IPE 401

Machine Tools

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 Chapter – 3
Case Study of Milling Machine

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Introduction to Milling Machine
• A type of machine which removes the material from the workpiece by feeding
the workpiece past a rotating multipoint cutter
• Widely used machine tool for form cutting
• Mostly used for slotting and gear cutting
• Almost all shapes and sizes of workpieces can be machined
• Typical milling operations are slab milling, slot milling, side milling, end milling,
face milling, form milling etc.

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Scopes of Milling Machine
• External or internal surfaces of different shapes
• Cutting straight or helical grooves
• Cutting external and internal threads
• Cutting gears

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Milling Operations

Click the following link for video on

Different Types of Milling Operations 5
Types of Milling Machine
• Knee & Column Type Milling Machine
• Plain Horizontal Milling Machine
• Universal Horizontal Milling Machine
• Vertical and Ram-head (Omniversal) Milling Machine Ram-head Milling Machine

• Vertical Bed Type Milling Machine

• Planer Type Milling Machine Plain Horizontal Milling Machine

• Single-column/Open-side Milling Machine

• Double-column Milling Machine

• Continuous Milling Machine

• Revolving Table Milling Machine
• Drum Type Milling Machine Planer Type (Double-column) Milling Machine

• Specialized (Thread, Keyway, Spline-shaft etc.) Milling Machine Click the following link for video
Different Types of Milling Machine 6
Parts of Milling Machine

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Universal Milling Machine
• 3 axis motion of table (longitudinal, cross and vertical)

• Ability to swivel ±45° on the horizontal plane to

facilitate helical gear cutting

• Presence of dividing head for dividing the

circumference or periphery of circular/cylindrical
surfaces into equal no. of divisions

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Horizontal vs Vertical Milling Machine
Comparator Horizontal Milling Machine Vertical Milling Machine
Axis of Spindle Rotation Horizontal Vertical

Arbor Present Mostly absent

Movement of head No movement Can be swiveled or move up-down

Use Case Gear forming Slot cutting

Cost of Machine Expensive Cheap

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Various Milling Cutters

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Different Types of Milling Cutters 10
Dimension of Milling Machine
The main dimension of general purpose milling machines is the size of the working
surface of the table

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Kinematic Diagram of Milling Machine

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Basic Speed and Feed Info
1. Main Motor Speed (for Spindle): 1460 rpm
2. Number of Available Spindle Speed: 18
3. Auxiliary Motor Speed (for Feed): 1430 rpm
4. Number of Available Feed: 18

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Gear Train for Principal Movement (Spindle Speed)
𝟐𝟕 𝟏𝟗 𝟐𝟕 𝟏𝟗
𝒏𝒔𝒑 = 𝟏𝟒𝟔𝟎 × × × ×
𝟓𝟑 𝟑𝟓 𝟑𝟕 𝟔𝟗
𝟐𝟐 𝟏𝟕 𝟔𝟐
𝟑𝟐 𝟒𝟔 𝟑𝟖
𝟏𝟔 𝟑𝟖
𝟑𝟖 𝟐𝟔

18 Speeds

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Gear Train for Feed Movement
• Clutch 𝑪𝟐 engaged
𝟐𝟔 𝟐𝟔 𝟏𝟖 𝟏𝟖 𝟒𝟎 𝟐𝟖 𝟏𝟖 𝟑𝟑 𝟏𝟖 𝟏𝟖
𝒏𝒔𝒑 = 𝟏𝟒𝟑𝟎 × × × × × × × × × × ×𝟔
𝟓𝟎 𝟓𝟕 𝟑𝟔 𝟒𝟎 𝟒𝟎 𝟑𝟓 𝟑𝟑 𝟑𝟕 𝟏𝟔 𝟏𝟖
𝟐𝟕 𝟐𝟏
𝟐𝟕 𝟑𝟕

𝟑𝟔 𝟐𝟒
𝟏𝟖 𝟑𝟒

Pitch of lead screw is 6 mm

9 Feeds

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Gear Train for Feed Movement
• Clutch 𝑪𝟐 disengaged
𝟐𝟔 𝟐𝟔 𝟏𝟖 𝟏𝟖 𝟏𝟑 𝟏𝟖 𝟒𝟎 𝟐𝟖 𝟏𝟖 𝟑𝟑 𝟏𝟖 𝟏𝟖
𝒏𝒔𝒑 = 𝟏𝟒𝟑𝟎 × × × × × × × × × × × × ×𝟔
𝟓𝟎 𝟓𝟕 𝟑𝟔 𝟒𝟎 𝟒𝟓 𝟒𝟎 𝟒𝟎 𝟑𝟓 𝟑𝟑 𝟑𝟕 𝟏𝟔 𝟏𝟖
𝟐𝟕 𝟐𝟏
𝟐𝟕 𝟑𝟕

𝟑𝟔 𝟐𝟒
𝟏𝟖 𝟑𝟒

9 Feeds

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Gear Cutting Process

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Universal Dividing Head
• Dividing head is used for indexing cylindrical workpiece like gears
• In general, indexing means dividing the periphery (or circumference) of any
cylindrical (or circular) workpiece into equal no. of divisions
• Dividing head is mounted on the bed and holds the workpiece

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Components of Dividing Head
• Index Plate – holes of any circular row of index plate
divides it into equal segments, each circular row
contains different no. of holes
• Index Crank – helps index pin to rotate index plate
Spindle
• Index Pin – helps to rotate the index plate and lock Index Pin
the plate in the desired position Adjustable
Sector
• Adjustable Sector – eliminates the need of counting Index Crank

holes for each rotation Index Plate

• Spindle – holds the workpiece

• Change Gears – provides additional rotation to index
plate in differential indexing
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Types of Indexing
Indexing can be 3 Types
• Simple Indexing
• Differential Indexing
• Indexing for Cutting Helical Grooves

Indexing mainly needed in gear cutting

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Simple Indexing
• Simple indexing consists in turning the spindle through the required angle by
rotating the index crank
• If the periphery of a workpiece is to be divided into 𝒑 no. of divisions, this can be
achieved directly from the reading of index plate in simple indexing
• This process of indexing involves the use of a crank, index plate, spur gear train,
worm and worm wheel
• 40 turns of the index crank will make one revolution of the spindle

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Simple Indexing
• In the gear train, there are 2 pairs of spur gears, a pair of
bevel gear and a pair of worm – worm wheel
• In simple indexing, only 1 pair of spur gears and the worm
– worm wheel are required
• 𝒁 = no. of start of the worm gear = 1
• 𝒛𝟎 = no. of teeth of worm wheel = 40
• Gear ratio between all the meshing spur and bevel gear
pairs is equal to 1

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Simple Indexing
• Let 𝒑 no. of divisions required on the periphery of the workpiece
• Let 𝒏 is the amount of revolution of the index crank to rotate
through the workpiece in the required spacing i.e.,
𝟏
𝑟𝑒𝑣. 𝑜𝑓 𝑠𝑝𝑖𝑛𝑑𝑙𝑒
𝒑

• Kinematic balance equation is

𝒁 𝟏
𝒏∙𝟏∙ =
𝒛𝟎 𝒑
• Putting 𝒛𝟎 = 𝟒𝟎, 𝒁 = 1 and simplifying the relationship,
𝟒𝟎
𝒏= 𝒁 = no. of start of the worm gear = 1
𝒑 𝒛𝟎 = no. of teeth of worm wheel = 40
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Simple Indexing
Example: Describe the indexing procedure for cutting 33 teeth gear. The available index
plate hole circles are as follows:
Plate 1: 15, 16, 17, 18, 19, 20
Plate 2: 21, 23, 27, 29, 31, 33
Plate 3: 37, 39, 41, 43, 47, 49

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 Plate 1: 15, 16, 17, 18, 19, 20
Simple Indexing Plate 2: 21, 23, 27, 29, 31, 33
Plate 3: 37, 39, 41, 43, 47, 49

Solution: The gear blank has to be divided into 33. Therefore 𝒑 = 33.
𝟒𝟎 𝟒𝟎 𝟕
𝒏= = =𝟏+ rev
𝒑 𝟑𝟑 𝟑𝟑
• This means the index crank has to undergo 1 complete revolution
𝟕
and then another portion of 1 revolution
𝟑𝟑

𝟕
• In order to achieve portion of one revolution, we have to select a
𝟑𝟑
index plate with hole number equal to multiple to 33. Therefore
select index plate 2.
• Now using the adjustable sector we have to adjust a gap 7 holes to
avoid counting in each go.

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 Plate 1: 15, 16, 17, 18, 19, 20
Differential Indexing Plate 2: 21, 23, 27, 29, 31, 33
Plate 3: 37, 39, 41, 43, 47, 49

• Differential indexing is employed where simple indexing cannot be effected. That

means, where an index plate with the required number of holes for simple
indexing is not available
• For example if you want to cut a gear with 51 teeth using the same three index
𝟒𝟎 𝟒𝟎
plates from previous example, then for simple indexing 𝒏 = = rev. Now in
𝒑 𝟓𝟏
order to achieve that, you’ll need a index plate of 51 holes which is not available
in this case.
• Differential indexing involves change gears

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Differential Indexing
• In differential indexing, the required turn of the dividing
head spindle is obtained as a sum of two turns
1. Rotation of index crank with respect to index plate
(same as simple indexing)
2. Rotation of the index plate itself which is driven by
the spindle rotation and transmitted through
change gears
Differential Indexing
• Let 𝒑 no. of divisions required on the periphery of the workpiece
• As 𝒑 no. of holes is not available in the index plates, then choose
the nearest available hole 𝒑𝒙 . This 𝒑𝒙 can be greater and smaller
than 𝒑.
• 𝒏 is the amount of revolution of the index crank with respect to
index plate to rotate through the workpiece in the required
𝒛𝟎
spacing ⇒ 𝒏 =
𝒑𝒙

𝒁 = no. of start of the worm gear = 1

𝒛𝟎 = no. of teeth of worm wheel = 40

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Differential Indexing
Number of revolution of index crank
𝑧0
𝑛1 =
𝑍𝑝𝑥 𝑧0 1 𝑎 𝑐 𝑧0
Number of revolution of index plate + ∙ ∙ ∙ 1∙1=
𝑍𝑝𝑥 𝑝 𝑏 𝑑 𝑍𝑝
1 𝑎 𝑐
𝑛2 = ∙ ∙ ∙ 1∙1
𝑝 𝑏 𝑑 𝒂 𝒄 𝒛𝟎
Absolute number of revolution of index crank ⇒ ∙ = (𝒑 −𝒑)
𝒃 𝒅 𝒑𝒙 𝒙
𝑛 = 𝑛1 + 𝑛2
𝑧0 1 𝑎 𝑐
𝑛= + ∙ ∙ ∙ 1∙1
𝑍𝑝𝑥 𝑝 𝑏 𝑑

According to indexing formula

𝑧0
𝑛=
𝑍𝑝
𝒁 = no. of start of the worm gear = 1
𝒛𝟎 = no. of teeth of worm wheel = 40

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Differential Indexing
1. If 𝒑𝒙 > 𝒑
• The rotation of spindle due to the rotation of index crank
with respect to index plate will be smaller than the
required spindle rotation
• The index plate has to be rotated in the same direction of
the rotation of index crank to cover up this lag
• To make it happen, auxiliary idler gear will be required
𝒂 𝒄
• The sign of ∙ term will be positive
𝒃 𝒅

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Differential Indexing
1. If 𝒑𝒙 < 𝒑
• The rotation of spindle due to the rotation of index crank
with respect to index plate will be greater than the
required spindle rotation
• The index plate has to be rotated in the opposite direction
of the rotation of index crank to cover up this lag
• To make it happen, no auxiliary idler gear will be required in
the change gear train
𝒂 𝒄
• The sign of ∙ term will be negative
𝒃 𝒅

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Differential Indexing
Example: Select the differential change gears and the index plate for cutting a gear with
47 teeth. Also determine the number of revolutions of the index crank with respect to
index plate.
Plate 1: 15, 16, 17, 18, 19, 20
Plate 2: 21, 23, 27, 29, 31, 33
Plate 3: 37, 39, 41, 43, 45, 49
Available Change Gears: 24, 24, 28, 32, 40, 44, 48, 56, 64, 72, 86

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 Plate 1: 15, 16, 17, 18, 19, 20
Plate 2: 21, 23, 27, 29, 31, 33

Differential Indexing Plate 3: 37, 39, 41, 43, 45, 49

Available Change Gears

Solution: 24, 24, 28, 32, 40, 44, 48, 56, 64, 72, 86

• The gear blank has to be divided into 47 divisions. Therefore 𝒑 = 𝟒𝟕. Let, 𝒑𝒙 = 𝟒𝟗.
Therefore index plate 3 will be used (𝒂𝒏𝒔)
𝒛𝟎 𝟒𝟎
• Revolution of the index crank with respect to index plate, 𝒏 = = (𝒂𝒏𝒔)
𝒑𝒙 𝟒𝟗

𝒂 𝒄 𝒛𝟎 𝟒𝟎 𝟒𝟎
• Change gears ∙ = (𝒑𝒙 −𝒑) = (𝟒𝟗 − 𝟒𝟕) = ∙𝟐
𝒃 𝒅 𝒑𝒙 𝟒𝟗 𝟒𝟗
𝒂 𝒄 𝟒𝟎 ∙ 𝟐 𝟒𝟎 ∙ 𝟐 ∙ 𝟒 ∙ 𝟖 𝟒𝟎 ∙ 𝟔𝟒 𝟒𝟎 𝟔𝟒
⇒ ∙ = = = = ∙
𝒃 𝒅 𝟕∙𝟕 𝟕∙𝟒 ∙ 𝟕∙𝟖 𝟐𝟖 ∙ 𝟓𝟔 𝟐𝟖 𝟓𝟔

∴ 𝒂 = 𝟒𝟎, 𝒃 = 𝟐𝟖, 𝒄 = 𝟔𝟒, 𝒅 = 𝟓𝟔 (𝒂𝒏𝒔)

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Indexing for Cutting Helical Grooves
• This indexing is required for cutting helical gears
• The fundamental behind this indexing is the longitudinal movement of table must
be synchronized with the rotation of dividing head spindle
• In 1 rotation of dividing head spindle, the table should move distance equal to the
lead of the helix to be imparted on the helical gear
• This synchronization is achieved using the change gears
• Change gears transfer the motion from spindle of dividing head to the lead screw of
the table

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Indexing for Cutting Helical Grooves
• To achieve the helical grooves, the table has to be set at an angle of the perpendicular
of the arbor axis.

−𝟏 𝝅𝑫
• If the helix angle of the helical gear is 𝜶, then the set angle of table, 𝝎 = 𝐭𝐚𝐧
𝑷𝒉.𝒈
where 𝑫 is the diameter of the workpiece being cut

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Indexing for Cutting Helical Grooves
• Kinematic Balance Equation

𝒛𝟎 𝒂 𝒄
𝟏 𝒔𝒑 𝒓𝒆𝒗 ∙ ∙ 𝟏 ∙ 𝟏 ∙ 𝟏 ∙ ∙ ∙ 𝑷𝒍.𝒔 = 𝑷𝒉.𝒈
𝒁 𝒃 𝒅

𝑤ℎ𝑒𝑟𝑒, 𝑃𝑙.𝑠 = 𝐿𝑒𝑎𝑑 𝑜𝑓 𝐿𝑒𝑎𝑑 𝑆𝑐𝑟𝑒𝑤

With 𝒁 = 𝟏 and 𝒛𝟎 = 𝟒𝟎

𝒂 𝒄 𝑷𝒉.𝒈
∙ =
𝒃 𝒅 𝟒𝟎 ∙ 𝑷𝒍.𝒔

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