THE INDEXING OR DIVIDING HEAD
UNIT 8: THE INDEXING OR DIVIDING HEAD
INTRODUCTION
Is used to divide the circumference of a workpiece into equally spaced divisions; eg.
gears, splines, hexagons, squares, etc.
Used to rotate a workpiece at a ratio to the table feed rate to produce helical grooves on
gears, drills, reamers, etc.
LEARNING OUTCOME
After completing the unit, students should be able to:
1. Identify the various parts of a universal indexing head
2. Explain the different types of indexing
3. Set-up the indexing head to machine table
4. Calculate the indexing procedure
5. Perform various types of workpiece profiles.
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8.1 construction Of Indexing Head
1. Housing 8. Cutter
2. Indexing Spindle 9. Sector Arm
3. Worm Gear with 40 teeth 10. Plunger Pin
4. Worm Shaft 11. Indexing Pin for Direct Indexing
5. Indexing Plate (changeable) 12. Indexing Plate for Direct Indexing
6. Crank 13. Carrier Block
7. Indexing Pin 14. Workpiece
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8.2 Method Of Indexing
8.2.1 Direct Indexing
• Simplest form of indexing. Used for quick indexing of a workpiece, eg.
Hexagon, square, etc.
• We use the ‘indexing plate for direct indexing which is mounted on the main
spindle which also carries the workpiece.
• The number of holes in the direct indexing plate limits the number of
divisions required by direct indexing. Holes circle in direct indexing plate
available are 24, 30 and 36 holes or slots.
• To perform this method, the worm shaft must be disengaged from the worm
gear wheel.
Which divisions can be machined with the direct indexing plate?
Since most direct indexing plate has 24 holes, all divisions of which 24 is a
divisible (24, 12, 8, 6, 4, 3, 2) can be produced with this plate.
Formula:
Indexing data = N N = No. of holes in Index Plate
T = No. of required divisions
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Eg : What direct indexing is necessary to mill 8 slots of a workpiece?
Then, Indexing data = N
= 24
= 3 (means, 3 holes on a 24 hole circle)
Whenever you start to machine the first hole, make sure that the indexing pin is
in the hole or slot No. : 0 = 24 of the indexing plate.
When you have done the necessary indexing moment, clamp the indexing
spindle so that the cutting force will not go onto the indexing plate and indexing
pin.
8.2.2 Indirect Indexing
• Used when the index number does not permit direct indexing.
• The worm shaft, attached to the crank, must be engaged with the worm
wheel on the indexing spindle.
• The index crank rotates the indexing spindle, over a worm gear set with a
single threadworm shaft and the worm gear wheel with 40 teeth.
• There are 40 teeth on the worm gear wheel. One complete turn of the index
crank will cause the spindle and the work to rotate 1/40 of a turn.
• Similarly, 40 turns of the crank will rotate the workpiece one complete turn.
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To calculate the indexing data or the number of turns of the crank for most
divisions, it is necessary only to divide 40 by number of divisions to be cut.
Formula:
Indexing data = 40/N (number of required divisions)
(crank revolution)
Index plates which are available:
Plate 1 16, 30, 33, 36, 39, 51, 57, 63
Plate 2 22, 24, 27, 29, 37, 43, 49, 59
Plate 3 23, 25, 28, 31, 41, 47, 53, 61
Eg. Calculate indexing required cutting 8 slots of the workpiece:
Indexing data = 40/N
= 40/8
= 5 (means, 5 complete turns of the index crank).
Indirect Indexing with Fraction
If, however, it is necessary to mill 7 slots, then the indexing data would be:
Indexing data = 40N
= 40/7
= 5 5/7 turns of the index crank
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Five complete turns of the crank are easily made, however, the 5/7 of a turn
involves the use of the index plate and sector arms. To get 5/7 of a turn, choose
any hole circle which is divisible by the denominator 7, such as 28.
Then, take 5/7 of 28 = 20 (means, 20 holes on a 28 hole circle plate).
Therefore, the indexing data for 7 slots would be 40/7 = 5 5/7 turns or 5
completed turns plus 20 holes on 28 holes circle plate.
To eliminate the need for counting the required number of holes each time, the
sector arms are set so that the angle between them includes 20 holes.
8.2.3 Angular Indexing
When the angular distance between divisions is given, instead of the number of
divisions, the set up for indirect indexing may be used. However, the method of
calculating the indexing data is changed.
One complete turn of the index crank turns the work 1/40 of a turn, or 1.40 of
360°, which equals to 9°.
When the angular dimension is given in degrees, the indexing data is then
calculated as follows:
Indexing data in degrees = No. of degrees required/9
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Example:
Calculate the indexing data for (a) 45° and (b) 60°:
(a) Indexing data for 45° = 45/9
= 5 complete turns.
(b) Indexing data for 60° = 60/9
= 6 2/3 (means, 6 complete turns,
Plus 22 holes on a 33 hole circle).
8.3 Spur Gear Cutting (Rack And Pinion)
A gear consists of a multiple form toothed wheel which is used to transmit rotary
motion or force from one shaft to another, at a completely uniform rate (positive
drive or no slippage). A gear is also used to change the direction and speed of
rotation.
Gears are applied on nearly all types of machine tools, automobiles and heavy
manufacturing machinery. Gears may be used to transmit motion between shafts
which are parallel or intersecting. A gear connected to the source of power is
called driver, and the one to which motion is transmitted is called the driven.
8.3.1 Types of Gears
Various types of gears are used in the design of machines. Those which are
most common are the:
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a) spur gears
b) helical gears
c) herringbone gears
d) bevel gears
e) worm gears
f) rack and pinion
8.3.2 The construction of a gear
Gears generally have involutes teeth. This means that the shape of the tooth is
generated with an involutes curve. Such curve may be drawn with a pencil
inserted in the loop of a string wound around a cylinder. This form of tooth has
been found to give excellent results in terms of quietness and smoothness of
operation.
The size of a gear is given in terms of its diameter at the pitch circle, which is
called the pitch diameter.
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Metric gears are always made according to the module (m) system. The module
represents the amount of pitch diameter per gear tooth. Therefore, the higher the
module number, the larger the sizes of the gear tooth.
8.3.3 Definitions of a Gear
1. Addendum is the radial distance between the pitch circle and the outside
diameter
2. Circular pitch is the distance from a point on one tooth to a corresponding
point on the next tooth measured on the pitch circle.
3. Clearance is the radial distance between the top of one tooth and the
bottom of the mating tooth space.
4. Dedendum is the radial distance from the pitch circle to the bottom of the
tooth space. The dedendum is equal to the dedendum plus the clearance.
5. Module (metric gears) is the pitch diameter of a gear divided by the
number of teeth.
6. The hole depth of the tooth is the sum of the addendum and the
dedendum
7. Outside diameter is the overall diameter of the gear which is the pitch
circle plus two addendums.
8. Pitch circle is a circle which has the radius of half the pitch diameter with
its center at the axis of the gear.
9. Pitch diameter is the diameter of the pitch circle which is equal to the
outside diameter minus two addendums.
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10. Pressure angle is the angle formed by a line through the point of contact
of two mating teeth and tangent to the two base circles and a line at right
angles to the center line of the gears.
8.3.4 Rules and Formulas for Spur Gears
Example of gear calculations
Given a2-module gear with a pitch diameter of 60 mm, find the:-
(a) Number of teeth (b) Outside diameter (c) Whole depth
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Solution
PD 60
a) Z= = = 30teeth
M 2
b) OD = M (Z + 2) = 2 (32) = 64mm
13
c) H= × 2 = 4.33mm
6
8.3.5 Selection of module gear cutter
Gear cutters are an example of formed cutters. Gear cutters are available in
many module sizes, ranging from 0.5 to 10. Any metric module size is available
in a set of eight cutters, numbered form # 1 + # 8 The table below shows the
cutters available and the range of teeth on the workpiece which should be cut
with the respective cutter. A spur gear has a PO of 60 mm and 20 teeth.
Calculate:
Metric Module Cutter
Milling Cutter Number
Cutter No. For Cutting
1 12-13 teeth
2 14-16 teeth
3 17-20 teeth
4 21-25 teeth
5 26-34 teeth
6 35-54 teeth
7 55-134 teeth
8 135 teeth to rack
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Example
A spur gear has a PD of 60 mm and 20 teeth. Calculate
(a) Module (b) Outside diameter (c) Cutter number
Solution
PD
(a) M = (b) OD = (Z+2) m (c) Cutter no. = 3
2
60
= = 22 x 3 (Refer to table)
20
= 3 mm = 66 mm
8.3.6 Manufacturing of Gears
Gears normally are mass-produced on special machines which have been
designed for this purpose. The most common types of gear generating machines
are the gear-shaping machines and gear-hobbing machines.
However, gears can also be cut on a milling machine with a module gear cutter.
In this method, the gear blank is mounted on a mandrel or arbor and is clamped
between centers on the universal dividing head and tailstock.
8.3.7 Differential Indexing
When it is impossible to calculate the required indexing by the indirect indexing
method, that is when the fraction 40/N cannot be reduced to a factor of one of the
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available hole circles, it is necessary to use differential indexing. With this method
of indexing, the index plate is unlocked leaving it free to turn either forward or
backward, as part of a turn to attain the proper spacing or indexing.
A gear train is set-up to joint the outer end of the spindle to the worm shaft. When
the index crank is turned to move the spindle, the gear train will cause the index
plate to turn at the same time. The rotation of the plate may be either in the same
direction (positive) or in the opposite direction (negative) of the index crank. This
change of rotation is caused by an idler gear or gears in the gear train.
When it is necessary to calculate the indexing data for a required number of
divisions by the differential method, a number is chosen close to the required
divisions which can be indexed by indirect indexing.
To illustrate the principle of differential indexing, assume that the index crank has
to be rotated 1/9 of a turn and that there is only an 8 hole circle available.
If the crank is moved 1/9 of a turn, the index pin will contact the plate at a spot
before the first hole on the 8 circle. The exact position of this spot would be the
difference between 1/8 and 1/9 of a revolution of the crank. This would be:
1 1 9−8 1 1 1
− = = of a turn less than of a turn, or of a turn
8 9 72 72 8 72
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short of the first hole. Since there is no hole at this point into which the pin could
engage, it is necessary to cause the plate to rotate backwards by means of
change gears 1/72 of a turn so that the pin will engage in a hole. At this point the
index crank will be locked at exactly 1/9 of a turn. The method of calculating the
change gears required to rotate the plate the proper amount is as follows:
Change gear ratio = (A – N) x 40/A
DRIVER(WorkSpindleGear )
=
DRIVER (WorkShaftGear )
A = approximate number of divisions (selected number)
N = required number of divisions
When the approximate number of divisions is larger than the required number,
the resulting fraction is plus and the index plate must move in the same direction
as the crank (clockwise). However, if the approximate number is smaller than the
required number, the resulting fraction is minus and the index plate must move in
a counter clockwise direction. The numerator of the fraction represents the
driving (work spindle) gear or gears, while the denominator represents the driven
(worm shaft) gear or gears.
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EXERCISES
Question Sheet
1. Calculate the indexing required drilling 4 holes equally spaced on the circumference
of a workpiece. (A 24 - hole circle plate is provided).
2. A hexagon shaped workpiece have to be milled on a milling machine. Calculate the
number of holes required. (A 24 - hole circle plate is provided).
3. Calculate the indexing required milling a 9 groove on a reamer using the indirect
indexing method.
4. Calculate the indexing required to mill 23 slots evenly on the circumference of a
workpiece.
5. Calculate the indexing required for 107°.
6. Calculate the indexing required for 42° 36’.
7. List three types of gears commonly used.
8. What is the advantage of helical gear teeth over spur gear teeth?
9. State the formula used to determine:
a. Module
b. Outside diameter
c. No. of teeth
10. A spur gear has 72 teeth and needs to be cut by using module cutter of 2 mm.
Calculate:
a. Outside diameter
b. Pitch diameter
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c. Cutter number
11. What type of gearing system is used to reduce the speed from one shaft to
another?
12. For what purpose is differential indexing used?
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13. What is meant by positive rotation of index plate in the differential indexing?
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14. Calculate the differential indexing to cut 71 teeth. (Refer to the table to select
index plate and gear change available).
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Answer Sheet
1. Direct Indexing = N
= 24
= 6 (means, 6 holes on 24 holes circle plate)
2. Direct Indexing = N
= 24
= 4 (means, 4 holes on 24 holes circle plate)
3. Indirect Indexing = 40
= 40
= 4 4/9 (x 4/4)
= 4 16/36
Means, 4 complete turns plus 16 holes in a 36 holes circle plate.
4. Indirect Indexing = 40
= 40
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23
= 1 17/23
Means, one complete turn plus 17 holes on a 23 holes circle plate.
5. Angular Indexing = N
= 107
= 11 8/9 (x 4/4)
= 11 32/36
Means, 11 complete turns, plus 32 holes on a 36 holes circle plate.
6. Angular Indexing = N
9 (42° 36’) = 42 x 60)’
= 2556’ = 2520 + 36’
9 x 60
= 4 11/15 (x 2/2)
= 4 22/30
Means, 4 complete turns plus 22 holes on a 30 holes circle plate.
7. (a) Spur Gear
(b) Helical Gear
(c) Bevel Gear
8. Provide greater strength and smoother operation at high speed.
PitchDiameter
9. (a) Module =
[Link]
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(b) Outside diameter = Module (no. of teeth + 2)
PitchDiameter
(c) No. of teeth =
Module
10. (a) Outside diameter = M (Z+2)
= 2 (74)
= 148 mm
(b) Pitch diameter = M.Z
= 2 x 72
= 144 mm
(c) Cutter number =7
11. Worm and Worm Gear.
1.2 Differential indexing is used when it is impossible to calculate the required
indexing by indirect indexing method, that is, when the fraction 40/N cannot be reduced
to a factor of one of the available hole circles.
1.3 Positive rotation means the index plate must rotate in the same direction
as the crank (clockwise).
1.4 (i) Select A to be 72.
40
Indexing =
N
40
=
72
5 (7 )
=
9 (7 )
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35
=
63
40
(ii) Gear ratio = (A – N)
A
40
= (72 – 71)
72
5 (8)
=
7 (8)
40 ( Driver
=
72 Driver
Means : 35 holes on the 63 circle hole
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