CENTRALIZED WORKSHOP

(Milling Section)

Workshop Manual

B.Tech (Sixth semester)

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 VISION of University
YMCA University of Science and Technology aspires to be a nationally and internationally

acclaimed leader in technical and higher education in all spheres which transforms the life of

students through integration of teaching, research and character building.

MISSION of University

 To contribute to the development of science and technology by synthesizing teaching, research

and creative activities.

 To provide an enviable research environment and state-of-the-art technological exposure to its

scholars.

 To develop human potential to its fullest extent and make them emerge as world class leaders

in their professions and enthuse them towards their social responsibilities.

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 DEPARTMENT OF MECHANICAL ENGINEERING
VISION

“To be a centre of excellence by producing high calibre, competent and self-reliant mechanical

engineers, who possess scientific temperament and would engage in activities relevant to

industries with ethical values and flair to research”.

MISSION

 To provide efficient engineers for global requirements by imparting quality education.

 To explore, create and develop innovations in various aspects of engineering through

industries and institutions.

 To emphasize on practical skills and socially relevant technology.

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 DEPARTMENT OF MECHANICAL ENGINEERING

Program Educational Outcomes (PEO’S): B.Tech. Mechanical Engineering

PEO-1:

To train students with practical skills and experimental practices related to core and applied areas

of mechanical engineering to expand their knowledge horizon beyond books.

PEO-2:

To enable students to design, develop and maintain mechanical equipments which are useful for

the society.

PEO-3:

To improve team building, team working and leadership skills of the students with high regard

for ethical values and social responsibilities.

PEO- 4:

To enable students to communicate effectively and demonstrate the knowledge of project

management and independent research.

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 DEPARTMENT OF MECHANICAL ENGINEERING
PROGRAMME OUTCOMES (PO)

PO Engineering Graduates will be able to:

Engineering knowledge: Apply knowledge of mathematics, science, engineering

PO1 fundamentals, and mechanical engineering to the solution of engineering problems.
Problem analysis: Identify, formulate, review literature and analyze mechanical
PO2 engineering problems to design, conduct experiments, analyze data and interpret data.
Design /development of solutions: Design solution for mechanical engineering
PO3 problems and design system component of processes that meet the desired needs with
appropriate consideration for the public health and safety, and the cultural, societal and
the environmental considerations.
Conduct investigations of complex problems: Use research based knowledge and
PO4 research methods including design of experiments, analysis and interpretation of data, and
synthesis of the information to provide valid conclusions in mechanical engineering.
Modern tool usage: Create, select, and apply appropriate techniques, resources, and
PO5 modern engineering and IT tools including prediction and modeling to mechanical
engineering activities with an understanding of the limitations.
The engineer and society: Apply reasoning informed by the contextual knowledge to
PO6 assess societal, health, safety, legal and cultural issues and the consequent responsibilities
relevant to mechanical engineering practice.
Environment and sustainability: Understand the impact of the mechanical engineering
PO7 solutions in societal and environmental contexts, and demonstrate the knowledge and
need for sustainable development.
Ethics: Apply ethical principles and commit to professional ethics and responsibilities
PO8 and norms of the mechanical engineering practice.
Individual and team work: Function affectively as an individual, and as a member or
PO9 leader in diverse teams, and in multidisciplinary settings in mechanical engineering.
Communication: Communicate effectively on complex engineering activities with the
PO10 engineering committee and with society at large, such as, being able to comprehend and
write affective reports and design documentation, make effective presentations in
mechanical engineering.

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 Project Management and finance: Demonstrate knowledge & understanding of the
PO11 mechanical engineering principles and management principles and apply these to one’s
own work, as a member and leader in a team, to manage projects and in multidisciplinary
environments in mechanical engineering.
Life- long learning: Recognize the need for, and the preparation and ability to engage in
PO12 independent research and lifelong learning in the broadest contest of technological
changes in mechanical engineering.

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 DEPARTMENT OF MECHANICAL ENGINEERING
PROGRAMME SPECIFIC OUTCOMES (PSO)

PSO Engineering Graduates will be able to:

To empower the students to apply practical skills, knowledge in major streams such
as thermal, design, manufacturing and industrial engineering.
PSO1

To enable the student to take-up career in industries or to pursue higher studies in

mechanical and interdisciplinary programs with high regard for ethical values,
PSO2
environmental and social issues.

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 WORKSHOP- VI (WS-362C)
B.Tech- VI Semester
No. of credits: 3 Internal: 30 Marks
L T P Total External: 70 Marks
0 0 6 6 Total: 100 Marks
Duration of Exam: 3 Hours

Pre-requisite: Turning, Milling, Welding, Refrigeration and air conditioning.

Successive: Conventional machines, arc, metal inert gas/metal active gas (MIG/MAG), tungsten inert gas (TIG) arc
welding ,gas welding & refrigeration and air conditioning etc .
Course Objectives: To understand the mechanical engineering by conventional and non conventional
machines, welding, refrigeration and air conditioning and exercises.
Course Outcomes (COs): After studying this course the students will be able to:
CO 1- Cut gears on a work piece by gear hobbing/gear shaper.
CO 2- Create various jobs on conventional lathe, milling/shaper.
CO 3- Prepare various jobs by Arc, MIG/MAG, TIG and Gas welding techniques.
CO 4- Learn troubleshooting of all metering devices, testing of leakage in refrigeration system and
electrical wiring of coolers, deep freezers and room air conditioners.
List of Exercises:
(Turning, Milling, Welding & RAC Workshop)
1. To prepare a job consisting of drilling, tapping, recessing/spline, chamfering operations etc on
milling/shaper and drilling machine.
2. To prepare a bush on lathe machine (facing, drilling, boring, turning, chamfering operations etc).
3. To perform gear cutting operation by gear hobbing/gear shaper.
4. To prepare single point brazed tool with carbide tip on a mild steel shank involving milling and
brazing operation.
5. To prepare straight continuous bead in upward and downward direction in vertical position and
closed butt joint in horizontal position on mild steel plate by arc welding.
6. To prepare T-fillet joint in flat position on mild steel plate by MIG/MAG welding.
7. To prepare straight continuous bead on stainless steel/aluminum sheet by TIG welding.
8. To prepare butt joint in flat position on mild steel sheet with mild steel copper coated (MSCC)
Filler rod by gas welding.
9. To find out the storage capacity of a refrigerator.
10. To study different types of metering devices along with their dismantling and assembling
procedures and troubleshooting.
11. To identify leakage in a refrigeration system.
12. To perform electrical wiring of refrigerators, coolers, deep freezers, multi-temperature units
and room air conditioners.

Note:- At least nine exercises should be performed from the above list; remaining three may
either be performed from above list or designed by the concerned institution as per the
scope of the syllabus and facilities available in the institute.

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 INDEX

Sr. Description Page

No. No.
1 Safety precautions on milling section 10

2 Working principle, parts, specification, operations, 11-17

and tools of shaper machine.
3 Working principle, parts, specification, and 18-22
operations tools (drill and tap) of drilling machine.
4 Working principle, parts, specification, operations, 23-29
and tools (milling cutters), indexing of milling
machine.
5 Exercise - 1 To perform gear cutting operation by 30-38
gear hobbing/gear shaper.

6 Exercise - 2 To prepare a job consisting of drilling, 39-40

tapping, recessing chamfering operations etc on
milling/shaper and drilling machine.
7 Exercise - 3 To prepare single point brazed tool 41
with carbide tip on a mild steel shank involving
milling operation.

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SAFETY PRECAUTIONS ON MILLING SECTION

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 SHAPING MACHINE (SHAPER)

Introduction
Shaping is a process of machining a flat surface which may be horizontal, vertical,
inclined, concave or convex using a reciprocating single point tool. A shaping machine is a
reciprocating type of machine tool. James Nesmith, an Englishman designed a shaping
machine to produce flat surfaces in the year 1836.

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WORKING PRINCIPLE OF SHAPER:-
Shaper is used for machining horizontal, vertical, angular surfaces of metal piece in desired
shape. A single point cutting tool reciprocates over stationery workpiece and workpiece is
rigidly gripped in a machine vice or clamped on the table. The tool is held in tool head mounted
on the ram of machine. When the ram moves forward cutting of material start and in backward
stroke no cutting of material takes place. The time taken is less as compared to forward stroke
and this is obtained by quick return mechanism.

Quick return mechanism

The ram moves at a comparatively slower speed during the forward cutting stroke.
During the return stroke, the mechanism is so designed to make the tool move at a faster rate
to reduce the idle return time. This mechanism is known as quick return mechanism.
As the ram moves at a faster rate during return stroke, the time taken becomes less.
The total machining time decreases and the rate of production increases. The following
mechanisms are used for quick return of the ram.
Crank and slotted link mechanism
Hydraulic mechanism
Whitworth mechanism

Crank and slotted link mechanism

An electrical motor runs the driving pinion(S) at a uniform speed. This pinion makes
the bull gear(M) to rotate at a uniform speed. Bull gear is a large gear fitted inside the
column. The point ‘O’ is the centre of the bull gear. A slotted link having a long slot along its
length is pivoted about the point ‘K’. A sliding block ‘N’ is fitted inside the slot and slides
along the length of the slotted link. ‘P’ is the crank pin and ‘OP’ can be considered as a
crank.
When the bull gear rotates, the sliding block also rotates in the crank pin circle. This
arrangement provides a rocking movement to the rocker arm. As the top of the slotted link is
connected to the ram, the ram reciprocates horizontally. So, bull gear rotation is converted
into the reciprocating movement of the ram.

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13
 Ratchet and Pawl mechanism (Automatic feed mechanism for the
table)

The table of a shaping machine travels in a cross direction when the cross feed screw is
rotated. The cross feed screw is attached to the ratchet wheel. A spring loaded ‘pawl’ is
positioned to be placed between the teeth of the ratchet wheel. The pawl is housed within a
frame known as rocker arm. The bull gear placed inside the column of the shaping machine
drives the gear B through the gear A.
There is a diametric slot provided on the face of the gear B. A crank pin is attached to a slider
placed in the slot. The bottom of the rocker arm and the crank pin are connected by a
connecting rod. The rotation of the gear B makes the crank pin to rotate. This movement
makes the rocker arm to rock about the centre of the ratchet wheel. The pawl makes the
ratchet to rotate by a small amount in one direction only. As the cross feed screw is attached
to the ratchet wheel, the rotation of the ratchet wheel will make the table to move in a cross
direction.
If the direction of the table feed is to be reversed, the pawl is turned about 180° from its
position. The ratchet wheel and the cross feed screw will rotate in the opposite direction
resulting in the table movement in the opposite direction
When power feed is not necessary for the table, the pawl is disengaged from the ratchet
wheel.

Knob

Spring

Pawl

Ratchet
wheel

Cross feed Crank pin

screw

Connecting rod
Rocker arm

Ratchet and Pawl mechanism

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TYPES OF SHAPER:-
According to type of driving mechanism:-
1. Crank type shaper
2. Hydraulic shaper
3. Geared shaper

According to type of cutting stroke:-

1. Push cut shaper
2. Draw cut shaper

According to position of travel of ram:-

1. Horizontal shaper
2. Vertical shaper

PARTS OF SHAPER:-
1. Base
2. Column
3. Cross rail
4. Table
5. Ram
6. Tool head
a. Tool slide
b. Clapper box
c. Tool post

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SPECIFICATIONS OF SHAPER:-
1. Travel of ram (maximum length of stroke)
2. Types of drive
3. Range of speed
4. Horse power of motor
5. Cutting to return stroke ratio
6. Maximum vertical and horizontal travel of table
7. Approximate weight and floor space covered by machine

TOOLS USED IN SHAPER MACHINE:-

1. Right hand tool
2. Left hand tool
3. Roughing tool
4. Slot cutting tool

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OPERATIONS PERFORMED ON SHAPER:-
1. Horizontal surface machining
2. Vertical surface machining
3. Angular surface machining
4. Concave surface machining
5. V-groove machining
6. Deep slot machining
7. Step cut machining
8. Key way machining(internal and external)

SAFETY PRECAUTIONS ASSOSIATED WITH SHAPER:-

1. Workpiece should be properly gripped in machine vice or properly clamed on the

table.
2. Do not use blunt tool.
3. Deep cut should be avoided.
4. Stroke length should be adjusted according to workpiece.
5. Do not check the machining surface by hand while ram of machine is
reciprocating.
6. Long handle brush shall be used to remove chips and scraps from the work table.

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 DRILL AND DRILLING

Drill is a cutting tool used to produce a cylindrical hole in a work piece and process of
making hole is called Drilling
TYPES OF DRILL:
1) Flat Drill
2) Straight Fluted Drill
3) Twist Drill
4) Oil hole drill
5) Center Drill
6) Step Drill
7) Core Drill
8)

TWIST DRILL: twist drill is widely used in drilling practice. It consist two main parts
shank and body. The shank is held in drilling machine and the body is cutting unit in flutes,
land margin, cutting edge and drill points.
According to shape of shank it can be further classified in to two types
1) Parallel shank twist drill
2) Taper shank twist drill

The cutting angle or point angle for drilling of mild steel, cast iron and other general works
is 1180 . Its cutting angle increases for hard metal and decreases for soft metal. Generally
twist drills are made up of HCS and HSS.

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PRECAUTIONS WHILE DRILLING OPERATIONS:
1) A dark indentation should be marked with center punch for proper location of drilling
2) Drill bit should be properly fitted with drill chuck or drill machine spindle.
3) Never left drill chuck key in Drill chuck.
4) Speed and feed of drill machine should be adjusted according to work and material
5) Use proper coolant during drilling operation.
6) A small hole or pilot hole should be made previously for making big size hole.

DRILLING MACHINE

There are so many types of drilling machines to produce cylindrical holes and other
operations
Different types of drilling machines are:
1) Portable Drilling Machine
2) Bench or Sensitive Drilling Machine
3) Upright Drilling Machine
4) Multiple spindle
5) Radial Drilling Machine
6) Deep hole Drilling Machine
7) Gang Drilling Machine
8) Horizontal Drilling Machine
9) Automatic Drilling Machine

Main Parts of Drilling Machine:

1) Head
2) Spindle
3) Drill Chuck
4) Table
5) Base
6) Column

Operations performed on drilling machines are:

1) drilling
2) reaming
3) counter sinking
4) boring and counter boring
5) Spot facing
6) tapping

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 Speed, Feed and Machining Time:
Speed: Cutting speed for drill is the distance that point of circumference of drill will
travel in one minute.
Cutting speed(s) = πDN/1000 m/min {where D is dia of drill in mm,N=rpm of drill}
Feed: Feed of a drill is the distance that drill advances into workpiece on each revolution
of drill. Feed is expressed in mm/rev. of drill.
Fm=fr*N {where fm= feed per min, fr= feed/rev}

Machining Time for drilling:

Time for drilling= (L+0.3d)/fr *N {where L=depth of drilled hole,d= dia of drill}

COUNTER SINKING:
Counter sinking is an operation by which drilled hole may be converted into cone shape/
chamfered shape at one end by counter sinking bit. The counter sinking bit are fitted in drill
chuck of drill machine and rotate the mount of drilled hole .Counter sink tools are available in
many

sizes and make an angle 90 degree at opening of hole mouth during operation for easy entry of
tap-set and proper setting counter sink headed screw in a workpiece. This tool is generally
made of HSS.

THREADING TOOLS:
TAPS: Taps are used to make internal thread in a drilled hole. The operation is known as
tapping. Generally taps are made of HCS or HSS. The main parts of tap is body and shank. The
upper end of shank i.e. square tang is used for holding in tap wrench and external threads are
formed on body of tap for cutting internal threads in a drilled hole. The chip out material comes
through flutes of body. The size of thread, typeof thread and pitch of threads are mentioned on
the shank of taps. Generally taps are manufactured in a set of three.
1. Taper tap or Rougher Tap or First Tap: In taper tap, 8 to 10 teeth are tapered at
bottom end for easy entry and starting thread formation. A circle is marked on upper
portion of shank for its identification.
2. Intermediate tap or 2nd tap: In intermediate tap, 3 to 4 teeth are tapered at bottom
end. It is used after taper tap. Double circle is marked on the top of shank for its
identification.
3. Bottoming tap or Plug tap or Final tap or 3rd tap: It is used after second tap .0 to 1
teeth is tapered or grounded at bottom end of a tap body.

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21
Drill size for Tapping:
D.S= T.S-2d {where D.S= Drill size for tapping& d=0.61P for matric thread
and 0.64P ( for BSW, BA & BSP)
Where, T.S. =Tap Size, d=depth of thread, P=pitch of thread
(For BSW, BSP, BA P=1/no. of Thread per inch (TPI)
So, the drill size for metric threads system
D.S= T.S- 2*0.61P

Precautions while tapping:

1) Drilling size should be exact according to tap size.
2) Job should be properly clamped in vice.
3) Drilled hole should be exactly perpendicular to the vice.
4) Tap should be properly gripped in tap wrench.
5) Tap should be exactly perpendicular to the surface of worpiece.
6) Tap should be revolved one rotation in clockwise and half in anti-clockwise
simultaneously, so that chips might come out after breaking.
7) Use proper lubricant while tapping.
8) Keep it at proper place after use.

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 MILLING MACHINE
INTRODUCTION AND WORKING PRINCIPLE:-
Milling machine is most versatile machine of all machine tool. In milling machine metal is
removed from workpiece with rotating milling cutter(multi point cutting tool). For cutting
workpiece is fed into the milling cutter and metal is removed in form of chips.

CLASSIFICATION OF MILLING MACHINE:-

1. Column and knee type
 Plain milling machine
 Universal milling machine
 Omniversal milling machine
 Vertical milling machine
2. Table type milling machine
3. Planer type milling machine
4. Special purpose milling machine

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 PARTS OF MILLING MACHINE:-
1. Base
2. Elevating screw
3. Knee
4. Saddle
5. Table
6. Column
7. Spindle
8. Head

SIZE OR SPECIFICATION OF MILLING MACHINE:-

1. Size of table ( length and width)
2. Maximum length of longitudinal cross and vertical travel of table.
3. No. of spindle speed
4. No. of feed.
5. Spindle nose taper
6. Power required
7. Types of machine
8. Net weight and floor area of the machine

FUNDAMENTAL OF MILLING PROCESS:-

1. Peripheral milling
2. Vertical milling
Peripheral milling:
1. Up milling: In up milling the cutting tools rotate in opposite direction to the
motion of feed this tends to lift the workpiece from the table. There is possibility
that the cutting tool will run the workpiece before starting the material removal.
2. Down milling: In down milling cutting and feed motions are same in direction and
tendency of workpiece being dragged into the cutter however down milling
provides better surface milling finish and longer tool life.

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 Vertical milling: In vertical milling operation cutter axis is vertically and generally
perpendicular to the work surface. Example of vertical milling is following:
1. Slot milling
2. Face milling
3. End milling

MILLING ATTACHMENT:-
1. Vertical milling attachment
2. Universal milling attachment
3. Slotting attachment
4. Rotary table attachment
5. Index head attachment

STANDARD MILLING CUTTERS:-

Milling cutters are generally made of high speed steel (HSS). Following types of milling
cutters are used during milling operation.
1. Plain milling cutter
2. Side milling cutter
3. Angle milling cutter
4. Metal slitting saw
5. End milling cutter
6. T-slot milling cutter

MILLING OPERATION:
1. Plain milling
2. Face milling
3. Side milling
4. Straddle milling
5. Angular milling
6. Gang milling
7. Form milling
8. End milling
9. Gear cutting
10. Thread milling
11. Milling keyway grooves and slot.

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 MILLING OPERATIONS

Indexing head
Indexing is the method of dividing the periphery of a piece of work into any number
of equal parts. The attachment used for performing indexing is known as indexing head.

The indexing operation can be adapted for cutting gears, ratchet wheels, keyways, fluted
drills, taps and reamers. The indexing head serves as an attachment for holding and indexing the
work in doing the above tasks. There are three different types of indexing heads namely
1. Plain or simple dividing head
2. Universal dividing head
3. Optical dividing head.

Construction of indexing head

The construction of a universal dividing head explained below:
Base
The base of the indexing head is fitted in the ‘T’ – slots of the milling machine table.
It supports all the other parts of dividing head.

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 Worm gear

Spindle

Centre
Index
plate

Worm

Handle Worm shaft

Concentric
hole circles
Sector arms
Index
plate

Crank pin

Construction of a index head

Spindle
The spindle is situated at the centre of the dividing head. It has a taper hole to receive
a live center. The spindle is supported on a swiveling block, which makes the spindle to be
tilted through any angle from 5º below horizontal to 10º beyond vertical. A worm wheel is
mounted on the spindle. While doing direct or rapid indexing, the index plate is directly fitted
on the front end of the spindle nose.

Worm shaft
It is situated at right angles to the main spindle of the dividing head. A single threaded
worm is mounted on the worm shaft, which meshes with the worm wheel. An index plate is
fitted on the front end of the worm shaft and with the help of a handle the worm shaft can be
rotated to a predetermined amount.

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Index plate

It is mounted on the front end of the worm shaft. It is a circular disk having different
numbers of equally spaced holes arranged in concentric circles. The crank is positioned in the
required hole circle and rotated through a calculated amount while indexing. The sector arm is
used to eliminate the necessity of counting the holes on the index plate each time the index
crank is moved.

Index plate
Spindle
Index head Tailstock

Crank

Index head

Driven shaft
It is parallel to the spindle and perpendicular to the worm shaft.
Dead center
The work is held between the center of the spindle and the dead center. It can be made
to slide and positioned at the required location.
Working principle of dividing head
When the crank is rotated with help of a handle through the required number of holes
in the index plate, the work is rotated to required amount. This is possible because of the
worm and worm wheel mechanism.

A gear train is arranged between the main spindle and the driven shaft when indexing
is done by differential indexing method. The work is rotated as usual when the handle is
rotated. At the same time, the index plate is also made to rotate a small amount through the
gear train. When indexing is by this differential indexing method, the index plate is released
from the lock pin.

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Indexing methods
There are several methods of indexing and they are
1. Direct or rapid indexing
2. Plain or simple indexing
3. Compound indexing
4. Differential indexing
5. Angular indexing

CUTTING SPEED, FEED AND DEPTH OF CUT:

CUTTING SPEED: It is distance by point on cutting edge of milling cutter to remove metal in
one minute.
Cutting speed = (𝜋DN) / 1000 m/min, where D= dia of cutter and N= spindle speed in rpm.

FEED: It is defined as the distance of workpiece advance under the cutter

DEPTH OF CUT: It is thickness of material removed in one pass of the work below the cutter.
It is expressed in mm.

milling cutter materials

The milling cutters are generally made of the following materials.
1. Tool steel - High speed steel (HSS)
High carbon steel (HCS)
Cemented carbide
Stellite
In general shop work, the high speed steel cutters are most widely used.

SAFETY PRECAUTIONS:
1. Make sure that the cutter and the arbor are secure
2. Use cutters that are correctly ground and in good condition
3. To avoid striking hands on the cutter while setting up, move table with work as far
away from cutter as possible.
4. Check speed and feed, it should be proper.
5. Keep hand away from the work when machining.
6. Do not strike over milling cutters.
7. Clean the machines after completion of work and remove chips from brush.

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 EXERCISE – 1

Aim:- To perform gear cutting operation by gear hobbing/gear

shaper

GEAR CUTTING OPERATION

Basic Purpose of Use of Gears

1. Gears are widely used in various mechanisms and devices to transmit power and
motion positively (without slip) between parallel, intersecting ( axis) or non-
intersecting non parallel shafts,
2. without change in the direction of rotation
3. with change in the direction of rotation
4. without change of speed (of rotation)
5. with change in speed at any desired ratio

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General Applications Of Gears

 Speed gear box, feed gear box and some other kinematic units of machine tools
 Speed drives in textile, jute and similar machineries
 Gear boxes of automobiles
 Speed and / or feed drives of several metal forming machines
 Machineries for mining, tea processing etc.
 Large and heavy duty gear boxes used in cement industries, sugar industries, cranes,
conveyors etc.
 Precision equipments, clocks and watches
 Industrial robots and toys.

Types of Gears and their characteristics

1. According to configuration
• External gear • Internal gear

2. According to axes of transmission

Spur gears – transmitting rotation between parallel shafts as shown in

 Straight toothed
 Helical toothed
(A)Single helical, (B) double helical (herringbone)

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 According to pattern of motion
 Rotation to rotation : wheel type gears
 Rotation to translation or vice versa – e.g. rack and pinion
 Straight toothed
 Helical toothed

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Types of Gear Cutting Operations

 Gear milling or Forming

 Gear shaping
 Gear Hobbing
 Gear Finishing

Gear Milling or Forming

 The gear milling operation is used for gear cutting. All types of gears can be made by
using gear milling.
 Milling cutter is selected specifically for a particular type of gear and module. The
periphery of the gear blank is divided into required number of equi-spaced parts.

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  The required number of parts should be equal to the number teeth to be made on the gear
blank.
 The method of dividing the periphery is called indexing which is an integral part of the
operation of gear milling.

Gear Milling
 In gear form cutting, the cutting edge of the cutting tool has a shape identical with the
shape of the space between the gear teeth.

Disadvantages of Gear Milling

 Gear milling is a slower process of gear generation as compared to other gear

generation process.
 In this process gear is generated by cutting one-by-one tooth.
 Gears are to be made, it is not suitable for larger batch size.
 The other methods required very high capital cost and setup cost as compared to gear
milling so these are not economical for smaller batch size, only gear cutting by milling
operation is recommended for smaller batch size.

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Gear Shaping

 Gear shaping used a cutting tool in the shape of a gear which is reciprocated axially
across the gear blank to cut the teeth while the blank rotates around the shaper tool.
 It is a true shape-generation process in which the gear-shaped tool cuts itself into mesh
with the gear blank as shown in fig.
 The accuracy is good, but any errors in one tooth of the shaper cutter will be directly
transferred to the gear. Internal gears can be cut with this method as well.

Shaping with a pinion-shaped cutter

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 Gear Shaping Machine

Shaping with a rack-shaped cutter

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Gear Hobbing

 Gear hobbing is a machining process in which gear teeth are progressively generated by
a series of cuts with a helical cutting tool (hob).
 All motions in hobbing are rotary, and the hob and gear blank rotate continuously as in
two gears meshing until all teeth are cut.

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Gear Finishing
 As produced by any of the process described, the surface finish and dimensional
accuracy may not be accurate enough for certain applications.
 Several finishing operations are available, including the conventional process of
shaving, and a number of abrasive operations, including grinding, honing, and lapping,
shaping.
 While interacting with the gears, the cutting teeth of the shaving cutter keep on
smoothening the mating gear flanks by fine machining to high accuracy and surface
finish.

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 EXERCISE - 2
Aim: -To prepare a job consisting of drilling, tapping, recessing
chamfering operations etc on milling/shaper and drilling
machine.

Material: - ms flat 72 x 26 x 15 mm.

Tools & Equipment required:-

Vernier caliper (200 mm), Vernier height gauge (300mm), Flat File (150mm), Shell end
mill cutter, Single point cutting tool, double end spanner, Surface plate, Angle plate
,center punch, center drill ,twist drill ( ∅6.5),drill chuck key, counter sinking tool, drill chuck
and sleeve MT4, drift , and tap set M8 X 1.25 mm.etc.

Machine used:-
 Milling machine,
 Shaper.
 Drilling machine

DRILLING, TAPPING, RECESSING, CHAMFERING ON A BLOCK

Procedures:-
1. Mark the workpiece for drilling ∅ 6.5 mm as per drawing
2. Hold the workpiece on punching plate and mark center punch at the point of
intersection for drilling operations.
3. Hold the workpiece in drilling vice and clamp the drill vice on the drill
machine table.
4. Fit the drill chuck in spindle of drill machine and hold the center drill in drill
chuck.
5. Set the machine RPM for center drill.
6. Make center drill hole on the punch marked.
7. Remove center drill from drill chuck and fit the drill∅ 6.5mm in drill chuck
for drilling operations.
8. Make drilled hole (∅6.5 mm) hole for tapping operation.
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 9. Remove the drill from drill chuck and fit counter sinking tool in drill chuck.
10. Remove burr and sharp edges from drilled hole with help of counter sinking
tool.
11. Remove counter sinking tool from drill chuck and workpiece from drilling
vice.
12. Mark the workpiece for recessing operation as per drawing
13. Hold the work piece in machine vice of milling machine/shaper and cutting
tool (shell end mill cutter/single point cutting tool) on tool holder of vertical
milling machine/shaper.
14. Set the RPM and feed of machine for recessing operation.
15. Remove extra material from workpiece and maintain thickness 13mm as per
drawing.
16. Remove the workpiece from shaper/milling and hold it in bench vice for
tapping M8.
17. Use M8 tap set for tapped hole M8.
18. Chamfering (1x45ᵒ) all edges with help of flat file (150mm).
19. Punch the roll no. on thickness and side of workpiece and remove burr from
all sides.
Result:-
Thus the job (clamp) (drilling, tapping, recessing chamfering operations of
block) has been completed as per drawing.
Precautions:-
1 Hold the work piece properly in machine vice.
2 Use cutter and single pt. cutting tool that are correctly ground and in good condition.
3 To avoid striking hands on the cutter while setting up, move table with work as far away
from cutter as possible.
4 Check speed and feed and depth of cut it should be proper.
5 Keep hand away from the work when machining.
6 Do not strike over milling cutters, single pt. cutting tool, drill and tap set.
7 Use proper coolant while drilling and tapping operations.
8 Clean the machines after completion of work and remove chips from brush.

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 EXERCISE – 3 (A)
Aim: - To prepare single point brazed tool with carbide tip on a
mild steel shank involving milling operation.

Material: - ms flat SQ. 25 X 160 mm and carbide bit.

Tools & Equipment required:-
Vernier caliper (200 mm), Flat File (150mm), end mill cutter, double end spanner etc.
Machine used:- Vertical milling machine
MILD STEEL SHANK MACHINING FOR SINGLE POINT CUTTING TOOL

Procedures:-
1. Cut sq.25mm in 160mm length on power hacksaw.
2. Remove burr and sharp edges with help of flat file.
3. Hold the work piece on machine vice of milling machine.
4. Set the end mill cutter on tool holder of milling machine.
5. Remove extra material from shank as per insert (to be brazed on shank).
6. Remove the end mill cutter from tool holder and workpiece from machine vice.
7. Send the shank to welding section for tip (insert) brazing.
Result:-
Thus the machining of shank (single point brazed tool with carbide tip on a
Mild steel shank) has been completed on milling machine.
Precautions:-
1. Hold the work piece and cutting tool properly on the machine.
2. Use milling cutter that are correctly ground and in good condition.
3. To avoid striking hands on the cutter while setting up, move table
with work as far away from cutter as possible.
4. Check speed and feed and depth of cut it should be proper.
5. Keep hand away from the work when machining.
6. Clean the machines after completion of work and remove chips
from brush.
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