Name : S'M' Prasad,

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Department Of Technical Education, Andhra Pradesh.

• Name S.M. Prasad,
• Designation H.M.E.S.
• Branch Mechanical Engineering
• Institute Govt Polytechnic ,Warangal
• Year\semester V semester
• Subject Manufacturing technology-II
• Subject code M-505
• Topic Milling and Gear making
• Duration 50 mins
• Sub-topic Milling operations
• Teaching aids Visuals Diagrams

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Recap

• In the last class we have learnt about,
• Basic milling operations.
• Climb milling and conventional milling.
• Plain or slab milling, face milling, straddle
  milling.

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Objectives

• On completion of this period , you would be able
  to know about
• Milling operations.
• Other types of milling operations.

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Gang milling

• Operation of machining several surfaces
  simultaneously by different types of cutters.
• All cutters are mounted on the same horizontal
  arbor.
• No spacing collars are used.

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Plain milling cutter
Angle milling cutter
Arbor
Gang milling
Fig.1
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Angular milling

• Cutting a flat surface at an inclination to the
  axis of the cutter.
• Achieved by angular milling cutter.
• Swiveling the work or the spindle can also
  provide angular milling.

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Angle milling cutter
Fig.2
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Form milling

• Cutting the surface having a regular or irregular
  outline.
• The contours are convex ,concave or a gear tooth
  cutting.

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Form milling
Fig.3

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Concave milling
Convex milling
Fig.4

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Profile milling

• Operation of machining complex shapes with the
  help of template on a tracer machine.
• The end mill is mostly used for profile milling.

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End milling

• Operation of machining horizontal or vertical
  surfaces by end mill.
• Generally performed on a vertical milling machine.

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End milling
Fig.5
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Saw milling

• Machining narrow slots or grooves using metal
  slitting saw.
• Also used for parting off operations.

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HSS metal saw
Diamond tipped saw
Fig.6
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Key-way milling

• Cutting key-ways and slots using a special
  cutter, key-cutter.
• T slots can be cut with the help of T- slot
  cutter.

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Parts with Key ways
Fig.7
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Parts with Key ways
Fig.8
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Gear cutting

• Spur gears and helical gears are cut on milling
  machine with help of gear cutters.
• Profile is identical with tooth space of gear to
  be cut.
• It involves indexing operation.

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Gear milling cutter
Fig.9
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Spur gear cutting
Helical gear cutting
Fig.10
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Cam milling

• Milling a cam profile on milling machine using
  dividing head.
• End milling cutter is held in vertical
  attachment such that axis of the spindle and
  blank remain parallel.
• The movement of blank is controlled by dividing
  head.
• Also, using CAM software, milling can be
  performed.

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Cam-milling
Fig.11

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Cam-turning
Cam-milling
Fig.12
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Summary

• In this class we have learnt about ,
• Various milling operations like
• Gang milling ,
• gear milling,
• angular milling, cam milling,
• end milling ,
• profile milling ,
• key way milling.

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Quiz

• 1. Saw milling is used for
• a) flute milling
• b) parting off
• c) slotting
• d) None of the above

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Quiz

• 2.Gear cutting operation is performed by
• a) gear cutter
• b) side cutter
• c) keyway cutter
• d) None of the above

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Quiz

• 3. Cutting a flat surface at an inclination to
  the axis of the
• cutter obtained by
• a) angular milling cutter
• b) end mill
• c) plain mill
• d) None of the above

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Frequently asked Questions

• Explain gang milling with a neat sketch.
• Explain form milling with a sketch.
• Write short notes on
• a) End milling
• b) Profile milling