Unit 5.

Milling, Broaching, and shaping and

planning Process
Syllabus
❑ Fundamental aspects, cutter types and
geometry, Operations performed on milling
machine, dividing head method of indexing.
❑ Construction, working and operations performed
on shaper, planer, and broaching machines.

1
 Part A:
Milling Machine

2
 Milling Process
• Milling is a cutting process that uses a multi-edge
cutting tool to remove material while traveling
along various axes with respect to the workpiece,
able to generate complex shapes and profiles.

3
Slab Milling Process
• Slab Milling (peripheral
milling): process where
axis of cutting tool is
parallel to the workpiece
surface to be machined
• -- used to create flat
surfaces or slots
• -- cutter may have either
straight or helical teeth

4
Up Milling Process
• Conventional or Up milling –
• Direction of travel of w/p
and direction of rotation of
cutter
• Cutter is rotated against
direction of travel of w/p
• Thickness of chip – min.at
start – max. at end of cut

5
Down Milling Process
➢ Down or climb milling – cutter
rotates in the same direction as
that of travel of w/p
➢ Thickness of chip is maximum at
start and reduces when cut
terminates
➢ Cutter bites the w/p without
sliding at start
➢ Cutting force is variable
throughout cut
➢ Direction of cutting force tends to
seat the work firmly in work
holding device
➢ Chip disposal does not interfere
cutting
➢ Coolant application is direct at
cutting zone- improved surface
finish
6
 Face Milling

Face Milling: process where the cutter is mounted having an axis of

rotation perpendicular to the workpiece surface.
--used to create flat surfaces
--cutting action may be both Up or Down milling
-- leaves cutting marks on the machined surface
7
 Face Milling
• Flat surface
perpendicular to axis of
rotation of cutter
• Teeth – periphery and
face ( not extending up
to centre)
• Actual cutting by
peripheral teeth
• Teeth on face – finishes
by removing very mall
material

8
 Applications of Milling Process
➢ Flat surface in vertical, horizontal and inclined planes
➢ Making slots or ribs of various sections
➢ Slitting or parting
➢ Often producing surfaces of revolution
➢ Making helical grooves like flutes of the drills
➢ Long thread milling on large leadscrews, power screws, worms
etc and short thread milling for small size fastening screws,
bolts etc.
➢ 2-D contouring like cam profiles, clutches etc and 3-D
contouring like die or mould cavities
➢ Cutting teeth in piece or batch production of spur gears,
straight toothed bevel gears, worm wheels, sprockets, clutches
etc.
➢ Producing some salient features like grooves, flutes, gushing
and profiles in various cutting tools, e.g., drills, taps, reamers,
hobs, gear shaping cutters etc. 9
Processing Parameters in
Milling

10
Spindle Speed

11
Depth of cut

12
Typical Milling Operations

13
Typical Milling Operations

14
Typical Milling Operations

15
Typical Milling Operations

16
MILLING CUTTER

17
 DESCRIPTION
• Milling cutters are cutting tools typically used in
milling machines or machining centres (and
occasionally in other machine tools). They remove
material by their movement within the machine
(e.g., a ball nose mill) or directly from the cutter's
shape (e.g., a form tool such as a hobbing cutter).

18
 GEOMETRY
➢ A variety of grooves, slots, and pockets in the
workpiece may be produced from a variety of tool
bits. Common tool bit types are: square end cutters,
ball end cutters, t-slot cutters, and shell mills. Square
end cutters can mill square slots, pockets, and edges.
Ball end cutters mill radiused slots or fillets. T-slot
cutters mill exactly that: t-shaped slots. Shell end
cutters are used for large flat surfaces and for angle
cuts. There are variations of these tool types as well.
➢ There are four critical angles of each cutting tool: end
cutting edge angle, axial relief angle, radial relief
angle, and radial rake angle. See graph for common
values.
19
 GEOMETRY
➢Depending on the material being milled, and what
task should be performed, different tool types and
geometry may be used. For instance, when milling
a material like aluminium, it may be advantageous
to use a tool with very deep, polished flutes and a
very sharp cutting edge. When machining a tough
material such as stainless steel, however, shallow
flutes and a squared-off cutting edge will optimize
material removal and tool life.

20
 GEOMETRY
• A wide variety of materials are used to produce the
cutting tools. Carbide inserts are the most common
because they are good for high production milling.
High speed steel is commonly used when a special
tool shape is needed, not usually used for high
production processes. Ceramics inserts are typically
used in high speed machining with high production.
Diamond inserts are typically used on products that
require tight tolerances, typically consisting of high
surface qualities (nonferrous or nonmetallic
materials). In the early 1990s, use of coatings to
reduce wear and friction (among other things)
became more common. Most of these coatings are
referred to by their chemical composition, such as:
21
 GEOMETRY
➢ TiN (a basic yellowish coating that has fallen out of wide use)
➢ TiCN (a popular bluish-grey coating)
➢ TiAlN and AlTiN (an extremely popular dark purple coating)
➢ TiAlCrN, AlTiCrN and AlCrTiN (PVD coating).
➢ PCD veins. Though not a coating some endmills are manufactured
with a 'vein' of polycrystaline diamond. The vein is formed in a high
temperature-high pressure environment. The vein is formed in a
blank and then the material is ground out along the vein to form
the cutting edge. The tools can be very costly, however can last
many times longer than other tooling.
➢ Advances in endmill coatings are being made, however, with
coatings such as Amorphous Diamond and nanocomposite PVD
coatings beginning to be seen at high-end shops (as of 2004).
22
 TYPES OF MILLING CUTTER
1. Arbor Type of Milling Cutter
a) Plain Milling
b) Side Milling
c) Form Milling
d) Fly Cutter
2. Shank Type of Milling Cutter
a) End Mill
b) Inserted Tooth
c) T-slot
d) Fly Cutter
23
 Arbor Types of Milling Cutter
• Arbor milling is a cutting process which
removes material via a multi-toothed cutter.
An arbor mill is a type of milling machine
Characterized by its ability to rapidly remove
material from a variety of materials, this
milling process is not only rapid but also
versatile.

24
 Plain Milling
• Once widely used
• Cylinder of high-speed steel with teeth
cut on periphery
• Used to produce flat surface
• Several types
• Light-duty
• Light-duty helical
• Heavy-duty
• High-helix
25
 Side Milling
➢Comparatively narrow cylindrical milling
cutters with teeth on each side and on
periphery
➢Used for cutting slots and
for face and straddle milling
operations
➢Free cutting action at high
speeds and feeds
➢Suited for milling deep, narrow slots

26
 Form Milling
➢Incorporate exact shape of part to be
produced
➢Useful for production of small parts
➢Each tooth identical in shape
➢Sharpened by grinding tooth face (may
have positive, zero or negative rake)
➢Important to maintain original rake
➢Difficult to sharpen

27
 Types of Formed Cutter

Concave Convex Gear Tooth

28
 Angular Cutter
➢Teeth neither parallel nor perpendicular
to cutting axis
➢Used for milling angular surfaces
➢Grooves, serrations, chamfers and reamer
teeth
➢Divided into two groups
➢Single-angle milling cutters
➢Double-angle milling cutters

29
 Angular Cutter
• Single-angle
• Teeth on angular surface
• May or may not have teeth on flat
• 45º or 60º
• Double-angle
• Two intersecting angular surfaces
with cutting teeth on both
• Equal angles on both side of line
at right angle to axis

30
 Fly Cutter
• Single-pointed cutting tool with cutting
end ground to desired shape
• Mounted in special
adapter or arbor
• Fine feed must be used
• Used in experimental
work instead of a
specially shaped cutter

31
 End Mill
• Cutting teeth on end as well as
periphery
• Fitted to spindle by suitable adapter
• Two types
• Solid end mill: shank and cutter integral
• Smaller with either straight or helical flutes
• Two flute or four flute
• Shell end mill: separate shank

32
 Inserted Tooth
• Only such cutters as are made from a single
piece of tool steel have been so far considered.
In large cutters, however, the cost of the steel
becomes an important item, and there is the
ever-present danger of losing a large amount of
labor

33
 Inserted Tooth
• Courtesy of Becker Milling Machine Company,
Hyde Park, Massachusetts by breakage when
hardening. To make an economical, serviceable
cutter of large size, it is customary to use a cast-
iron body with inserted tool steel teeth. There
are several different methods of inserting and
holding these teeth. Usually, when the inserted
tooth is in the form of a blade, they are held by
taper pins or screws, Fig. 211. These blades are
renewable, the cast-iron body being used many
times.

34
 Inserted Tooth
• Another form of inserted-tooth cutter
consists of round, hardened steel pins driven
into holes in a cast-iron body. This cutter is
also permanent in form, Fig. 212, as broken
teeth cannot be replaced; and, when the
teeth are worn almost down to the body, the
whole cutter is thrown away.

35
 Inserted Tooth

Fig. Form of Inserted-Tooth

Fig. Cutter with Inserted Cutter Called Slabbing Cutter.
Teeth. 36
 Shell Type (End Mill)

• Face milling cutters

under 6 inch
• Solid, multiple-tooth
cutters with teeth on
face and periphery
• Held on stub arbor
• May be threaded or use
key in shank to drive
cutter
37
 T-slot
• Used to cut wide horizontal groove at
bottom of T-slot
• After narrow vertical groove machined
with end mill or side milling cutter
• Consists of small side milling cutter
with teeth on both sides and integral
shank for mounting

38
 Fly Cutter
• Single-pointed cutting tool with cutting
end ground to desired shape
• Mounted in special
adapter or arbor
• Fine feed must be used
• Used in experimental
work instead of a
specially shaped cutter

39
 PARTS AND THEIR FUNCTIONS
• Flutes / teeth: The flutes of the milling bit are the
deep helical grooves running up the cutter, while the
sharp blade along the edge of the flute is known as
the tooth. The tooth cuts the material, and chips of
this material are pulled up the flute by the rotation of
the cutter. There is almost always one tooth per flute,
but some cutters have two teeth per flute.[1] Often,
the words flute and tooth are used interchangeably.
Milling cutters may have from one to many teeth,
with 2, 3 and 4 being most common. Typically, the
more teeth a cutter has, the more rapidly it can
remove material. So, a 4-tooth cutter can remove
material at twice the rate of a 2-tooth cutter

40
 PARTS AND THEIR FUNCTIONS
➢Helix angle: The flutes of a milling cutter are
almost always helical. If the flutes were straight,
the whole tooth would impact the material at
once, causing vibration and reducing accuracy
and surface quality. Setting the flutes at an angle
allows the tooth to enter the material gradually,
reducing vibration. Typically, finishing cutters
have a higher rake angle (tighter helix) to give a
better finish.

41
 PARTS AND THEIR FUNCTIONS
• Center cutting: Some milling cutters can drill
straight down (plunge) through the material, while
others cannot. This is because the teeth of some
cutters do not go all the way to the centre of the
end face. However, these cutters can cut
downwards at an angle of 45 degrees or so.

42
 PARTS AND THEIR FUNCTIONS
➢Shank: The shank is the cylindrical (non-fluted)
part of the tool which is used to hold and locate it
in the tool holder. A shank may be perfectly round,
and held by friction, or it may have a Weldon Flat,
where a grub screw makes contact for increased
torque without the tool slipping. The diameter
may be different from the diameter of the cutting
part of the tool, so that it can be held by a
standard tool holder.

43
 Indexing

• Indexing is an operation of dividing the

periphery of a piece of work into any number
of equal parts.

• Accomplished by Dividing head or index head

44
Dividing Head

45
Principle or mechanism of dividing head
➢ Main spindle – drives
w/p
➢ Index plate – holes with
crank and pin
➢ Index crank drives spindle
through a worm gear
➢ Worm gear has 40 teeth
➢ For one rotation of w/p
we need 40 revolutions
of index crank

46
 Explain with principle or
mechanism of dividing head
• Index plate – equi-spaced
holes around various
circles
• Brown and sharp company
• Three plate –
• 1. – 15,16,17,18,19,20
• 2. – 21,23,27,29,31,33
• 3- 37,39,41,43,47,49

47
Index plate

48
Universal dividing head

49
 Universal dividing head
• Used for all forms of indexing
• Used for
• 1. setting work in vertical, horizontal or in inclined
positions , relative to table surface
• For turning w/p periodically through a given angle
to impart indexing movement
• For imparting continuous rotary motion to w/p for
milling helical grooves

50
51
 Methods of Indexing

1.Simple or Plain Indexing

2.Compound Indexing
3.Differential Indexing

52
 Simple or Plain Indexing
• Simple – indexing using any one of indexing
plate in conjunction with worm
• To find index crank movement

40
Indexcrankmovement =
N

• N – number of divisions required

53
• Milling of gear with 20 teeth
• N = 20
• Index crank movement = 40/20
• Index crank movement is 2 – whole number
• Index crank is to be rotated through 2
complete turns

54
• Gear with 30 teeth
• Index crank movement = 40/30
40 1
Indexcrankmovement = =1
30 3
• One complete turn of crank and additional
one third of turn
• For obtaining additional one third turn

55
• Select plate
• Plate should have number of holes in plate
circle= denominator of fraction part and a
common number or in multiples of
denominator
• No of holes in plate circle - 3 * X
• Let us have X = 7
• No of holes in plate circle = 3*7 = 21

56
• Select plate having circle with 21 holes
• For indexing – one complete turn pf crank
and additional movement of 7 hole in 21 hole
circle

57
58
 Compound Indexing
• Two separate movements of index crank in
two different hole circles of one index
plate to obtain crank movement not
obtainable by simple indexing

59
 Compound Indexing

• Two movements
• One of index crank as in simple indexing
• Second of index plate – after locking the
plate with plunger

60
 Compound Indexing

• First – crank pin is rotated through required

number of spaces in one of the hole circles of
index plate and crank pin is engaged

61
• Second movement –
removing rear lock pin
and rotating plate
together with index
crank – forward or
backward through
calculated number of
spaces of another hole
circle and then lock pin
is engaged

62
 Rule for compound indexing
40 n1 n2
= 
N N1 N 2
• N – No of divisions required
• N1 - hole circle used by crank pin
• N2= - hole circle used by lock pin
• n1 – hole spaces moved by crank pin in N1 hole
circle
• n2 - hole spaces moved by crank pin in N2 hole
circle

63
• Index 69 divisions by
compound indexing

40 n1 n2
= 
N N1 N 2

40 n1 n2
= 
69 N1 N 2

64
• 1. Resolve into factors • 69 = 23*3
the number of divisions
required
• 2. Choose at random • Index circles 23 and 33
hole circles
• Subtract hole number
of one circle from • 33-23 = 10
another

65
• Factor the difference • 10 = 2*5
• Place factors of division
required and factors of • 69 = 23*3
difference above • 10 = 2*5
horizontal line
• ______________

66
• Next factor the • ______________
numbers of turns of 40 = 2*2 *2*5
crank required for one 23 = 23*1
revolution of spindle
and also factors of hole 33 = 3*11
circles
• Place these factors
below line

67
• Cancel common 69 = 23*3
factors above and 10 = 2*5
below line ___________
• All factors above can be 40 = 2*2 *2*5
cancelled , hole circles
23 and 33 can be used 23 = 23*1
so N1 = 23 and N2 = 33 33 = 3*11

68
• If factors above line can
not be cancelled
completely then two
other circles should be
chosen for trail
calculation

69
• Factors which remain • 2*2*11 = 44
uncancelled below line
are multiplied to obtain • i.e. 44 is the number of
spaces in hole circle to holes spaces to be
be moved by two moved for indexing
indexing movements

70
 44 44 44 21 11 21 11
= − = 1 −1 = −
69 23 33 23 33 23 33

• Index crank should be moved by 21 holes in 23

hole circle in forward direction and then the
plate and crank together by 11 holes in 33 hle
circle in backward direction

71
 Differential indexing

• Required division is obtained by combination of

two movements
• 1. Movement of index similar to simple indexing
• 2. Simultaneous movement of index plate when
crank is turned

72
• Lock pin 11 is disengaged with
index plate which is screwed to
sleeve Mitre gear(15) is fastened
to other end of sleeve
• Index plate (12),sleeve and mitre
gear ( 15) are free to rotate on
worm shaft(10).
• Mitre gear meshes with another
mitre gear on shaft (16)
• Tail end of spindle 5 holds a stud
( 3)

73
• Change gear 2 may be
mounted between stud
3 and shaft 16
• Gear on spindle 5 is
driving gear and gear
on shaft 16 is driven
gear
• Change gear train2 may
be simple or compound

74
• As crank 13 is turned , rotating
spindle 5, the index plate is
slowly rotated in one direction or
other , depending upon gearing
2.
• Thus differential movement of
crank 13 relative to plate 12 is
obtained
• Total movement of crank is equal
to movement relative to plate
plus movement of plate

75
• Movement of index
plate 12 may be added
or subtracted according
to direction of rotation
of plate
• Change gears –
24,24,28.32.40.44.48,56,
64,72,86,100

76
 Rule for differential indexing
• Gear ratio, indexing
movement of crank and
number of idlers

= ( A − N ) 40
• Gear ratio

A
• A = selected number which
can be indexed by plain
indexing and number is
approximately equal to N
• N = required number of
divisions to be indexed

77
• In gear ratio so calculated, numerators of
fraction indicates driving gears on index head
spindle and denominator indicates driven
gears on index plate

78
• 3. Index crank movement = 40/A
Index crank will have to be moved by an amount
(40/A) for N number of complete division of
work
• 4.Index crank should move in same direction or
opposite to each other depending on type of
gearing ratio and selected number A chosen

79
If (A-N) is positive plate must rotate in same
direction as crank and if (A-N) is negative the
index plate must rotate in direction opposite
to that of a crank

80
• To achieve these conditions number of idlers
used depends upon :
a. If gear train is simple and ( A-N) is positive ,
only one idlergear is used
b. If gear train is compound and (A-N) is positive,
no idler gear is used
c. If gear train is simple and (A-N) is negative, two
idlers are used
d. If gear train is compound and (A-N) is negative ,
only one idler is used.
81
 Index 83 divisions

• First find out whether index crank can be

indexed by plain indexing or not
Index crank movement inplian indexing =
40/N = 40/83
since there is no plate with 83 number of
holes number can not be indexed by plain
indexing
82
• Assume A - let us take A = 86
( 86 is near to 83 and can be indexed by plain
indexing)

83
• Gear ratio
= ( A− NA)40
= ( 86 −83 ) 40
86

40
= 3
86

72 40
= 
24 86

84
2.Therefore, driver gears = 72,40
driven gears = 24,86
40 20
= =
3. Index crank movement 86 43

For complete indexing , index crank will be have to

be moved by 20 holes in 43 circle hole
4. As ( A- N) i.e. (86-83) = 3 , is positive and gearing
ratio is compound , no idler is required

85
Part B: Broaching

86
BASIC PRINCIPLES OF BROACHING
• Broaching is a machining process for removal of a layer of material of desired
width and depth usually in one stroke by a slender rod or bar type cutter
having a series of cutting edges with gradually increased protrusion as
indicated in Fig.a. In shaping, attaining full depth requires a number of strokes
to remove the material in thin layers step – by – step by gradually in-feeding
the single point tool (Fig.b).. Whereas, broaching enables remove the whole
material in one stroke only by the gradually rising teeth of the cutter called
broach. The amount of tooth rise between the successive teeth of the broach is
equivalent to the in feed given in shaping.
Basic principles of Broaching
Basic principles of Broaching

Finishing hole by broaching

Geometry of Broach tool

90
Geometry of where:
➢ P = pitch
Broach tool ➢ RPT = rise per tooth
➢ Ls = Shank length
➢ D = Depth of a tooth (0.4P)
➢ L = Land (behind the cutting
edge) (0.25P)
➢ R = Radius of the gullet
(0.25P)
➢ α = Hook angle or rake
angle
➢ γ = Back-off angle
or clearance angle

91
 Different Types Of Broaches And Their
Applications
• Broaching is getting more and more widely used,
wherever feasible, for high productivity as well as
product quality. Various types of broaches have been
developed and are used for wide range of
applications.
– Broaches can be broadly classified in several aspects such
as,
– Internal broaching or External broaching
– Pull type or Push type
– Ordinary cut or Progressive type
– Solid, Sectional or Modular type
– Profile sharpened or form relieved type
 Internal broaching and broaches
• Internal broaching tools are used to enlarge and finish various
contours in through holes preformed by casting, forging, rolling,
drilling, punching etc. Internal broaching tools are mostly pull type
but may be push type also for lighter work. Pull type internal
broaching tools are generally provided with a set of roughing teeth
followed by few semi-finishing teeth and then some finishing teeth
which may also include a few burnishing teeth at the end. The wide
range of internal broaching tools and their applications include;
– through holes of different form and dimensions as indicated in figure.
– non-circular holes and internal slots
– internal keyway and splines
– teeth of straight and helical fluted internal spur gears as indicated in
figure.
Internal broaching and broaches
 External broaching

• External surface broaching competes with milling, shaping and planing and,
wherever feasible, outperforms those processes in respect of productivity and
product quality. External broaching tools may be both pull and push type.
• Major applications of external broaching are :
– un-obstructed outside surfacing; flat, peripheral and contour surfaces
– grooves, slots, keyways etc. on through outer surfaces of objects
– external splines of different forms
– teeth of external spur gears or gear sectors as shown in Figure and Figure
 Pull type and push type broaches
➢During operation a pull type broach is subjected to
tensile force, which helps in maintaining alignment
and prevents buckling.
➢Pull type broaches are generally made as a long
single piece and are more widely used, for internal
broaching in particular. Push type broaches are
essentially shorter in length (to avoid buckling) and
may be made in segments. Push type broaches are
generally used for external broaching, preferably,
requiring light cuts and small depth of material
removal.
 Ordinary – cut and Progressive type
broach

• Most of the broaches fall under the category of

Ordinary – cut type where the teeth increase in
height or protrusion gradually from tooth to
tooth along the length of the broach. By such
broaches, work material is removed in thin
layers over the complete form. Whereas,
Progressive – cut type broaches have their teeth
increasing in width instead of height. Figure
shows the working principle and configuration
of such broach.
 Solid, Sectional and module type
broaches
• Broaches are mostly made in
single pieces specially those used
for pull type internal broaching.
But some broaches called
sectional broaches, are made by
assemblying several sections or
cutter-pieces in series for
convenience in manufacturing
and resharpening and also for
having little flexibility required by
production in batches having
interbatch slight job variation.
External broaches are often made
by combining a number of
modules or segments for ease of
manufacturing and handling.
Figure typically shows solid,
sectional and segmented
(module) type broaches.
 Types of Broaching Machine
• According to purpose of use
– general purpose
– single purpose
– special purpose
• According to nature of work
– internal broaching
– external (surface) broaching
• According to configuration
– horizontal
– vertical
• According to number of slides or stations
– single station type
– multiple station type
– indexing type
• According to tool / work motion
– intermittent (one job at a time) type
– continuous type
Part C: Planer and
Shaper machine

100
Planer

Working Principle

101
DIFFERENCE BETWEEN SHAPER AND PLANER

102
Types of planer

103
 Boring
Boring is a process of producing circular internal profiles on a
hole made by drilling or another process. It uses single point
cutting tool called a boring bar. In boring, the boring bar can
be rotated, or the workpart can be rotated. Machine tools
which rotate the boring bar against a stationary workpiece are
called boring machines (also boring mills). Boring can be
accomplished on a turning machine with a stationary boring
bar positioned in the tool post and rotating workpiece held in
the lathe chuck as illustrated in the figure.

104
Cutting conditions in boring

105
 Types of boring machine

Horizontal boring machine

Vertical boring machine

106