13.
MILLING MACHINES
The milling machine is used to machine plane surfaces, keyways, slots,
dovetails, angles and various other shapes.
It has a T-slotted table which carries the machine vice to grip the work – the
work may also be clamped straight onto the table.
Operation differs from the lathe in that the
cutting tool rotates in one position and the work-
piece is moved to provide the feed.
13.1 VERTICAL MILLING MACHINE:
In this machine the spindle carrying the cutters is
vertical (forms right angle with face of table)
In some cases attachments can be fitted to
convert machine for horizontal milling.
The head can also be tilted at various angles.
13.2 HORIZONTAL MILLING
MACHINE:
In this machine the ‘spindle” carrying
the cutting tools is mounted
horizontally – the arbour.
The arbour carries the milling cutters
and has a series of collars – it also has
a keyway throughout its length.
It is held & driven by its tapered shank
or by the machine spindle.
13.3 VERTICAL-HORIZONTAL
MILLING MACHINE:
This machine can converted from a vertical
milling machine to a horizontal milling
machine.
The vertical head is removed, and the top
section is moved forward on its dovetail slide.
An arbour steady is fitted to the front of the
top section which can support the front of the
arbour.
An arbour is inserted between the drive spindle
nose and the arbour steady.
13.4 MILLING CUTTERS
Side and face cutters – used for milling slots, grooves and straddle milling.
Slitting Cutters:- made in varying diameters and thickness. Used for parting
off, grooves, slots, keyways etc.
T-Slot Cutters & Slot Drills:- used in the vertical head to cut slots
P a g e | 80
Slab/Plain Milling Cutter:- made with straight or helical teeth. Teeth are
‘nicked” to prevent chips, improve cutting action & reduce chatter & power
consumption.
13.5. Down-cut vs Up-cut milling:
VS
Advantages of up-cut milling:
The cut can start from underneath the hardened outer skin of the casting or
forging
There is less vibration
A coarse feed is possible
Advantages of down-cut milling:
Cutting is more efficient – larger chips are removed
There is a tendency for less chatter
Better surface finish
P a g e | 81
13.6 DIVIDING HEAD
It is an attachment to the milling machine which makes it possible to machine
components with an accurate number of
grooves, holes, splines, teeth and flats
along its circumference.
By using the dividing head, you can
divide the circumference of a circular
object into any number of divisions.
The dividing head is in actual fact a worm
and worm wheel reduction unit with a
reduction ratio of 40:1.
If you turn the worm one revolution, the
output shaft will make 1/40 of a turn.
In order for the output to turn one full
revolution, you will need to turn the input or worm 40 revolutions.
INDEXING CRANK HANDLE
You turn the indexing crank handle to turn the single – start worm (input
movements)
The worm then engages the wormwheel to turn the spindle or work piece
(output).
INDEX PLATE
The index plate makes provision for dividing a fraction of a turn accurately by
means of holes spaced evenly on a pitch circle.
There are several pitch circles on a index plate, which facilitates the calculation
of a fraction of a turn by an easily divisible pitch - hole circles.
The common index plates used are:
Plate 1: 15, 16, 17, 18, 19, 20 holes
Plate 2: 21, 23, 27, 29, 31, 33 holes
Plate 3: 37, 39, 41, 43, 47, 49 holes
INDEX PLUNGER AND PIN
The index plunger and
pin are connected to the
crank handle.
The plunger or pin
locates into one of the
pitch holes on the index
plate to indicate the end
position ready for
machining station.
SECTOR ARMS
These consists of two
radial arms that illustrate
the division of a fraction
of one turn.
P a g e | 82
They are usually locked into position by a lock screw.
They cling to the index plate by means of a spring horseshoe plate that provides
a friction lock.
INDEXING METHODS
The four methods of indexing with the use of dividing head are:
Rapid indexing
Simple indexing
Angular indexing
Differential indexing
RAPID INDEXING
When you want to perform rapid indexing, you must ensure that the special
rapid index plate with the required number of slots is fitted behind the drive
plate.
Rapid index plates usually have, 36, 24 or 12 slots on their circumferences.
STEPS:
Disengage the worm from the wormwheel. The lever for doing so is usually clearly
visible on the opposite side of the dividing head
Mark the slots to be used for indexing with chalk. If you are using the 24-slot rapid
index plate and 6 grooves have to be machined, you would mark hole numbers
0,4,8,12,16,20. The starting point would again be 0.
Place the plunger in the marked slot and cut the first division.
Remove the plunger from the slot, turn the spindle by hand and engage the
plunger in the next marked slot. Cut the next division.
Repeat until all the divisions have been machined.
13.6 SIMPLE INDEXING
Number of turns on index crank =
EXAMPLE 1
Calculate the number of turns on the crank handle and the index plate setting
required to give 13 equally spaced divisions, by using the Cincinnati index plate:
24,25,28,30,37,38,39,41,42,43.
Solution
Simple index setting = 40/N where N = number of divisions req’d
= 40/13
= 3 & 1/13 turns
You therefore have 3 whole turns of the crank handle and 1/13 of a turn.
Note: you do not have a 13 hole circle to divide a full turn into 1/13 of a
turn, but you do have a 39 hole circle which is divisible by 13.
Therefore 1/13 of a turn is equal to 3 holes in a 39-hole circle.
Answer: 3 full turns and 3 holes in a 39-hole circle
EXERCISES:
Find indexing required to obtain the following number of divisions:
(a) 22 (b) 34 (c) 9
P a g e | 83
Available index plates are:
Plate 1 15, 16, 17, 18, 19, 20 holes
Plate 2 21, 23, 27, 29, 31, 33 holes
Plate 3 37, 39, 41, 43, 47, 49 holes
