“Heaven’s Light is our guide”

Rajshahi University of Engineering & Technology

Department of Mechanical Engineering

A report on

Universal Milling Machine

Course No : ME-4808
Subject : Machine Tool ІІ Lab
Session : 2011-12
Class : 4th Year, 8th Semester

Name : Rifatul Mursalin , Md. MozahidurRahman,

Hasib Hasan shaon, shakil sheikh,
abdur Rahim , md. Abu rayhan,
asraf islam , Rubina akter
Roll No : 112061, 112062, 112063, 112064, 112065,
112066, 112067, 112068
Introduction:
The milling machine is one the most versatile and widely used machine tools for
both tool room and production purposes. Its history dates back to about 1772,
when metal was removed with a rotary cutting tool. In 1818, Eli Whitney invented
the plain milling machine, one of the important machine tools in that era. About
1850, the Lincoln miller was produced and widely used throughout the United
States. In 1861, Joseph R. Brown, of the Brown & Sharpe Company, invented the
prototype of the present universal milling machine; it was used primarily to make
the tools used in the production of musket parts.

Objectives:
1. To study universal milling machine.

2. To cut a spur gear.

Milling:
Milling is a process of removing material with a rotating multiple-tooth cutting
tool called a milling cutter which consists of number of cutting edge.
 Over arm

Spindle

Indexing

Table
Saddle
Column

Arbor with cutter

Principal parts of a milling machine:

1. Base

2. Spindle with arbor

3. Over arm

4. Table

5. Saddle

6. Knee

7. Column

8. Motors

Base:

Base is the foundation of the Milling machine. It is a heavy rigid casting , made in
one piece. It is the backbone of the milling machine. It holds or supports all the
other parts of the milling machine.
Spindle:

The spindle holds and drives the various cutting tools. It is a shaft mounted on
bearings supported by the column. The spindle is driven by an electric motor
through a train of gears all mounted within the column. The front end of the
spindle has a tapered hole and driving keys for locating and driving various cutting
tools, chucks, and arbors.

Over arm:
The over arm is mounted on the top of the column and guided in perfect
alignment by the machined dovetailed surfaces. It supports the arbor and is
adjustable and can be tightened in any position. Some machines have two rounds
over arm.

Table:

The table holds the work piece. It rest on the dovetailed guides of the saddle. T
slots are machined along the length of the top surface of the table. They are used
to align the job or the fixture, which holds the job. Bolts fit loosely in the T slots
and are used to clamp the job, vise, or fixture to the table

Saddle:

The saddle supports the table. It is supported and guided by the accurately
machined surfaces of the knee.
Knee:

The knee supports the saddle. The feed-change gearing is enclosed within the
knee. The knee can be raised or lowered on the column face. It is supported and
can be adjusted by the elevating screw.

Column:

The column is the main casting, which supports all the other parts of the machine.
The front of the column, the column face, is machined to provide an accurate
guide for the vertical travel of the knee.

Attachment:
Universal milling attachment:

A universal milling attachment as it name implies, is fully universal

because its spindle may be set at any angle in both planes. The spindle
speed is faster than the regular spindle. It may be 1.6 or 3.5 times as
fast as the regular spindle.

Rotary attachment:
It is used on a variety of circular milling such as circular T-slots, segment
outlines, and so forth, and on many tool and die making jobs that
require splinting, slotting, or irregular form milling. In addition to the
hand feed unit, rotary attachments are also available as power fed
units.

Slotting attachment:

It is largely used in tool making, such as forming box tools for screw
machines, making templates, and splinting keyways. The working parts
consist of a tool slide, driven from the machine spindle by an adjustable
crank that allows the stroke to be set for different lenths.The
attachment may be set at any angle between zero to and 90◦.

Rack milling attachment:

It I used for cutting teeth in racks. It can also be used in connection

with the universal spiral-index centers for cutting worms, on universal
milling machines, and for other miscellaneous operations. The cutter is
mounted on the end of a spindle that extends through the attachment
case parallel to the table T slots.

High speed milling attachment:

A high speed milling attachment consists primarily of a pair of gears for
increasing the normal speed of the milling machine spindle, and an
auxiliary spindle that drives the cutter. It is used in order to obtain the
correct speed for small milling cutters, which should be run more
rapidly than the fastest spindle speed of the milling machine, when the
cutting keyways, slots, etc.

Universal spiral milling attachment:

It is a device that is designed principally for the milling of helical and

spiral gear teeth. It is also suitable for vertical and angular milling, for
cutting worms and coarse pitch screw threads, milling cutters, twist
drills etc.

Working Principle:
1. At first cutting tool necessary stock material has been collected.
2. Then the work piece has been attached to mandrel & cutting tool (involute spur
gear cutter) was clamped to arbor.
3. After that the machine was switched ON.
4. The total no of teeth to be cut on the W/P was then identified.
5. Then through indexing the first tooth was cut on W/P.
6. After that by making one revolution of index handle the location for 2nd tooth
was determined.
7. Similar way the location of gear cutter for the rest teeth was determined.
8. Finally 40 teeth were cut on the periphery of the W/P & a spur gear was
obtained.

Feed:
Feed is the rate at which the work piece advances under the cutter. There are
three ways feed is controlled:

1. Manual feed.

2. Inches per revolution of the spindle or cutter.

3. Inches per minute (imp).

The feed (F) in inches per minute can be found as follows:

max . metalremoval i n3 per minute

F= depth of cut∗width of cut

Spur gear cutting calculation:

I = 40/N Let, N=40

I=40/40 =1

OD = (N+2)/DP

WD = 2.157/DP

Where,
 N = No. of teeth.

DP = Diametral pitch.

WD = Whole depth.

I = Rotation of index crank pin.

OD = Outside diameter of the gear blank.

Indexing:
Indexing in reference to motion is moving (or being moved) into a new position or
location quickly and easily but also precisely. After a machine part has been
indexed, its location is known to within a few hundredths of a millimeter
(thousandths of an inch), or often even to within a few thousandths of a millimeter
(ten-thousandths of an inch), despite the fact that no elaborate measuring or layout
was needed to establish that location. Indexing is a necessary kind of motion in
many areas of mechanical engineering and machining. A part that indexes, or can
be indexed, is said to be indexable.

Usually when the word indexing is used, it refers specifically to rotation. That is,
indexing is most often the quick and easy but precise rotation of a machine part
through a certain known number of degrees. However, the swapping of one part for
another, or other controlled movements, is also sometimes referred to as indexing,
even if rotation is not the focus.
Precautions:
1. We ensured that m/c is switched off at main switch.
2. Made sure that m/c has been lubricated & is cleaned & is free from all metal
chips, with particular attention to sideways.
3. We selected suitable work-holding device. Mount the w/p so that the surface
to be cut is over the centre of the table. Check that w/p is secure. Removed
all unwanted items from table.
4. Mount cutters after thoroughly cleaning the bore, keyway & boss faces
ensuring that cutter is clear of the surface of the w/p.
5. Fixed all safety guard.
6. Set controls for depth of cut, speed of cutter & rate of feed.
7. Adjusted the position of cutting fluid nozzle when coolant is required.
8. Switch on m/c check its running.