CHAPTER NOTES

SPECIALIZED MILLING-CAM MILLING

Specific Objectives

 Types of CAMS
 Parts of Cam milling attachments
 Cutters used for cam milling
 Work-set up for cam-milling

I. INTRODUCTION
-Milling is the process of machining flat, curved or irregular surfaces by feeding the workpiece
against a rotating tool containing a number of cutting edges.
-The milling machine consists of a motor-driven spindle, which mounts and revolves the milling
cutter and reciprocating the work-table, which mounts and feeds the work-table.
-Cam-milling involves machining of workpiece with the milling cutter in radial position in order
to produce a highly precise cam shape.
-Milling cutters are made of high-speed steels and are available in variety of shapes and sizes.
-In milling machine, the cutter is rotating and the workpiece is fed against it. This machine can
hold more than one tool at a time. The cutter rotates at high speed and because of many cutting
edges, it removes metal at very fast rate.

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 Figure 1: Parts of a milling machine
-Thus, milling machines are amongst the important workshop machines used to perform various
machining operations.
Advantages of milling machine over other machines

(a) The metal removal rate is high.

(b) It has good accuracy.
(c) It has a better surface finish on the workpiece.

II. TYPES OF CAMS

-The major types of cams include;
(a) Disk or plate cam
(b) Cylindrical cam
(c) Wedge cam
(d) Spiral cam

III. PARTS OF CAM MILLING ATTACHMENTS

-Attachments are available to increase the capabilities of cam milling machines.
Major attachments of a cam milling

(a) Digital read-outs: These are accessory measuring equipment used to reduce the chances
of errors when machining complex parts (cams).
(b) Indexing heads: They are used for making angular alignments.
(c) Rotary tables: They can allow various milling operations to take.
(d) Guards: They provide effective protection to the operator against chips.

IV. CUTTERS USED FOR CAM MILLING

-The major cutters used for cam milling includes:

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 V. WORK-SET FOR CAM MILLING
-Cam milling is the operation of producing cams in a milling machine by using a universal
dividing head and a vertical milling attachment.

Part of a cam milling machine

-The workpiece to be used for cam milling is mounted at the end of the dividing head spindle and
an end-mill is held in the vertical attachment.
-The dividing head is geared to the work-table of a milling so that cam workpiece is rotated
about its axis while it is fed against the end-mill.

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-The axis of the cam can be set from 0 to 90 degrees in reference to surfaces of the work-table
for obtaining different rise of the cams.

VI. SAFETY PRECAUTIONS

(i) Always inspect the milling machine more frequently.
(ii) Always wear the appropriate protective gear, such as gloves, safety glasses, helmets,
while machining.
(iii) Keep away from the revolving milling cutters.
(iv) Don’t use the milling machines with no guards.

VII. CARE AND MAINTENANCE OF SPECIALIZED MILLING MACHINES

(i) Clean down the work-table after machining operations.
(ii) Use the appropriate lubricants on the moving parts to minimize the friction.
(iii) Never tighten or loosen the arbor nut without the overarm support in position.
(iv) Replace the worn-out parts of a machine.

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 CHAPTER NOTES
SPECIALIZED MILLING-HELICAL MILLING
Specific Objectives

 Helical milling cutters.

 Work-set up for helical milling.
 Indexing operations for helical milling.
 Speeds and feeds for helical milling.
 Care and maintenance of helical milling machines.

I. INTRODUCTION
-The cutting tool used in milling operation is called milling cutter, which consists of multiple
edges called teeth.
- Milling machine is the machine tool that performs the milling operations by producing
required relative motion between workpiece and tool .
-It provides the required relative motion under very controlled conditions.
-Helical milling is a hole-making process in which the milling tool produces a helical path while
rotating around its own axis.
-Due to its kinematics, low cutting forces and low-tool wear, a high quality borehole can easily
be achieved.
-Helical milling can be undertaken on vertical and horizontal milling machines.

II. HELICAL MILLING CUTTERS

-The helical milling cutters are specially designed to enhance the milling operation process.
-They achieve high-material-removal rate, minimizing cycle time and reduce wearing action.
-These milling cutters are used in automotive and aerospace applications.
-Working under low cutting pressure, the effective design and compact length of helical milling
cutters promote smooth operations.
Types of helical milling cutters

(i) End-mill cutter: it has cutting teeth at one end.

(ii) Fly cutter: it is used for machining large, flat surfaces of job.
(iii) Slab mill: it is used for machining large broad surfaces quickly.

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 (iv) Ball cutter: it is used for milling large corner radius.
Features of helical milling cutters

(i) They have titanium compound coating to prevent thermal fatigue.

(ii) They are designed from carbide material and hence, they have longer service life.
(iii) They usually have multiple cutting edges.
Advantages of helical milling cutters

(i) Chips are removed easily due to good chip clearance in helical mill cutters.
(ii) Promote smooth operation due to effective design and compact length of helical mill
cutters.
(iii) Reduced undesirable vibrations and oscillations during milling processes.
(iv) Allow wide range of milling operations due to their versatility.

III. WORK SET-UP FOR HELICAL MILLING

-Before operating helical milling machine, all the tools and accessories are to be placed properly
and conveniently.
-Ensure that the work-table is free from impurities and burrs.
-Clamp or hold the workpiece properly on the work-table of a helical milling machine. This
helps to reduce possible vibrations during milling.
-Clamping of workpiece is determined by the size of the workpiece, geometrical nature of a
work, position of the workpiece face to be machined and kind of clamping tools available.
-When the workpiece is well-set, then the milling operation is started.

IV. INDEXING OPERATIONS FOR HELICAL MILLING

- Indexing is the operation of dividing the periphery of a workpiece into any number of
equal parts.
-For example, if a hexagonal bolt is to be made. Head of the bolt is given hexagonal shape. Then,
indexing is done to divide circular workpiece into six equal parts and then all the six parts are
milled to an identical flat surface.
-The main component used in indexing operation is universal dividing head.

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Universal indexing head
- Universal dividing head can set the workpiece in vertical, horizontal, or in inclined position
relative to the worktable in addition to working principle.

Universal indexing head

-An indexing plate is like a circular disc having concentric rings of different number of equally
spaced holes.
Indexing Methods
-These are; (a)
Direct indexing.
(b) Simple indexing.
(c) Compound indexing.
(d) Differential indexing.
(a) Direct Indexing or rapid indexing
- In direct indexing method, direct indexing plate is used which has 24 equally spaced holes in a
circle.
-It is possible to divide the surface of workpiece into any number of equal divisions out of 2, 3,
4, 6, 8, 12, 24 parts.
-These all numbers are the factors of 24.
-In this case fist of all worm and worm wheel is disengaged.
-if the surface is to be divided into 6 parts, then then the number of holes to be made can be
obtained as follows;

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 𝟐𝟒
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐻𝑜𝑙𝑒𝑠 =
𝑵
Where N represents the number of parts. (i.e 6)
(b) Simple Indexing Method or plain indexing
- It overcomes the major limitation of direct indexing that is possibility of dividing
circumference of workpiece into some fixed number of divisions.

- In this case, one complete turn of indexing crank revolves the workpiece by revolutions.

- Three indexing plates are used.

-The indexing plates have concentric circles of holes with their different numbers as described
below;

Indexing Procedure

(i) Divide 40 by the number of divisions to be done on the circumference of workpiece. This
gives movement of indexing crank.

Indexing crank movement =

Where;
N is the number of divisions to be made on the circumference of workpiece.

(ii) If the above number is a whole number, then crank is rotated by that much number of
revolutions after each milling operation, till the completion of the work.
For example, if we want to divide the circumference into 10 number of parts.
𝟒𝟎
𝑰𝒏𝒅𝒆𝒙𝒊𝒏𝒈 𝒄𝒓𝒂𝒏𝒌 𝐦𝐨𝐯𝐞𝐦𝐞𝐧𝐭 = = 𝟒 𝐫𝐞𝐯𝐨𝐥𝐮𝐭𝐢𝐨𝐧𝐬
𝟏𝟎

This means that the indexing crank is given 4 revolutions after each of milling operation for 9
more milling operations.

(iii) If indexing crank movement calculated by is not whole number, it is simplified and
then expressed as a whole number and a fraction.

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(iv) The fractional part of the above number is further processed by multiplying its
denominator and numerator by a suitable common number so that the denominator will
turn to a number equal to any number of holes available on the any of indexing plates.

(v) That particular hole circle is selected for the movement of crank pin.
(vi) The numerator of the process fraction stands for the number of holes to be moved by the
indexing crank in the selected hole circle in addition to complete turns of indexing crank
equal to whole number part 𝑜𝑓 .
For example;
Let us do the indexing to cut 30 teeth on a spur gear blank that means we need to
divide the circumference of gear blank into 30 identical parts. Crank movement is
calculated s given below.

Crank movement = = =1

Multiply both numerator and denominator by 5

Therefore;
1 ,
Denominator becomes „15‟ so we will select 15 hole circle of plate 1.

(d) Compound Indexing method

- The word compound indexing is an indicative of compound movements of indexing crank and
then plate along with crank.
-In this method, indexing plate is normally held stationary by a lock pin, first we rotate the
indexing crank through a required number of holes in a selected hole circle, then crank is fixed
through pin.
-It is followed by another movement by disengaging the rear lock pin, the indexing plate along
with indexing crank is rotated in forward or backward direction through predetermined holes in a
selected hole circle, then lock pin is reengaged.
-Following steps are to be followed for
Procedure for compound indexing operation with an example
Let us make 69 divisions of workpiece circumference by indexing method. (Using
compound indexing)
Solution
(i) Factor the divisions to be make (69 = 3 x 23), N = 69.
(ii) Select two-hole circles at random (These are 27 and 33 in this case, both of the hole
circles should be from same plate).

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 (iii) Subtract smaller number of holes from larger number and factor it as (33 – 27 = 6 = 2
x 3).
(iv) Factor the number of turns of the crank required for one revolution of the spindle
(40). Also factorize the selected hole circles.

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 (v) Place the factors of N and difference above the horizontal line and factors of 40 and
selected both the hole circles below the horizontal line as given below. Cancel the
common values.

(vi) If all the factors above the line are cancelled by those which are below the line, then
the selected hole circles can be used for indexing otherwise select another two-hole
circles. In this case there is need to select another hole circles. Let us select 23 and
33 this time and repeat the step 5 as indicated below.

- Encircled numbers below the line are the left out numbers after canceling the common factors.
All the factors above the horizontal line are cancelled so selected hole circles with 22 and 33
holes can used for indexing.

(vii) Following formula is used for indexing

In this formula N1 = 23 and N2 = 33 (N1 is always given smaller value out of two)
(viii) Multiply all the remaining factors below the line as 2 x 2 x 11 = 44. The formula
above will turn to;

Therefore; for indexing of 69 divisions, the indexing crank should be moved by 21 holes circle
in forward direction and then crank along with the plate are moved by 11 holes in 33 hole circle
is reversed (backward) direction.

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(d) Differential Indexing Method
-In this indexing method, certain set of gears is incorporated between the indexing plate and
driving head spindle.
-During differential indexing, the index plate is unlocked and connected to a train of gears
which receive their motion from the worm gear spindle.
-Differential indexing makes it possible to rotate the work by any fraction of revolution with the
usual index plates furnished with the equipment.
-For making the necessary calculations and to find the change of gears to be placed between the
spindle and the worm shaft, use the relationship given below;

=(𝑛−𝑁)×
Where;

N = Number of divisions to be induced.

n = number slightly greater or less than N.
-The difference between N and n causes the index plate to rotate the plate itself in a proper
direction relative to a crank.
-If (n-N) is positive, the index plate will rotate in the direction in which crank is rotated and if
(nN) is negative, it will rotate in opposite direction to that of crank.

V. FEEDS AND SPEEDS

(a) Speeds for milling cutters
-The speed of milling is the distance in feet per minute at which the circumference of the cutter
passes over the work.
-The spindle RPM necessary to give a desired peripheral speed depends on the size of the
milling cutter.
Factors determining the speeds of milling cutters

(i) Type of a milling cutter: A metal slitting saw milling cutter can be rotated faster than
a plain milling cutter having a broad face.
(ii) Nature of the teeth on the milling cutters: Cutters having undercut teeth (positive
rake) cut more freely than those having radial teeth (without rake); hence, they may
run at higher speeds.
(iii) Helix angle of the teeth: Angle cutters must be run at slower speeds than plain or
side cutters.

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 (iv) Availability of cutting oils: A plentiful supply of cutting oil will permit the cutter to
run at higher speeds than without cutting oil
-The formula for calculating spindle speed in revolutions per minute is as follows:

𝑆𝑝𝑖𝑛𝑑𝑙𝑒 𝑠𝑝𝑒𝑒𝑑 (𝑅𝑃𝑀) = 𝑪𝒖𝒕𝒕𝒊𝒏𝒈 𝑺𝒑𝒆𝒆𝒅×𝟒

𝑫𝒊𝒂𝒎𝒆𝒕𝒆𝒓
Example:
The spindle speed for machining a piece of steel at a speed of 35 SFPM with a cutter 2 inches in
diameter is calculated as follows:

(b) Feeds
-Feed refers to the amount of material removed from workpiece in one revolution.
-The feed of the milling machine may be designated in inches per minute or millimeters per
minute.
-The milling feed is determined by multiplying the chip size (chip per tooth) desired.
-The number of teeth on the cutter, and the revolutions per minute of the cutter.
Factors governing feeds in milling

(i) The amount of force exerted on the milling cutters.

(ii) The magnitude of power required to turn the cutter
(iii) The amount of vibration experienced on the milling cutters. (iv) The type of
holding device sed during machining.
-the formula used to find the work-feed in inches per minute can be experienced as;
Inches Per Minute = Cheap Per Tooth x Number of teeth per minute x Revolution
Per Minute

VI. CARE AND MAINTENANCE OF HELICAL MILLING ATTACHMENT

(i) Clean down the work-table and dividing head or fixture after every job.
(ii) Oil or grease the machine regularly with the recommended lubricant.
(iii) Ensure that the cross-slides and other parts of the machine are well tightened.

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 (iv) Never leave the machine running to avoid unnecessary accidents.
(v) Ensure that the machine guards are in good working conditions.

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