE DISADVANTAGE  The workpiece has tendency to pulled up so proper clamping is required.  The tool has tendency to chatter.  the process is smooth  Contamination on surface does not affect tool life UP MILLING

8. DOWN MILLING  Known as climb milling.  The direction of cutter is opposite to feed motion

9. DISADVANTAGE  Not suitable for machining workpiece having scale  Presence of scale reduces tool life.  Better surface finish.  There is less radial pressure on arbour. ADVANTAGE

10.  Cutter is mounted on spindle having an axis of rotation perpendicular to workpiece  Used to mill flat faces FACE MILLING

11.  Cutter rotates on an axis perpendicular to workpiece  Used to mill end surfaces. END MILLING

12. a)Slab milling ( peripheral milling) b)Face milling c)End milling d)Straddle milling e)Form milling MILLING OPERATIONS

13.  Milled surfaces is generated by teeth located on the periphery of cutter body  Cutter generally made of HSS. SLAB MILLING

14.  Cutter is mounted on spindle having an axis of rotation perpendicular to workpiece  Used to mill flat faces FACE MILLING

15.  Two or more cutter are mounted on an arbour.  Used to machine two parallel surface. STRADDLE MILLING

16.  Cutter of specially shaped teeth are used for milling  Shapes of teeth is same as the form required on surface  Used for cutting gear teeth. FORM MILLING

17. TOOL NOMENCLATURE

18.  Column & knee type milling machine a)Horizontal milling machine b)Vertical milling machine  Fixed bed type milling machine  CNC milling machine TYPES OF MILLIN G MACHINES

19.  Worktable- on which workpiece is mounted  Saddle – supports table & can move transversly  Knee – supports saddle &give vertical movement to table.  Over arm – used in horizontal machine which is adjustable to accommodate different length.  Head – contains spindle &cutter holder. COMPONENTS

20.  In this machine,axis of cutter is parallel to workpiece.  Suitable for short production run. HORIZONTAL MILLING MACHINE

21.  MACHINE HAVING CUTTING TOOL SPINDLE VERTICAL TO WORKPIECE.  HAVE HEAVY OVERARM. VERTICAL MILLING MACHINE

22.  Used to mill flat surface having large bed which only moves in horizontal axis.  Work table is mounted on bed which replaces the knee BED TYPE MILLING MACHINE

23.  This machine is operated by computer numerical controls  Feed is given automatically. CNC MILLING MACHINE

24. WORK HOLDING DEVICES

25.  Used for holding workpiece commonly in workshop.  Good for quick loading and unloading. BENCH VICES

26.  Made of mild steel in which slot is made in centre and T- bolt passes through slot. four types Plain slot clamp Goose neck clamp Adjustable clamp  Used for checking straightness and for holding two types  Fixed  Tilted type CLAMPS AND ANGLE PLATE

27. INDEXING  INDEXING MEANS THE PROCESS OF DIVIDING THE PERIPHERY OF THE WORK INTO NUMBER OF EQUAL OR UNEQUAL DIVISIONS BY USING INDEX PLATE.  In indexing a plate consisting of number of holes at equally spaced distance is used.

28. There are four types  Direct indexing  Simple indexing  Compound indexing  Differential indexing INDEXING METHOD

29. DIRECT INDEXING  Direct indexing is simplest method of indexing.  It requires that the worm & worm wheel should be disengaged so that it move by hand.

32. Continue……  In direct indexing a plate of 24,30,36 hole plate is used  For choosing the correct plate, we choose it on basis of no. of division required.  There are several known indexing plates are available 15,16,17,18,19,20,21,23,27,29,31,33,37,39,41,43,47,49.  These number represent number of holes on the plate.

33. Let us take an example  If we have to make a round shaft into square at end then no of sides =4  Now choose among three 24,30,36. the one which is divisible by 4 is chosen.  24 &36 both are divisible by 4 but least will be taken  Divide 24/4=6  Mark the indexing plate consisting of 24 holes at equal interval of 6 holes.  The number obtained should be whole number. Continue……

35.  Thus for making a 4 square hole the indexing plate consisting of 24 holes must moved for 6 holes at one time.  Then a pin is attached on the plate is fixed on holes diameter.  Thus rotating a direct indexing plate by 6 holes in simultaneous 4 operation gives a full rotation to the work piece. Continue……

36.  In simple indexing the worm is engaged with the rotating hole plate.  This worm and worm wheel arrangement have 40:1 gear reduction ratio.  It is used when division is not possible by three hole plate,24,30,36.  It may be fraction.  The 40 rotation of the plate by pin cause one rotation to work piece. SIMPLE INDEXING

37. Continue……  Suppose we have to make 7 faces specimen on a round work piece.  Then it is given by 40/N ( where N denotes no of division required).  Here  But plate does not contain 7 holes  Then

38. Continue…… This means  Thus 5 full turn of the pin and 5/7 th turn of next Turn i.e. in a plate of 49 holes 35 will be moved by help of a guide and then making the milling at there.  This will be repeated by 7 times.  Finally we got desired shapes.

39. THANK YOU