Lec - 9 - Milling-Gear Cutting-CNC

ALEXANDRIA
PRODUCTION ENGINEERING
UNIVERSITY
DEPARTMENT
Lecture 9:
Milling - Gear Cutting - CNC
1
Milling machines:
1
Horizontal milling
machine:
2
Horizontal milling operations:
1. Slab milling:
The axis of cutter rotation is

parallel to the surface of the work
piece to be machined.
- Conventional milling (up milling):
The maximum chip thickness is at the end of the cut.
Advantages: Contamination or scale on the surface does not
affect tool life. It is the common method of milling.
Disadvantages: The work piece has a tendency to be pulled
upward, thus, proper clamping is important.
3
4
- Climb milling (down milling):
Cutting starts at the thickest location
of the chip.
Advantages: Cutting forces holds
the work piece in place,
particularly for slender parts.
Disadvantages: Not suitable for
machining work pieces that
have surface scale, such as hot
worked metals, forgings, and
castings because the scale is
hard and abrasive and thus
causes excessive wear and
damage to the cutter teeth.
5
Other horizontal milling
operations:
Slotting
Straddle milling
Slitting 6
Horizontal milling Vertical milling
7
Feed motion
8
2) Face milling:
The cutter is mounted on a spindle
with an axis of rotation
perpendicular to the work piece
surface.
9
3) End milling:
Flat surfaces as well
as varies profiles can
be produced by end
milling.
Some end mills have
cutting teeth also on
their end faces; these
teeth can be used as a
drill to start a cavity.
10
1
1
Gear milling:
12
cutter
workpiece
Dividing head
13
Dr. Soheir Backar 14
15
What are the main differences between horizontal
and vertical milling machines?
Horizontal milling machine Vertical milling machine
Main arm (arbor) is horizontal Main arbor is vertical
Main operations: Main operations:

- Slab milling - Face milling
Grooves and slot milling - End milling
Slitting Bevel milling
Form milling Slot milling
Straddle milling T-slot milling
- Gear milling - Gear milling
16
Gear Cutting &
Finishing
Gear Milling
In practice, gear milling is usually confined to:

• One-of-a-kind replacement gears.
• Small-lot production
• Roughing and finishing of coarse-pitch gears.
• Finish milling of gears having special tooth forms.
Gear Milling
Gear Cutter Sets for Milling
.
Advantages and Drawbacks
Advantages
• General purpose equipment and machines are used.
• Comparatively simple and easier setup is needed.
• Simple and cheap cutting tools are used.
• It is suitable for piece and small size production.
Drawbacks
• Inaccurate process due to profile deviations and indexing
errors.
• Low production capacity due to the idle time loss in indexing,
approaching, and withdrawal of the tool. However, the
productivity can be enhanced by multi-workpiece setup.
Gear Shaping
Progressive Shaping Head

Gear Planning
Template Machining
Gear Hobbing
Hobbed Products
Hobbing Machine
Hobbing Identical Parts
Gear Shaping with Pinion Cutter
Gear shaping with Rack Cutter
Shaping of Bevel Gears
Gear Grinding
CNC Machine Tools
• CNC machine tools were developed
in response to the limited
capabilities of conventional machine CAD drawing +
tools in terms of accuracy, Technical Details
complexity, and productivity.

CNC Machine Tools (system components)
• A controller that detects and processes
the control program and compares it with
the general movements that the machine
CAD drawing +
can perform. Technical Details
• The console contains software that stores
part programs so that they are not lost
when the machine stops working, and the
program can be repeated later to get
thousands of manufactured products
• A screen that displays the part program
and the path of the resulting cutter tool,
which can identify errors in the driver.
CNC Machine Tools
• The main advantages of CNC machine tools are:
• More efficient
• Do not rely on the user
• The consistency of the quality of the works
• Higher precision and repeatability
• Better utilization of cutting tool
• Shorter machining time
• Tool magazine
• Its drawbacks are:
• High investment costs
• High maintenance and service costs
• Possibility of catastrophic failure
• Setup time is long
CNC Machine Tools
• Programming types for CNC machines
• Manual programming: Direct preparation of the operational program by the production engineer.
• Automated programming: is the indirect preparation of the operational program through the use of
computerized design and manufacturing system (CAD/CAM - Computer Aided Design / Computer Aided
Manufacturing)
CNC Machine Tools
CNC Machine Tools
• The number of axes of a machine (the
degrees of freedom) are the number
of possibilities of object transitions, or
rotation around an axis, which
accurately describe the full potential of
an object's movement or direction of
movement.
• The degree of freedom is essential in
characterizing the capabilities of the
machine. The greater the freedom of
movement, the greater its potential,
especially in the manufacture of
complex products.
Dr-Eng. Mohamed Abd-Alrazzaq
PED- Alexandria University
38

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ALEXANDRIA

The axis of cutter rotation is

Main arm (arbor) is horizontal Main arbor is vertical

Main operations: Main operations:

In practice, gear milling is usually confined to:

Progressive Shaping Head

complexity, and productivity.

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