RECIPROCATING

MACHINE TOOLS

V.Gunasegaran
Assistant Professor
Department of Mechanical Engineering
School of Mechanical Sciences
BSAU, Chennai - 48
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Reciprocating machines
 Tool or work piece motion will be in
reciprocation
– If tool stationary – work is in motion
– If work is stationary – tool is in motion
 Machining surfaces, profile creation, slots,
keyway, grooves, recesses, etc.,
 Configurations and basic functions of
– Shaping machines
– Planing machines
– Slotting machines
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
 SHAPER
MACHINE TOOL

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Introduction to Shaper
A shaping machine is used to machine
surfaces
 It is a reciprocating type of machine tool
 Tool used for producing flat surfaces
(horizontal, vertical and inclined) with help of a
single point cutting tool
 Tool clamped in ram and its reciprocates
“to and fro” over the stationary workpiece
 Tool cuts the material in the forward stroke
(cutting stroke), No cutting during return stroke
(Idle stroke)
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Photographic view

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Principal parts of Shaper

 Base
 Column
 Table
 Cross Rail
 Ram
 Tool Head
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Swivel tool head

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Tool positioning

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Working Principle
 The reciprocating
motion of the ram is
obtained by a quick
return motion
mechanism
 The forward and
return strokes
constitute one
operating cycle of
the shaper

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Kinematic System
 The usual kinematic system provided in shaping machine for
transmitting power and motion from the motor to the tool

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Contd.,
 The central large bull gear receives its
rotation from the motor through the belt-
pulley, clutch, speed gear box and then the
pinion

 The rotation of the crank causes oscillation of

the link and thereby reciprocation of the ram

and hence the tool in straight path
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Types of Shaper
 Acc. to the ram driving mechanism
– Crank shaper
– Geared shaper
– Hydraulic shaper
 Acc to the position & travel of ram
– Horizontal shaper
– Vertical shaper
 Acc to the direction of cutting stroke
– Push cut shaper
– Draw cut shaper
 Acc to the design of the table
– Standard shaper
– Universal shaper
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Horizontal Shaper

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Vertical Shaper

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Hydraulic Shaper

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Operations done using a
Shaper Machine tool
 Machining Horizontal Surfaces

 Machining Vertical Surfaces

 Machining Angular Surfaces

 Cutting Slots, Grooves & Key ways

 Machining irregular surfaces

 Machining Splines / Cutting Gears

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Machining of flat surfaces

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Making of slot, pocket, T-
T-slot
and Vee block

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Making of grooves and gear
teeth cutting

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Advantages of Shapers
 The single point cutting tools used in shapers
are inexpensive, these tools can be easily
grounded to any desirable shape
 The simplicity and ease of holding work, its
easy adjustment, and the simple tool give the
shaper its great flexibility
 Shaper set up is very quick and easy and can
be readily changed from one job to another
 Thin or fragile jobs can be conveniently
machined on shapers because of lower cutting
forces
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Limitations

 Shape only one piece of stock at a time

Not suitable for mass production

 Shape stock only if longer than 25 cm

 Support long pieces of wood with

extension tables or roller supports

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Specifications of Shaping
Machine
 Maximum length of Stroke of Ram

 Type of Drive

 Power input

 Floor Space required

 Weight of the Machine

 Cutting to Return Stroke ratio (QRR)

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Quick Return Mechanisms
 Basic mechanism:
 Conversion of rotary motion into reciprocating motion
 In order to reduce the time wasted during the return non-cutting
stroke, shaping machines are fitted with a quick-return mechanism
 Usually crank and slotted-link design has been used
 As the disc rotates the black slide moves forwards and backwards

3D View Front View

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Types of QRM

 Crank and slotted lever mechanism

 Whitworth mechanism

 Hydraulic mechanism

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Crank and slotted lever
mechanism

 Here smallest link 2 is crank this gives oscillation

motion to link 4.
 It is used in shaping machine
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Contd.,

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Whitworth mechanism

 Here link 3 acts as crank which is driving and link 1

acts as slider which is driven.
 It is used in slotting machine
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Ex. for model

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Hydraulic mechanism

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Work holding devices
 Angle Plate
 Step Block
 Vice
 Parallel strips
 V-Blocks
 T- Bolt
 Clamps

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
 SLOTTER
MACHINE TOOL

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Introduction to slotter machine
 It is also called vertical Shaper
 The tool moves vertically rather than in a
horizontal direction
 A rotary table is mounted on the regular table
 Used mostly for machining internal surfaces
 Slots and key ways can be made at quit
accurately with spaced intervals
 It can work either outside or inside of part
 Generally for maintenance and repair work rather
than production (mostly for piece production)
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Photographic view of Slotter

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Principal parts

 Base
 Column
 Table
 Ram
 Tool Head

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Kinematic system of slotter

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Contd.,
 Vertical tool reciprocation with down stroke acting

 The vertical slide holding the cutting tool is

reciprocated by a crank and connecting rod
mechanism.
 The job, to be machined, is mounted directly or in
a vice on the work table.
 The intermittent rotation of the feed rod is derived
from the driving shaft with the help of a four bar
linkage as shown in the kinematic diagram.
 An additional rotary feed motion of the work table
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Types of slotter
 Punch slotter
 Tool room slotter
 Production slotter
 Special purpose slotter

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Operations / applications
 The following operations can be performed
on the slotter
– Internal flat surfaces
– Enlargement and / or finishing non-circular holes –
‘n’ numbers
– Blind geometrical holes like hexagonal socket
– Cutting of
• internal grooves
• key ways
• internal gears
• slots
• Recesses
• Curved sections
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Typical machining application

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Work holding devices
 Clamps
 T-bolts & step block
 Vice
 Adjustable block
 Parallel strips
 Chuck
 Special fixtures for holding work

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Contd.,

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

 PLANER
MACHINE TOOL

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Introduction to Planer
 A planer machine is used to produce plane
& flat surface by single point cutting tool
 It is also a reciprocating type of machine tool
 Cutting speed is achieved by a reciprocating
worktable that moves the part past the cutting
tool
 It is similar to shaper but its size is very large
and is adopted for producing flat surface of
much larger work than a shaper

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Photographic View of Planer

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Principal Parts of Planer

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Kinematic system of Planer
 The simple kinematic system of the planing machine
enables transmission and transformation of rotation
of the main motor into reciprocating motion of the
large work table and the slow transverse feed
motions (horizontal and vertical) of the tools

 The reciprocation of the table, which imparts cutting

motion to the job, is attained by rack-pinion
mechanism

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Contd.,
 The rack is fitted with the table at its bottom surface
and the pinion is fitted on the output shaft of the
speed gear box which not only enables change in the
number of stroke per minute but also quick return of
the table

 The blocks holding the cutting tools are moved

horizontally along the rail by screw-nut system and
the rail is again moved up and down by another
screw nut pair
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Basic types of Planer
 The open side planer, also known as a single-
housing planer
– It has a single column supporting the cross rail on which a
tool head is mounted
– The configuration of the open side planer permits very wide
work parts to be machined
 Double-housing planer
– It has two columns, one on either side of the bed and
worktable and housing are connecting at the top
– The columns support the cross rail on which one or more
tool heads are mounted
– The two columns provide a more rigid structure for the
operation but limit the width of the work that can be handled

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Other Types
 Pit Planer

 Plate Planer

 Planer (Plano) Miller or Grinder

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Pit Planer

 Used when work becomes extremely heavy

 Table is kept stationary and tool reciprocates
 Design is used to plane the largest kind of works
 It is convenient and economical to move machine than work
piece
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Plate planer

 Special purpose machine tool designed

 Specially used for squaring or leveling edges of heavy steel
plates
 The plate is clamped to a bed and the side mounted carriage is
move back and forth
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Planer Miller / Grinder

 Same as Double Housing Planer

 It has milling cutter or a grinding head in place of one or
more
 Conventional tool heads on cross rails
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Diff. in Basic types of Planer

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Difference between Planer
and Shaper
 Planing and shaping are similar operations, which differ in
the kinematics of the process
 In planer, the primary cutting motion is performed by the
work piece and feed motion is imparted by the cutting tool
 In shaper, the primary motion is performed by the tool,
and feed by the work piece

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Operations of Planer Machine
 Planing flat horizontal, vertical and
curved surfaces

 Planing at an angle and machining

dovetails

 Slots and grooves

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Quick Return Mechanism of
Planer

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Work Holding Devices
 Heavy duty vice
 T-bolts and Clamps
 Step blocks
 Poppets or stop pins
 Angle plates
 V-blocks
 Planer jacks
 Planer centres
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Contd.,

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Driving & Feed System
 Tool Heads maybe fed in crosswise or
vertical direction.
 Motor drive is usually at one side of
planar & drive mechanism is located
under the table.
 V=LN(1+K)/1000 m/min
– where, V= speed of cut
L= length of ram stroke
N= no. of full stroke
K= ratio of return time to cutting time

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

 MILLING
MACHINE TOOL

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Introduction to Milling
 Milling: is a metal cutting operation in which
the excess material from the work piece is
removed by rotating multipoint cutting tool
called milling cutter.

 Milling machine: is a power operated

machine tool in which work piece mounted
on a moving table is machined to various
shapes when moved under a slow revolving
serrated cutter.

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Contd.,
 In milling machine, The cutting tool is held on a
spindle called arbor and the work piece is fixed on a
table
 The table reciprocates past the cutting tool and metal
removal takes place
 Feed for the next cut and the depth of the cut are
given by the movement of the table
 Each tooth has the same profile
 Each tooth after taking a cut comes in operation after
some interval
 This allows the tool to cool down before the next cut
takes place
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Photographic view of milling
machine

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Two Forms of Milling

Two forms of milling: (a) peripheral milling, and (b) face milling.

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Peripheral Milling vs. Face
Milling
 Peripheral milling
– Cutter axis parallel to surface being
machined
– Cutting edges on outside periphery of
cutter
 Face milling
– Cutter axis perpendicular to surface being
milled
– Cutting edges on both the end and outside
periphery of the cutter
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Basic uses of Milling machine

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Principle of Milling

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

SL. UP MILLING DOWN MILLING
NO. (CONVENTIONAL MILLING) (CLIMB MILLING)

01 Work piece fed in the Work piece fed in the same

opposite direction that of the direction that of the cutter.
cutter.
02 Chips are progressively Chips are progressively thinner.
thicker.
03 Strong clamping is required Strong clamping is not required
since the cutting force is since the cutting force is directed
directed upwards & tends to downwards & keep the work piece
lift the work piece. pressed to the table.

04 Gives poor surface finish, Gives good surface finish, since

since chips gets accumulated the chips are thrown away during
at the cutting zone. cutting.

05 Used for hard materials. Used for soft materials and

finishing operations.
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Classification
1. Column and knee milling machines
a. Horizontal spindle type
b. Vertical spindle type
c. Universal type
2. Bed type milling machine
a. Simplex
b. Duplex
c. Triplex
3. Planer type milling machine (Plano millers)

4. Special purpose milling machine

a. Tracer controlled milling machine
b. Thread milling machine
c. CNC milling machine
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Horizontal Milling Machine

MAJOR PARTS
 Base
 Column
 Spindle
 Over arm
 Knee
 Saddle
 Worktable

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Vertical Milling Machine

MAJOR PARTS
 Base
 Column
 Spindle
 Spindle Head
 Knee
 Saddle
 Worktable

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

SL. HORIZONTAL MILLING VERTICAL MILLING MACHINE
NO. MACHINE

Spindle is vertical &

Spindle is horizontal &
01 perpendicular to the
parallel to the worktable.
worktable.

Cutter cannot be moved Cutter can be moved up &

02
up & down. down.

Cutter is mounted on the Cutter is directly mounted on

03
arbor. the spindle.

Spindle can be tilted for

04 Spindle cannot be tilted.
angular cutting.

Operations such as slot

Operations such as plain
milling, T-slot milling,
milling, gear cutting, form
angular milling, flat milling
05 milling, straddle milling,
etc., can be performed and
gang milling etc., can be
also drilling, boring and
performed.
reaming can be carried out.
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Universal Type

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Bed Type

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Planer type milling machines
 Utilize several milling heads
 Can remove large amount of metal
while permitting the table and work
piece to move quite slowly
 Often, only single pass is required
 Good for heavy pieces

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Contd.,

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Special types
 Tracer mills (Profiling milling machines):
• Also called duplicators
• Designed to reproduce an irregular part
geometry that can be created on an template
• In two dimensions- tracer
• In three dimensions- duplicator
 CNC milling machines:
• Cutter path controlled by numerical data
• Suited to profile, pocket, surface contouring.

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Specifications of Milling Machine
 Size of the work table: expressed in length x width

 Longitudinal movement: Total movement of table in

mm (X-direction)
 Transverse movement: Total movement of saddle
along with table in mm (Y-direction)
 Vertical movement: Total movement of table, saddle &
knee in mm mm (Z-direction)
 Range of the speed: Speed variation in the gear box
in RPM
 Power capacity of the motor in HP
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Milling Cutters
 The tool used in milling is known as a milling cutter, the
cutting edges called teeth. Types of milling cutters are related
to the milling operations can be classified as:
 Plain milling cutters:
- Used in peripheral milling operations
- Cylindrical or disk shaped
- Have several straight or helical teeth on periphery
- Used to mill flat surfaces
 Side milling cutters:
- Similar to plain milling cutters
- Teeth extend radial part way across one or both ends of
cylinder toward the center
- Relatively narrow

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Contd.,
 Form milling cutters:
- Another peripheral milling cutter
- Teeth ground to a special shape to produce a
surface having a desired transverse contour,
convex, concave shape.
 End milling cutters:
- Looks like a drill bit, but it cuts with peripheral
teeth instead of it’s end.
- Have multiple teeth
- Used in milling slots, profiling and facing narrow
surfaces.

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Contd.,
 Face milling cutters:
- Have teeth on periphery and both sides
- Made of HSS
 T-slot cutters:
- Have teeth on periphery and both sides
- Used for milling the wide groove of a T-slot
- In order to use them, a vertical groove must first be
made with a slotting mill or an end mill to provide a
clearance for the shank
- T-slot cutter must be fed carefully, because it cuts in
5 surfaces
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Face-Milling Cutter with
Face-
Inserts

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Contd.,

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Contd.,

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Nomenclature of a Plain
Milling cutter

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Contd.,

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Milling Operations
 Plain or slab milling
 Face milling
 End milling
 Slot milling
 Angular milling
 Form milling
 Straddle milling
 Gang milling
 Slitting or saw milling
 Gear cutting
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Plain / Surface / Slab Milling
Plain Milling:
Process to get the flat
surface on the work piece
in which the cutter axis
and work piece axis are
parallel.

Cutter: Plain/ Slab milling

cutter.

Machine: Horizontal
Milling m/c.

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Face Milling

Face Milling:
Operation carried out for
producing a flat surface,
which is perpendicular to the
axis of rotating cutter.

Cutter: Face milling cutter.

Machine: Vertical Milling

Machine

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

End Milling

End Milling:
Operation performed for
producing flat surfaces, slots,
grooves or finishing the
edges of the work piece.

Cutter: End milling cutter.

Machine: Vertical Milling

Machine

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Slot Milling

Slot Milling:
Operation of producing slots
like T-slots, plain slots,
dovetail slots etc.,

T-slot Milling Cutter: End milling cutter, T-

slot cutter, dovetail cutter or
side milling cutter

Machine: Vertical Milling

Machine

Dove Tail Slot Milling

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Angular Milling

Angular Milling:
Operation of producing all
types of angular cuts like V-
notches and grooves,
serrations and angular
surfaces.

Cutter: Double angle cutter.

Machine: Horizontal Milling

Machine

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Form Milling

End Milling:
Operation of producing all
types of angular cuts like V-
notches and grooves,
serrations and angular
surfaces.

Cutter: Double angle cutter.

Machine: Horizontal Milling

Machine

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Straddle Milling

Straddle Milling:
Operation of machining two
parallel surfaces
simultaneously on a work
piece.

Cutter: 2 or more side & face

milling cutters

Machine: Horizontal Milling

Machine

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Gang Milling

Gang Milling:
Process to get different
profiles on the work piece
simultaneously with two or
more cutters at one stretch.

Cutter: Different cutters as

required.

Machine: Horizontal Milling

Machine

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Work holding devices
 Angle Plate
 Step Block
 Parallel strips
 T- Bolt
 Clamps
 Different types of Vice

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Contd.,

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Tool holding devices

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

 Indexing…

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Index Head / Dividing Head
 It is one of the most important
attachments for milling machine
 Used to divide circumference of work
piece into equally spaced divisions
when milling gear teeth, squares,
hexagons, and octagons
 Also used to rotate work piece at
predetermined ratio to table feed rate
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Photo view of Index Head

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Construction of Index Head

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Parts in Index Head

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Indexing Methods
 Direct or Rapid Indexing

 Plain or Simple Indexing

 Differential Indexing

 Angular Indexing

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Simple Indexing
 To index the work through any required
angle, the index crank pin is withdrawn
from the hole of the index plate than the
work is indexed through the required angle
by turning the index crank through a
calculated number of whole revolutions
and holes on one of the hole circles, after
which the index pin is relocated in the
required hole
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Contd.,

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Contd.,

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Index Plate Types
 Brown and Sharpe type consists of 3 plates of 6 circles

each drilled as follows:

– Plate I - 15, 16, 17, 18, 19, 20 holes

– Plate 2 - 21, 23, 27, 29, 31, 33 holes

– Plate 3 - 37, 39, 41, 43, 47, 49 holes

 Cincinnati type consists of one plate drilled on both sides

with circles divided as follows:

– First side - 24, 25, 28, 30, 34, 37, 38, 39, 41, 42, 43 holes

– Second side - 46, 47, 49, 51, 53, 54, 57, 58, 59, 62, 66 holes

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Spur Gear

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48

Gear Generation
 Calculate the blank diameter and find the
data of gear milling for a spur gear of pitch
circle diameter (PCD) 36mm and 18 teeth
 Index crank movement = 40/Z
 The holes available in Brown & Sharpe index
plates are
• Plate 1: 15-16-17-18-19-20
• Plate 2: 21-23-27-29-31-33
• Plate 3: 37-39-41-43-47-49
V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48
Basic Data for Gear Milling
Calculate the gear blank and a tooth proportions:
Sl.No Name of tooth element Gear tooth
proportions
1. Pitch diameter Zxm
2. Addendum 1m
3. Dedendum 1.25m
4. Working depth 2m
5. Tooth depth 2.25m
6. Outside diameter (Z+2)m
7. Tooth thickness 1.5708m
8. Clearance 0.25m

V.Gunasegaran, Assistant Professor, Department of Mechanical Engineering, BSACIST, Chennai - 48