Module 4 Milling , Shaping & gear shaping.pdf
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About This Presentation
in this ppt you will learn about shaping machine & Milling Machines.
Slide Content
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.inJSSSTU
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Module-4
Shaping & Gear shaping Machines
Milling Machines
Course Instructor
Vijay Praveen P M
Assistant Professor
Department of I&P Engg.
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Module-4
Shaping & Gear shaping Machines
Milling Machines
Course Instructor
Vijay Praveen P M
Assistant Professor
Department of I&P Engg.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.inJSSSTU
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syllabus
ShapingandGearShapingMachines:Construction
features,andoperationsofShapingandGear
ShapingMachines,horizontalbroachingmachines
forcuttinggearteeth.
MillingMachines:Classification,constructional
features,millingcuttersnomenclatures,Milling
operations,upmillinganddownmillingconcepts
anditsapplications.
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syllabus
ShapingandGearShapingMachines:Construction
features,andoperationsofShapingandGear
ShapingMachines,horizontalbroachingmachines
forcuttinggearteeth.
MillingMachines:Classification,constructional
features,millingcuttersnomenclatures,Milling
operations,upmillinganddownmillingconcepts
anditsapplications.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.inJSSSTU
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Milling Machines
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Milling Machines
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Introduction
➢Amillingmachineisamachinetoolthatremovesmetalastheworkisfed
againstarotatingmultipointcutter.
➢Themillingcutterrotatesathighspeedanditremovesmetalatavery
fastratewiththehelpofmultiplecuttingedges
➢Inthemillingprocess,theworkpieceisnormallyfedintoarotatingcutting
toolknownasmillingcutter.
➢Equallyspacedperipheralteethonthecuttercomeincontactwiththe
workpieceintermittentlyandmachinetheworkpiece.Thisiscalled
intermittentcutting.
➢Millingmachinesareusedtoproducepartshavingflataswellascurved
shapes.
➢Intricateshapes,whichcannotbeproducedontheothermachinetools,
canbemadeonthemillingmachines
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Introduction
➢Amillingmachineisamachinetoolthatremovesmetalastheworkisfed
againstarotatingmultipointcutter.
➢Themillingcutterrotatesathighspeedanditremovesmetalatavery
fastratewiththehelpofmultiplecuttingedges
➢Inthemillingprocess,theworkpieceisnormallyfedintoarotatingcutting
toolknownasmillingcutter.
➢Equallyspacedperipheralteethonthecuttercomeincontactwiththe
workpieceintermittentlyandmachinetheworkpiece.Thisiscalled
intermittentcutting.
➢Millingmachinesareusedtoproducepartshavingflataswellascurved
shapes.
➢Intricateshapes,whichcannotbeproducedontheothermachinetools,
canbemadeonthemillingmachines
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.inJSSSTU
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DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.inJSSSTU
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Principle of milling
•Inmillingmachine,themetaliscutbymeansofa
rotatingcutterhavingmultiple
•cuttingedges.Forcuttingoperation,theworkpiece
isfedagainsttherotarycutter.Astheworkpiece
movesagainstthecuttingedgesofmillingcutter,
metalisremovedinformchips
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Principle of milling
•Inmillingmachine,themetaliscutbymeansofa
rotatingcutterhavingmultiple
•cuttingedges.Forcuttingoperation,theworkpiece
isfedagainsttherotarycutter.Astheworkpiece
movesagainstthecuttingedgesofmillingcutter,
metalisremovedinformchips
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DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.inJSSSTU
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MILLING METHODS
•There are two distinct methods of milling
classified as follows:
•1. Up-milling or conventional milling, and
•2. Down milling or climb milling.
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MILLING METHODS
•There are two distinct methods of milling
classified as follows:
•1. Up-milling or conventional milling, and
•2. Down milling or climb milling.
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Up-milling or conventional milling
➢In‘‘upmillingprocess’’,theworkpieceisfedoppositetothe
cutter’stangentialvelocity.
➢Eachtoothofthecutterstartsthecutwithzerodepthofcut,
whichgraduallyincreasesandreachesthemaximumvalueas
thetoothleavesthecut.
➢Thechipthicknessatthestartiszeroincreasestomaximumat
theendofthecut.
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Up-milling or conventional milling
➢In‘‘upmillingprocess’’,theworkpieceisfedoppositetothe
cutter’stangentialvelocity.
➢Eachtoothofthecutterstartsthecutwithzerodepthofcut,
whichgraduallyincreasesandreachesthemaximumvalueas
thetoothleavesthecut.
➢Thechipthicknessatthestartiszeroincreasestomaximumat
theendofthecut.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.inJSSSTU
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•Themajordisadvantagesofup-milling
processarethetendencyofcuttingforce
tolifttheworkfromthefixturesandpoor
surfacefinishobtained.Butbeingasafer
process,itiscommonlyusedmethodof
milling.
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•Themajordisadvantagesofup-milling
processarethetendencyofcuttingforce
tolifttheworkfromthefixturesandpoor
surfacefinishobtained.Butbeingasafer
process,itiscommonlyusedmethodof
milling.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.inJSSSTU
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Down-Milling or Climb Milling
➢Inthismethod,themetalisremovedbyacutter
rotatinginthesamedirectionoffeedofthe
workpiece.
➢Theeffectofthisisthattheteethcutdownward
insteadofupwards.
➢Chipthicknessismaximumatthestartofthecutand
minimumintheend.
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Down-Milling or Climb Milling
➢Inthismethod,themetalisremovedbyacutter
rotatinginthesamedirectionoffeedofthe
workpiece.
➢Theeffectofthisisthattheteethcutdownward
insteadofupwards.
➢Chipthicknessismaximumatthestartofthecutand
minimumintheend.
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➢Inthismethod,itisclaimedthatthereisless
frictioninvolvedandconsequentlylessheatis
generatedonthecontactsurfaceofthecutterand
workpiece
➢Climbmillingcanbeusedadvantageouslyonmany
kindsofworktoincreasethenumberofpieces
persharpeningandtoproduceabetterfinish.
➢Withclimbmilling,sawscutlongthinslotsmore
satisfactorilythanwithstandardmilling.
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➢Inthismethod,itisclaimedthatthereisless
frictioninvolvedandconsequentlylessheatis
generatedonthecontactsurfaceofthecutterand
workpiece
➢Climbmillingcanbeusedadvantageouslyonmany
kindsofworktoincreasethenumberofpieces
persharpeningandtoproduceabetterfinish.
➢Withclimbmilling,sawscutlongthinslotsmore
satisfactorilythanwithstandardmilling.
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DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.inJSSSTU
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Classification of Milling Machines
1. Column and knee type :
(i) Horizontal milling machine.
(ii) Vertical milling machine.
(iii) Universal milling machine.
2. Manufacturing or fixed bed type :
(i) Simplex milling machine.
(ii) Duplex milling machine.
(iii) Triplex milling machine.
3. Planer type :
4. Special type :
(i) Rotary table milling machine.
(ii) Drum milling machine.
(iii) Planetary milling machine.
(iv) Pantograph, profiling and tracer controlled milling
machine.
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Classification of Milling Machines
1. Column and knee type :
(i) Horizontal milling machine.
(ii) Vertical milling machine.
(iii) Universal milling machine.
2. Manufacturing or fixed bed type :
(i) Simplex milling machine.
(ii) Duplex milling machine.
(iii) Triplex milling machine.
3. Planer type :
4. Special type :
(i) Rotary table milling machine.
(ii) Drum milling machine.
(iii) Planetary milling machine.
(iv) Pantograph, profiling and tracer controlled milling
machine.
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DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.inJSSSTU
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Horizontal Milling Machine
•Base
•Column
•Knee
•Saddle
•Table
•Arbor
•Spindle
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Horizontal Milling Machine
•Base
•Column
•Knee
•Saddle
•Table
•Arbor
•Spindle
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.1.Base:
Itisaheavycastingonwhichcolumnandotherpartsare
mounted.
▪Itmaybeboltedtothefloorstrongly.
▪2.Column:
▪Thereareguidewaysonthefrontfaceofthecolumn,onwhich
thekneeslides.
▪Ithousespowertransmissionunitssuchasgears,beltdrives
andpulleystogiverotarymotiontothearbor.Thedrive
mechanismsarealsousedtogiveautomaticfeedtothe
handleandtable.
▪3.Knee:
▪Itsupportsthesaddle,table,workpieceandotherclamping
devices.
▪Itmovesonguidewaysofthecolumn.
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.1.Base:
Itisaheavycastingonwhichcolumnandotherpartsare
mounted.
▪Itmaybeboltedtothefloorstrongly.
▪2.Column:
▪Thereareguidewaysonthefrontfaceofthecolumn,onwhich
thekneeslides.
▪Ithousespowertransmissionunitssuchasgears,beltdrives
andpulleystogiverotarymotiontothearbor.Thedrive
mechanismsarealsousedtogiveautomaticfeedtothe
handleandtable.
▪3.Knee:
▪Itsupportsthesaddle,table,workpieceandotherclamping
devices.
▪Itmovesonguidewaysofthecolumn.
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▪4.Saddle:
▪Itismountedonthekneeandcanbemovedbyahandwheelorby
power.
▪Thedirectionoftravelofthesaddleisrestrictedtobetowardsor
awayfromthecolumnface.
▪5.Table:
▪Itismountedonthesaddleandcanbemovedbyahandwheelor
bypower.
▪Itstopsurfaceismachinedaccuratelytoholdtheworkpieceand
otherholdingdevices.
▪Itmovesperpendiculartothedirectionofsaddlemovement.
▪6.Arbor:
▪Itsoneendisattachedtothecolumnandtheotherendis
supportedbyanoverarm.
▪Itholdsanddrivesdifferenttypesofmillingcutters.
▪7.Spindle:
▪Itgetspowerfromgears,beltdrives,todrivethemotor.
▪Ithasprovisiontoaddorremovemillingcuttersontothearbor.
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▪4.Saddle:
▪Itismountedonthekneeandcanbemovedbyahandwheelorby
power.
▪Thedirectionoftravelofthesaddleisrestrictedtobetowardsor
awayfromthecolumnface.
▪5.Table:
▪Itismountedonthesaddleandcanbemovedbyahandwheelor
bypower.
▪Itstopsurfaceismachinedaccuratelytoholdtheworkpieceand
otherholdingdevices.
▪Itmovesperpendiculartothedirectionofsaddlemovement.
▪6.Arbor:
▪Itsoneendisattachedtothecolumnandtheotherendis
supportedbyanoverarm.
▪Itholdsanddrivesdifferenttypesofmillingcutters.
▪7.Spindle:
▪Itgetspowerfromgears,beltdrives,todrivethemotor.
▪Ithasprovisiontoaddorremovemillingcuttersontothearbor.
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Vertical Milling Machine
Inverticalmillingmachine,thepositionofthespindleheadis
verticalandtheaxisofthespindleisperpendiculartothework
tableasshowninfig.
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Vertical Milling Machine
Inverticalmillingmachine,thepositionofthespindleheadis
verticalandtheaxisofthespindleisperpendiculartothework
tableasshowninfig.
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Inthismachineboththe‘base’and‘column’areintegralcastings.
➢Thespindleheadcanbemovedupanddownovertheguideways.
Theverticalmillingmachinemayhavefixedhead,swivelinghead
orslidableswivelingheadspindle.
➢The‘saddle’ismountedona‘knee’whichcanbemouldupand
downovertheguidewaysprovidedonthecolumnface.The
saddlecanbemovedhorizontallyeitherbyhandorbypower
overthekneeguideways.
➢Theworktablemountedonthesaddlecanbemoved
longitudinallyovertheguidewaysprovidedonthetopofthe
saddle.
➢Inthismachine,theworkpiececanbemovedbothinthevertical
planeandonthehorizontalplane.
➢Themachineisusedtomachinegrooves,slotsandflatsurfaces
usingendmillandfacemillcutters.
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Inthismachineboththe‘base’and‘column’areintegralcastings.
➢Thespindleheadcanbemovedupanddownovertheguideways.
Theverticalmillingmachinemayhavefixedhead,swivelinghead
orslidableswivelingheadspindle.
➢The‘saddle’ismountedona‘knee’whichcanbemouldupand
downovertheguidewaysprovidedonthecolumnface.The
saddlecanbemovedhorizontallyeitherbyhandorbypower
overthekneeguideways.
➢Theworktablemountedonthesaddlecanbemoved
longitudinallyovertheguidewaysprovidedonthetopofthe
saddle.
➢Inthismachine,theworkpiececanbemovedbothinthevertical
planeandonthehorizontalplane.
➢Themachineisusedtomachinegrooves,slotsandflatsurfaces
usingendmillandfacemillcutters.
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DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.inJSSSTU
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Specifications of a Milling Machine
The following are the specifications of a
column and knee type milling machine :
1. Width and length of the table.
2. Maximum distance the knee can travel.
3. Maximum longitudinal movement and cross
feed of the table.
4. Number of spindle speeds.
5. Power of the main drive motor.
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Specifications of a Milling Machine
The following are the specifications of a
column and knee type milling machine :
1. Width and length of the table.
2. Maximum distance the knee can travel.
3. Maximum longitudinal movement and cross
feed of the table.
4. Number of spindle speeds.
5. Power of the main drive motor.
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TYPES OF MILLING CUTTERS
(1) Plain milling cutters,
(2) Side milling cutters,
(3) Face milling cutter,
(4) Angle milling cutters,
(5) End milling cutter,
(6) Fly cutter,
(7) T-slot milling cutter,
(8) Formed cutters,
(9) Metal slitting saw,
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TYPES OF MILLING CUTTERS
(1) Plain milling cutters,
(2) Side milling cutters,
(3) Face milling cutter,
(4) Angle milling cutters,
(5) End milling cutter,
(6) Fly cutter,
(7) T-slot milling cutter,
(8) Formed cutters,
(9) Metal slitting saw,
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Milling Operations
1. Plain or slab milling
2. Face milling
3. Angular milling
4. Form milling
5. Straddle milling
6. Gang milling
7. End milling
8. slot milling
9. Saw milling
10. Involute gear cutting.
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Milling Operations
1. Plain or slab milling
2. Face milling
3. Angular milling
4. Form milling
5. Straddle milling
6. Gang milling
7. End milling
8. slot milling
9. Saw milling
10. Involute gear cutting.
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.1.Plainorslabmilling.Plainmillingisusedto
machineflatandhorizontalsurfaces
Hereplainmillingcutterisused,whichisheldin
thearborandrotated.Thetableismoved
upwardstogivetherequireddepthofcut.
ItiscarriedonHorizontalMillingMachine
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.1.Plainorslabmilling.Plainmillingisusedto
machineflatandhorizontalsurfaces
Hereplainmillingcutterisused,whichisheldin
thearborandrotated.Thetableismoved
upwardstogivetherequireddepthofcut.
ItiscarriedonHorizontalMillingMachine
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2.Facemilling.Thismillingprocessisusedfor
machiningaflatsurfacewhichisatrightanglesto
theaxisoftherotatingcutter.
Thecutterusedinthisoperationisthefacemilling
cutter
ItiscarriedonverticalmillingMachine
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2.Facemilling.Thismillingprocessisusedfor
machiningaflatsurfacewhichisatrightanglesto
theaxisoftherotatingcutter.
Thecutterusedinthisoperationisthefacemilling
cutter
ItiscarriedonverticalmillingMachine
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4.Formmilling:Thismillingprocessisusedformachining
thosesurfaceswhichareofirregularshapes.
Theirregularshapemaybeconvex,concave,orofanyother
shape..
Theformmillingcutterusedhastheshapeofitscuttingteeth
conformingtotheprofileofthesurfacestobeproduced.
ItiscarriedonHorizontalMillingM/C
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4.Formmilling:Thismillingprocessisusedformachining
thosesurfaceswhichareofirregularshapes.
Theirregularshapemaybeconvex,concave,orofanyother
shape..
Theformmillingcutterusedhastheshapeofitscuttingteeth
conformingtotheprofileofthesurfacestobeproduced.
ItiscarriedonHorizontalMillingM/C
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5.Straddlemilling.Straddlingmillingisanoperationin
whichapairofsidemillingcuttersisusedformachining
twoparallelverticalsurfacesofaworkpiece
simultaneously.
Thedistancebetweenthecuttersisadjustedbythe
spacers.
Thisprocessisusedtomillsquareandhexagonal
surfaces.
IscarriedonHorizontalMillingMachine
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5.Straddlemilling.Straddlingmillingisanoperationin
whichapairofsidemillingcuttersisusedformachining
twoparallelverticalsurfacesofaworkpiece
simultaneously.
Thedistancebetweenthecuttersisadjustedbythe
spacers.
Thisprocessisusedtomillsquareandhexagonal
surfaces.
IscarriedonHorizontalMillingMachine
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➢6.Gangmilling.isthenamegiventoamillingoperationwhich
involvestheuseofacombinationofmorethantwocutters,
mountedonacommonarbor,formillinganumberofflat
horizontalandverticalsurfacesofaworkpiece
simultaneously.
➢Thismethodsavesmuchofmachiningtimeandiswidely
usedinrepetitivework.Thecuttingspeedofagangofcutters
iscalculatedfromthecutterofthelargestdiameter.
➢IscarriedonHorizontalMillingMachine
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➢6.Gangmilling.isthenamegiventoamillingoperationwhich
involvestheuseofacombinationofmorethantwocutters,
mountedonacommonarbor,formillinganumberofflat
horizontalandverticalsurfacesofaworkpiece
simultaneously.
➢Thismethodsavesmuchofmachiningtimeandiswidely
usedinrepetitivework.Thecuttingspeedofagangofcutters
iscalculatedfromthecutterofthelargestdiameter.
➢IscarriedonHorizontalMillingMachine
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7.Endmilling.Itisanoperationofproducingnarrow
slots,groovesandkeywaysusinganendmillcutter.
Themilltoolmaybeattachedtotheverticalspindle
formillingtheslot.Depthofcutisgivenbyraising
themachinetable.
IscarriedonVerticalMillingMachine
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7.Endmilling.Itisanoperationofproducingnarrow
slots,groovesandkeywaysusinganendmillcutter.
Themilltoolmaybeattachedtotheverticalspindle
formillingtheslot.Depthofcutisgivenbyraising
themachinetable.
IscarriedonVerticalMillingMachine
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.inJSSSTU
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DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.inJSSSTU
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9.Sawmilling.Itisanoperationofproducingnarrow
groovesandslotsontheworkpiece.
Aslittingsawcutterisusedforsawmilling
•Thesaw-millingalsoperformedforcomplete
parting-offoperation.
IscarriedonHorizontalMillingMachine
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9.Sawmilling.Itisanoperationofproducingnarrow
groovesandslotsontheworkpiece.
Aslittingsawcutterisusedforsawmilling
•Thesaw-millingalsoperformedforcomplete
parting-offoperation.
IscarriedonHorizontalMillingMachine
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10.Involutegearcutting.Gearmillingoperation,
oftenreferredasgearcutting,involvescuttingof
differenttypesofgearsonamillingmachine.
Forthis,eitheranendmillcutteroraform
relievedcutterisused
ItiscarriedonverticalorhorizontalmillingM/C
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10.Involutegearcutting.Gearmillingoperation,
oftenreferredasgearcutting,involvescuttingof
differenttypesofgearsonamillingmachine.
Forthis,eitheranendmillcutteroraform
relievedcutterisused
ItiscarriedonverticalorhorizontalmillingM/C
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.inJSSSTU
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DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.inJSSSTU
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Milling Cutter Nomenclature
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Milling Cutter Nomenclature
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.inJSSSTU
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•Body:Themainframeofthecutteronwhichtheteethrests
toformintegralpartiscalledasbodyofcutter.
•Outsidediameter;Itisthediameterofthecirclepassing
throughtheperipheralcuttingEDGE
•Face:Itisasurfaceofcuttingtoothagainstwhichthechipis
forcedinthemetalcuttingoperation
•Land:Itisthebackpartofthetoothadjacenttothecutting
edge
•Flute:Thefluteisthechipspacebetweenthebackofthe
toothandfaceofthefollowingtooth
•Cuttingedge:Itistheintersectionofthefaceofthetoolwith
theleadingedgeoftheland
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•Body:Themainframeofthecutteronwhichtheteethrests
toformintegralpartiscalledasbodyofcutter.
•Outsidediameter;Itisthediameterofthecirclepassing
throughtheperipheralcuttingEDGE
•Face:Itisasurfaceofcuttingtoothagainstwhichthechipis
forcedinthemetalcuttingoperation
•Land:Itisthebackpartofthetoothadjacenttothecutting
edge
•Flute:Thefluteisthechipspacebetweenthebackofthe
toothandfaceofthefollowingtooth
•Cuttingedge:Itistheintersectionofthefaceofthetoolwith
theleadingedgeoftheland
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING www. jssstuniv.inJSSSTU
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Important Questions
1.Writeanoteonupmilinganddownmillingwith
neatsketch
2.WhatisthedifferencebetweenUpmilling&Down
milling
3.WriteanoteonclassificationofmillingM/Cand
explainwithaneatsketchconstructionandfeatures
ofHorizontalMillingMachine
4.explainwithaneatsketchconstructionand
featuresofVerticalMillingMachine
5.discussthemillingoperations
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Important Questions
1.Writeanoteonupmilinganddownmillingwith
neatsketch
2.WhatisthedifferencebetweenUpmilling&Down
milling
3.WriteanoteonclassificationofmillingM/Cand
explainwithaneatsketchconstructionandfeatures
ofHorizontalMillingMachine
4.explainwithaneatsketchconstructionand
featuresofVerticalMillingMachine
5.discussthemillingoperations
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