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Cutting Speed:
The cutting speed of a milling cutter is the distance travelled per minute by the
cutting edge of the cutter
It is measured in at the circumference of the cutter and expressed in m/min, feet/min
, depending upon the units that adapted
Considered
D: the diameter of the cutter
N: revolution per minutes
The distance travelled by its cutting edge in each revolution is equal to the
circumference of cutter = D
DN
1000
mt
min
min
Example 1
A milling cutter, 100mm dia, runs at 210 rpm. Calculate the
cutting speed
Ans:
Cuuting speed
DN
1000
22 100 210
66 m / min
7 1000
Cuuting speed
DN
12
22 4 70
73.33 ft / min
7 12
Feed: The feed in milling machine is defined as the rate at which the
workpiece advances under the cutter.
The feed is expressed in milling machine by the following three
methods.
1. Feed per minute(Sm) :is defined by the distance the work advances in
one minute.
mm/min
2.Feed per cutter revolution(Srev): the feed per revolution is the distance
of the work advances in the time when the cutter turns through one
complete revolution
mm/revolution of the cutter
3. Feed per tooth(Sz):is defined as the distance the work advances in the time between
engagement by the two successive teeth.
mm/teeth of cutter.
Sm=N*Srev=Sz*Z*N
Where
Z- Number of teeth in cutter
N-Cutter speed in rpm
Machining time
Time required to mill a surface by any operation can be calculated by the formula
T=L/Sz*Z*N
Where
T- Time required to complete the cut in minutes
L-The length of the total travel to complete the cut in mm.
Sz=- is the feed per tooth.
Z-Number of teeth on the cutter.
N rpm of the cutter.
Approach length for plain milling cutter A=Square root of (B(D-B))
Approach length for face milling cutter A=1/2(Dsquare root of(D2-B2))
Where
A is approach length in mm
B depth of cut in mm
D Dia of the cutter.
The index plate has several circles with different number of holes in each circle.
Detail of a typical index plate are given below:
Index plate No 1:
On one side,
49, 39, 29, 19 and 16 hole circle
On the other side, 47, 37, 27, 17 and 15 hole circle
Index pin is spring loaded and after every indexing it is set in the every required hole of the
appropriate circle
The index pin may move in the slot of index crank to fit over a required hole circle
Two arm of the adjustable sector may be opened and locked to accommodate a required number
of holes between them
Worm and worm wheel assembly are properly accommodated inside the housing
The dividing head is mounted on milling machine table such that the job to be indexed comes
directly under the cutter
The index plate is also mounted on the same spindle as the crank, but on a sleeve
such that the worm spindle and the crank move independent on index plate
The sector arms provided on the index plate are usually of detachable type and
can be set at a desired angle with one another in order to set a definite distance
along the desired hole circle
The index plates are available in a set of two or three with a number of hole
circle usually on both sides on them
The spindle carrying the worm wheel is provided with a job carrier and a center
at its front end
On the back side of dividing head is provided a bracket which carries a slot along
its length
One or two studs, according to the requirement, can be fitted in this slot and
predetermined set of change gear can be mounted on them
Methods of Indexing
In the first case, rotate indexing crank by one complete turn and 5 holes in 15 holes
circle. In the second case, one turn and 7 holes in 21 hole circle.
Ans:
Required movement = 40/35 = 8/7 = 1(1/7)
1/7 = 1/7 * 3/3 = 3/21
1 full turn and 3 holes on 21 holes circle
Compound indexing
Compound indexing is employed to obtain such
number of divisions that are beyond the range of
plain indexing system.
The desired spindle movement is obtained by:
First turn the index crank through a required number
of spaces in one of the hole circle of the index plate
(held stationary) in one direction as the plain
indexing, and
Then turn index plate together with the index crank in
the same direction or in the opposite direction
through the calculated number of spaces of another
hole circle.
Differential indexing
Differential indexing is introduced by Brown and Sharpe.
Differential indexing greatly resembles compound indexing. This
process is also carried out in two stages.
In the first operation, a crank is moved in a certain direction.
In the second phase, movement is added or subtracted by moving the
spindle by means of a gear train.
Example
Find the gear combination and indexing movement necessary
for 139 divisions
Sol:
Let us select a number slightly greater or smaller than the given
number such that the selected number can be easily indexed
through simple indexing
Simple indexing for 140 divisions = 40/140 = 2/7 = 6/21
6 holes on 21 circle plate
Now, if the index crank is turned 6/21 of a revolution of 139
times, it will make = 6/21 * 139 = 39(15/21)
For one complete turn of the job, it should make 40 complete
revolutions
Obviously, the job would not be, thus the indexed through exactly
139 divisions
The total movement done by crank is short of required 40 turns
by
40 39(15/21) = 6/21 of a revolution
This fraction is gained by the movement of the plate
In order to gain the movement, the plate will have to be turned
in the same direction as the crank
Also in order than the divisions are equal, this movement is to be
gained gradually such that a certain amount of it is added
equally to the crank movement in all 139 movements of the
latter so that it complete 40 turns at the end of these movement
This will be done employing a suitable gear train:
6 2 3 32 24 drivers
21 3 7 48 56 drivens
First driver 32 teeth, 1st followers 48 teeth
2nd driver 24 teeth, 2nd follower 56 teeth
Since it is a compound train and the motion is to be gained, no
idler is used.
Example 2
Differential indexing for 241 divisions
Sol:
We select 240 divisions
Simple indexing = 40/240 = 1/6 = 3/18
3 holes on 18 hole circle
Movement of the crank for 241 divisions = 241*3/18 = 40(1/6)
1/6 turns more than the required 40 turns
There is to be lost through plate movement
Gear ratio = 1/6 = (1*1)/(2*3) = (32*24)/(64*72)
Results:
First driver 32 teeth; first follower 64 teeth
2nd driver 24 teeth, 2nd follower 72 teeth
Compound train with one idler
Crank movement: 3 holes on 18 holes circle
Example 3
Differential Indexing for 73 divisions
Sol:
We select 70 divisions
Simple indexing = 40/70 = 4/7 = 12/21
12 holes on 21 holes circle
Movement of crank for 73 divisions
73*(4/7) = 41(5/7)
1(5/7) turns of crank are to be lost through the plate movement
Angular indexing
The indexing methods that
are discussed so far are used
for machining operations
that require certain number
of divisions of a circle.
Angular indexing is used for
angular
machining
operations.
Holes drilled at 75
degrees to each other