Lecture 4

Milling, Broaching and

Gear Manufacturing

Alokesh Pramanik
Office: 204.530
Phone: 92667981
Email: alokesh.pramanik@curtin.edu.au
Competitive Manufacturing Processes (MCEN 3003), S1
 Milling

Reference
Sandvik Technical information, https://www.sandvik.coromant.com/en-gb/pages/default.aspx
 Milling Process

Milling Parameters
Spindle speed (n) in rpm is the number of revolutions
the milling tool on the spindle makes per minute.
Cutting speed (vc) in m/min (ft/min) indicates the surface
speed at which the cutting edge machines the
workpiece.
Specified cutter diameter (DCX), having an effective
cutting depth to diameter (DC), which is the basis for the
cutting speed vc or ve.

n = Spindle speed, rpm (revolutions per minute)

vc = Cutting speed m/min (ft/min)
ve= Effective cutting speed m/min (ft/min)
DC = Cutter diameter mm (inch)
DCX = Maximum cutting diameter mm (inch)
 Milling Process

Milling Parameters
Feed per tooth, fz mm/tooth (inch/tooth), is a value in
milling for calculating the table feed. The feed per tooth
value is calculated from the recommended maximum
chip thickness value.
The number of available cutter teeth in the tool (zn)
varies considerably and is used to determine the table
feed while the effective number of teeth (zc) is the
number of effective teeth in cut.
Feed per minute, vf mm/min (inch/min), also known as
the table feed, machine feed or feed speed is the feed of
the tool in relation to the workpiece in distance per time-
unit related to feed per tooth and number of teeth in the
cutter.

vf = fz × zc × n mm/min (inch/min)
 Milling Process

Milling Parameters
Feed per revolution (fn) in mm/rev (inch/rev) is a value used
specifically for feed calculations and often to determine the
finishing capability of a cutter.

fn = fz x zc mm/rev (inch/rev)

fz = Feed per tooth mm/tooth (inch/tooth)

vf = Table feed mm/min (inch/min)
zn = Number of cutter teeth (pcs)
zc = Effective number of teeth (pcs) [in engagement]
fn = Feed per revolution mm/rev (inch/rev) [fz x zc]
n = Spindle speed (rpm)
 Milling Process

Milling Parameters
Axial depth of cut, ap mm (inch), is what the tool
removes in metal on the face of the workpiece. This
is the distance the tool is set below the unmachined
surface.
Radial cutting width, ae mm (inch), is the width of
the component engaged in cut by the diameter of
the cutter. It is the distance across the surface being
machined or, if the tool diameter is smaller, that is
covered by the tool.
 Milling Process

Milling Parameters
The net power (P ) is the power the machine must be able to
provide to the cutting edges in order to drive the cutting action. The
efficiency of the machine must be taken into consideration when
selecting cutting data.
The torque (Mc) is the torque value produced by the tool during
cutting action, which the machine must be able to provide.
The specific cutting force value (kc) is a material constant,
expressed in N/mm2 (lbs/inch2).
 Milling Process

Types of milling

In climb milling, In conventional milling

the insert starts its
cut with a large
chip thickness.
(also referred to as up
milling) the chip thick-
ness starts at zero and
increases to the end of
the cut.

The feed direction of the

workpiece is opposite to that of
Using climb milling (also referred to as down
the cutter rotation at the area of
milling), the burnishing effect is avoided,
cut.
resulting in less heat and minimal work-
hardening tendency.
Milling Process
 Milling Process
Types of milling
Milling is machining operation
for a variety of configurations
with the use of a milling
cutter.
 Milling Process
Types of milling
 Milling Process
Horizontal-milling or slab milling:
Milling Process
Milling Process

Major flank
Milling Process
Milling Process
Milling Process
 Milling Process
Example 3
 Broaching
Reference
Arrazola, P. J., Rech, J., M'Saoubi, R., & Axinte, D. (2020). Broaching: Cutting tools and machine tools
for manufacturing high quality features in components. CIRP Annals, 69(2), 554-577.
https://www.sciencedirect.com/science/article/pii/S0007850620301438
 Broach

Fixture systems Machine tools

Reference
Arrazola, P. J., Rech, J., M'Saoubi, R., & Axinte, D. (2020). Broaching: Cutting tools and machine tools for
manufacturing high quality features in
components. CIRP Annals, 69(2), 554-577.
https://www.sciencedirect.com/science/article/pii/S0007850620301438
 Gear Manufacturing

Reference
Gupta, Kapil, Neelesh Kumar Jain, and Rolf Laubscher. "Advanced gear manufacturing and finishing: classical
and modern processes." (2017).
https://ebookcentral.proquest.com/lib/curtin/reader.action?docID=4915539&ppg=9

Khodaee, Alireza. Gear rolling for production of high gears. Diss. KTH Royal Institute of Technology, 2015.
https://www.diva-portal.org/smash/get/diva2:853448/FULLTEXT01.pdf

Khodaee, Alireza, Arne Melander, and Sven Haglund. "The effects of blank geometry on gear rolling for large
gear modules: experiments and finite element simulations." IEEE Access 6 (2018): 33344-33352.
https://ieeexplore.ieee.org/stamp/stamp.jsp?arnumber=8392678
 Gear
Extrusion and cold drawing: form the required teeth geometry on cylindrical rods referred to as
pinion rods.