COMPETENCY BASED LEARNING

MATERIALS

SECTOR: METALS AND ENGINEERING

QUALIFICATION
TITLE: MACHINING NC II
UNIT OF
COMPETENCY: Mill Workpiece
MODULE TITLE:
Milling Workpiece

Phil-Nippon Technical College

Brgy. Punta Calamba City, Laguna 4027

Date Developed: Document No.

CBLM on Machining Issued by:
NCII Date Revised:

Developed by: Page i of vii

Mill Workpiece Darius N.
Hernandez Revision #
Competency-Based Learning Materials
Milling Workpiece

Date Developed: Document No.

CBLM on Machining Issued by:
NCII Date Revised:

Developed by: Page ii of vii

Mill Workpiece Darius N.
Hernandez Revision #
 HOW TO USE THIS COMPETENCY-BASED LEARNING MATERIAL

Welcome!

The unit of competency, “Mill Workpiece”, is one of the competencies

of MACHINING NC II, a course which compromises the knowledge, skills and
attitudes required to be a Machinist base on the competency standard.

The module “Milling Workpiece” contains the learning content from

the learning outcome “Set up Workpiece”. Each learning contents are
provided with information sheets. After reading the information sheet you
are going to answer the self-check assessment in order to measure your
knowledge and understanding of the previous learning content. Validate
your performance by comparing your answer to the answer key provided.
Do these activities on your own. On the last part of this module you are
going to perform the job sheet as per requirement before the completion of
the training. Perform the job sheet until you are confident that your
outputs conform to the performance criteria checklist.

Upon the completion of the training in this module, there will be a

competency evaluation in which you are required to pass. The assessment
could be made in different methods, as prescribed in the competency
standards. After you passed the assessment, you will be given a certificate
as proof that you met the standard requirements (knowledge, skills and
attitude) to be a certified Machinist.

If you have questions during your training, don’t hesitate to ask your
instructors for assistance. Your instructor will always be available to assist
you.

Date Developed: Document No.

CBLM on Machining Issued by:
NCII Date Revised:

Developed by: Page iii of vii

Mill Workpiece Darius N.
Hernandez Revision #
 MACHINING NC II
COMPETENCY-BASED LEARNING MATERIALS

List of Competencies

NO. Unit of Competency Module Title Code

Participate in
Participating in Workplace
1 Workplace 500311105
Communication
Communication
Work in Team Working in a Team
2 500311106
Environment Environment
Practice career Practicing career
3 500311107
professionalism professionalism
Practice occupational
Practice occupational health
4 health and safety 500311108
and safety procedures
procedures
Interpret Drawings and Interpreting DrawingsMEE722202
and
5
Sketches Sketches
Select and Cut Selecting and CuttingMEE722203
6
workshop materials workshop materials
Perform shop Performing shop MEE722204
7
computation computation(Basic)
8 Measure workpiece Measuring WorkpieceMEE722205
Perform shop Performing shop MEE722207
9
computation computation(Intermidiate)
Measure workpiece Measuring workpieceMEE722208
using
10 using Angular Angular measuring
measuring instrument instrument
Perform Preventive and Performing PreventiveMEE722211
and
11
Corrective maintenance Corrective maintenance
Performing Bench Work ( MEE722305
12 Perform Bench Work
Complex)
Turning Workpiece ( MEE722306
13 Turn Workpiece
Intermidiate)
Milling Workpiece ( MEE722307
14 Mill Workpiece
Intermidiate)
GrindingWorkpiece ( MEE722308
15 Grind Workpiece
Intermidiate)

Date Developed: Document No.

CBLM on Machining Issued by:
NCII Date Revised:

Developed by: Page iv of vii

Mill Workpiece Darius N.
Hernandez Revision #
 TABLE OF CONTENTS

COVER　PAGE……………………………………………………………….……..... i

COMPETENCY-BASED LEARNING MATERIALS……………………………...ii

HOW TO USE THIS COMPETENCY-BASED
LEARNING MATERIALS ………………………………………………...…......... iii

LIST OF COMPETENCIES………………………..……….……………..……….. iv

TABLE OF CONTENTS……………..……………………….………………..……..v

MODULE CONTENT……………………………………….….……………........... vi

LEARNING OUTCOME 1..……………………………………..………..…….......vii

LEARNING EXPERIENCES…………………………………………………………..1
Information Sheet 6.2-1……………………………………………………………..2
Self-check 6.2-1……………………………………………………………..12
Answer Key 6.2-1……………………………………………………………13

Information Sheet 6.2-2……………………………………………………………15

Self-check 6.2-2.…………………………………………………………….45
Answer key 6.2-2……………………………………………………………46

Information Sheet 6.2-3……………………………………………………………47

Self-check 6.2-3.…………………………………………………………….71
Answer key 6.2-3……………………………………………………………72

Information Sheet 6.2-4……………………………………………………………73

Self-check 6.2-4.…………………………………………………………….76
Answer key 6.2-4……………………………………………………………77
Operation Sheet ..……………………………………………………………………78
Performance Criteria Checklist …………………………………………………80
Definition of Terms. ………………………………………………………………..81

Date Developed: Document No.

CBLM on Machining Issued by:
NCII Date Revised:

Developed by: Page v of vii

Mill Workpiece Darius N.
Hernandez Revision #
 MODULE CONTENT

UNIT OF COMPETENCY : MILL WOKPIECE

UNIT CODE : MEE721307

MODULE TITLE : MILLING WORKPIECE

MODULE DESCRIPTOR : This unit covers the skills required to setup and
mill workpiece to drawing specifications . It
details the requirements for performing milling
operations such as indexing, milling splines,
equally-spaced grooves, 45 serrations in
cylindrical workpiece, spur gear and rack,
ratchets, converging faces, large radial slots,
internal radii and plain bevel gear.

NOMINAL DURATION : 96hours

SUMMARY OF LEARNING OUTCOMES:

Upon completion of this module, the trainee/student must be able to:

LO 1. Set work piece

LO 2. Perform milling operations/ check measure work piece

Date Developed: Document No.

CBLM on Machining Issued by:
NCII Date Revised:

Developed by: Page vi of vii

Mill Workpiece Darius N.
Hernandez Revision #
Learning Outcome 1. Set up Workpiece

CONTENT

 Interpret working drawing

 Kinds and uses of work holding devices
 Procedure in setting up work piece
 Safety practices

ASSESSMENT CRITERIA:

 Plans/ drawing interpreted to procedure part according to specification

 Cutting tools and work holding devices are selected according to job
requirement
 Set up operation are performed in accordance with safety procedures
and practices.

CONDITIONS:
The student/trainee must be provided with the following:

 working drawing
 work piece
 cutting tools
 milling machine and its accessories
 measuring instrument
 PPE

ASSESSMENT METHODS:
 Interview
 Written
 Practical Exercises
 Direct observation

Date Developed: Document No.

CBLM on Machining Issued by:
NCII Date Revised:
Page vii of
Developed by: vii
Mill Workpiece Darius N.
Hernandez Revision #
 Learning Experiences

Learning Outcome 1. Set up Workpiece

Learning Activities Special Instructions

 Read information sheet 6.2-1

on Interpret working drawing

 Read information sheet 6.2-2

on Kinds and uses of work
holding devices
Compare answers with answer key
 Read information sheet 6.2-3
on Procedure in setting up
work piece
 Read information sheet 6.2-4
on Safety Milling Operations
practices
Perform Operation Sheet 6.3-3 The performance criteria checklist
set up workpiece will guide you and help you to
evaluate your work as you are
practicing your skills. When you are
ready present your work to your
trainer for final evaluation and
recording.

Date Developed: Document No.

CBLM on Machining Issued by:
NCII Date Revised:
Page 1 of
Developed by: 83
Mill Workpiece Darius N.
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 INFORMATION SHEET 6.2-1
Interpret Working Drawing

Learning Objectives:
After satisfactorily completing this unit the students/trainees must
be able to:
a. Identify the different elements and interpret working drawings and
specifications.
b. Enumerate the different types of line use in drawing.
c. Differentiate the different views of projections.

Introduction
We will discuss to you about engineering drawing especially technical
drawing prior to Machining operations.
Technical Drawing is used to full and clearly define the requirements
for engineered items/works, and usually created in accordance with
standardized conventions for lay-out, nomenclature, interpretation,
appearance and size etc. The purposed of these is to accurately and
unambiguously capture all the geometric features of the components or
products. And it conveys all the required information that will allow a
manufacturer/producer to produce those components/products.

Purpose of Drawing

a. It is not an illustration

b. It is the specification of the size and shape of the components part

or assembly.

c. The importance information on the drawing is the dimensions and

the tolerance of all its features.

i. Dimension is a a measure of spatial extent, especially

width, height, length and diameter etc.

ii. Tolerance is the permissible limit or limits of variation

in dimension or space between mating part or
assembles parts/components.

Elements of Drawing

A. Graphic Language is mainly describing the shape of the drawing.

a. Type of lines

1 Center lines shall be composed of long and short

dashes, alternately and evenly spaced, with a long
dash at each end. Center lines shall cross without
voids.
2 Dimension lines shall terminate in arrowheads at
each end. They shall be unbroken except where
space is required for the dimension.
3 Leader lines shall be used to indicate a part or
portion to which a number, note, or other reference
applies and shall be an unbroken line terminating
in an arrowhead, dot, or wavy line. Arrowheads
should always terminate at a line; dots should be
within the outline of an object.
4 Break (long) line Short breaks shall be indicated
by solid freehand lines. For long breaks, full ruled
lines with freehand zigzags shall be used. Shafts,
rods, tubes, etc., which have a portion of their
length broken out, shall have the ends of the break
drawn
5 Section/ Extension lines. Sectioning lines shall
be used to indicate the exposed surfaces of an
object in a sectional view. They are generally thin
full lines, Extension lines are used to indicate the
extension of a surface or to point to a location
outside the part outline. They start with a short,
visible gap from the outline of the part and are
usually perpendicular to their associated
dimension lines, but may vary with the kind of
material shown in section.
6 Phantom lines parts of the item delineated,
repeated detail, or the relative position of an absent
part and shall be composed of alternating one long
and two short dashes, evenly spaced, with a long
dash at each end.
7 Hidden lines shall consist of short dashes, evenly
spaced. These lines are used to show the hidden
features of a part. They shall always begin with a
dash in contact with the line from which they
begin, except when such a dash would form a
continuation of a full line. Dashes shall touch at
corners, and arcs shall begin with dashes on the
tangent points.
8 Stitch lines shall be used to indicate the
stitching or sewing lines on an article and shall
consist of a series of very short dashes,
approximately half the length of dash or hidden
lines, evenly spaced. Long lines of stitching may be
indicated by a series of stitch lines connected by
phantom lines

9 Datum lines shall be used to indicate the position

of a datum plane and shall consist of one long dash
and two short dashes, evenly
 10 Cutting plane/ Viewing plane The cutting-plane
lines shall be used to indicate a plane or planes in
which a section is taken. The viewing-plane lines
shall be used to indicate the plane or planes from
which a surface or surfaces are viewed.

b. Geometric Construction is the drawing of shapes,

angles or lines accurately using compasses, rulers and
pencils. Geometric construction involves the putting
together of figures and lengths that is restricted only to
straight edges. Geometric constructions are sometimes
referred to as Euclidean constructions and examples
are pentagons, equilateral triangles and angle bisectors.

c. Projection method .The projection is achieved by the use

of imaginary "projectors". The projected, mental image
becomes the technician’s vision of the desired, finished
picture. By following the protocol the technician may
produce the envisioned picture on a planar surface
such as drawing paper.

i. Parallel projections have lines of projection that are

parallel both in reality and in the projection plane.

1 Orthographic projection is derived from

the principles of descriptive geometry,
and is a type of parallel projection where
the projection rays are perpendicular to
the projection plane. The orthographic
projection shows the object as it looks
from the front, right, left, top, bottom, or
back, and are typically positioned relative
to each other according to the rules of
either first-angle or third-angle
projection. The origin and vector direction
of the projectors (also called projection
lines) differs, as explained below.
First-
angle
 projection, the projectors originate as if
radiated from a viewer's eyeballs and
shoot through the 3D object to project a
2D image onto the plane behind it. The
3D object is projected into 2D "paper"
space as if you were looking at
aradiograph of the object: the top view is
under the front view, the right view is at
the left of the front view. First-angle
projection is the ISO standard and is
primarily used in Europe.

Third-angle projection, the projectors

originate as if radiated from the 3D
object itself and shoot away from the
3D object to project a 2D image onto
the plane in front of it. The views of
the 3D object are like the panels of a box
that envelopes the object, and the panels
pivot as they open up flat into the plane
of the drawing. Thus the left view is
placed on the left and the top view on the
top; and the features closest to the front
of the 3D object will appear closest to the
front view in the drawing.

2 Isometric Drawing it is a
pictorial representation of an object in
which all three dimensions are drawn at
full scale rather than foreshortening them
to the true projection. An isometric
drawing looks like an isometric
projection but all its lines parallel to the
three major axes are measurable.
 3 PerspectiveProjection
Geometric drawing that mimics
how objects look to the human eye. In
this projection the dimensions cannot be
scaled because the different parts of a
depicted object are at varying scales

B. Word Language is describing the size, location and specification of the

drawing.

i. Lettering and Numeral

All lettering shall be uppercase (capital letters).

Numbers shall be Arabic numerals. The lettering and
numerals shall always be placed in a horizontal reading
position as far as practicable. Other than this, lettering
shall be in a horizontal reading position when the
drawing is rotated 90° clockwise. Legible lettering is
essential for reproductions. Letters and/or numerals
shall not run together.
When typewritten letters or digits are used on drawings
or related data, nothing smaller than pica type is
permitted.

Tolerance and Fit

The tolerance of a size is defined as the difference between the upper and
lower limit dimensions of the part. In order to meet the requirements of
various production branches for accuracy of the product. Fit is relationship
between two mating parts. It determined by amount of clearance or
interference when they are assembled

Depending on the mutual position of tolerance zones of the coupled parts, 3

types of fit can be distinguished:
A. Clearance fit
It is a fit that always enables a clearance between the hole and shaft
in the coupling. The lower limit size of the hole is greater or at least
equal to the upper limit size of the shaft.
a. Fits with great clearances with parts having great tolerances.
Use: Pivots, latches, fits of parts exposed to corrosive effects,
contamination with dust and thermal or mechanical
deformations.
b. Running fits with greater clearances without any special
requirements for accuracy of guiding shafts. 
Use: Multiple fits of shafts of production and piston machines,
parts rotating very rarely or only swinging.
c. Running fits with greater clearances without any special
requirements for fit accuracy.
 Use: Fits of long shafts, e.g. in agricultural machines, bearings
of pumps, fans and piston machines.
d. Running fits with smaller clearances with general requirements
for fit accuracy. 
Use: Main fits of machine tools. General fits of shafts, regulator
bearings, machine tool spindles, sliding rods.
e. Slipping fits of parts with great tolerances. The parts can easily
be slid one into the other and turn.
Use: Easily demountable parts, distance rings, parts of
machines fixed to shafts using pins, bolts, rivets or welds.
f. Running fits with very small clearances for accurate guiding of
shafts. Without any noticeable clearance after assembly.
Use: Parts of machine tools, sliding gears and clutch disks,
crankshaft journals, pistons of hydraulic machines, rods sliding
in bearings, grinding machine spindles.
g. Sliding fits with very small clearances for precise guiding and
centring of parts. Mounting by sliding on without use of any
great force, after lubrication the parts can be turned and slid by
hand. 
Use: Precise guiding of machines and preparations,
exchangeable wheels, roller guides. 
B. Transition fit
It is a fit where (depending on the actual sizes of the hole and shaft)
both clearance and interference may occur in the coupling. Tolerance
zones of the hole and shaft partly or completely interfere.
a. Tight fits with small clearances or negligible interference. The
parts can be assembled or disassembled manually.
Use: Easily dismountable fits of hubs of gears, pulleys and
bushings, retaining rings, frequently removed bearing bushings.
b. Similar fits with small clearances or small interferences. The
parts can be assembled or disassembled without great force
using a rubber mallet.
Use: Demountable fits of hubs of gears and pulleys, manual
wheels, clutches, brake disks.
c. Fixed fits with negligible clearances or small interferences.
Mounting of fits using pressing and light force.
Use: Fixed plugs, driven bushings, armatures of electric motors
on shafts, gear rims, flushed bolts.
C. Interference fit
It is a fit always ensuring some interference between the hole and
shaft in the coupling. The upper limit size of the hole is smaller or at
least equal to the lower limit size of the shaft.
 a. Pressed fits with guaranteed interference. Assembly of the parts
can be carried out using cold pressing.
Use: Hubs of clutch disks, bearing bushings.
b. Pressed fits with medium interference. Assembly of parts using
hot pressing. Assembly using cold pressing only with use of
large forces.
Use: Permanent coupling of gears with shafts, bearing bushings.
c. Pressed fits with big interferences. Assembly using pressing
and great forces under different temperatures of the parts.
Use: permanent couplings of gears with shafts, flanges. 

Surface texture is the characteristics of a surface. It has three

components: lay, surface roughness, and waviness.

A. Lay is the direction of the predominant surface pattern ordinarily

determined by the production method used.
B. Waviness is the measure of surface irregularities with spacing greater
than that of surface roughness. These usually occur due
to warping, vibrations, or deflection during machining
C. Surface roughness commonly shortened to roughness, is a measure of
the finely spaced surface irregularities.
 Surface Texture Specification

Self Check 6.2-1

Interpret Working Drawing

This brief self-test will help you measure your knowledge and
understanding of interpreting drawing. Please answering the ff. questions.

1. What is technical drawing?

________________________________________________________________

2. These lines are used to show the hidden features of a part.

a. Center line c. hidden line

b. Phantom line d. datum line

3. Differentiate the different between first angle and third angle of

projection?

_________________________________________________________________

_________________________________________________________________

_________________________________________________________________

4. What is tolerance and fit?

_________________________________________________________________

_________________________________________________________________

5. Enumerate the 3 types of fit and explain.

_________________________________________________________________

_________________________________________________________________

_________________________________________________________________

6. What is surface texture/finish? And draw the drawing symbol.

_________________________________________________________________

_________________________________________________________________

_________________________________________________________________
 Answer Key 6.2-1
Interpret Working Drawing

1. What is technical drawing?

Technical Drawing is used to full and clearly define the requirements for
engineered items/works, and usually created in accordance with
standardized conventions for lay-out, nomenclature, interpretation,
appearance and size etc. the purposed of these is to accurately and
unambiguously capture all the geometric features of the components or
products.

2. These lines are used to show the hidden features of a part.

c. hidden line

3. Differentiate the different between first angle and third angle of

projection?

First-angle projection the projectors originate as if radiated from a viewer's

eyeballs and shoot through the 3D object to project a 2D image onto the
plane behind it while Third-angle projection, the projectors originate as if
radiated from the 3D object itself and shoot away from the 3D object to
project a 2D image onto the plane in front of it

4. What is tolerance t?

The tolerance of a size is defined as the difference between the upper and
lower limit dimensions of the part .

5. Enumerate the 3 types of fit and explain.

Clearance fit is a fit that always enables a clearance between the hole
and shaft in the coupling. The lower limit size of the hole is greater or at
least equal to the upper limit size of the shaft.

Transition fit is a fit where (depending on the actual sizes of the hole
and shaft) both clearance and interference may occur in the coupling.
Tolerance zones of the hole and shaft partly or completely interfere.

Interference fit
It is a fit always ensuring some interference between the hole and shaft
in the coupling. The upper limit size of the hole is smaller or at least
equal to the lower limit size of the shaft.

6. What is surface texture/finish? And draw the drawing symbol.

 Surface texture is the characteristics of a surface. It has three
components: lay, surface roughness, and waviness.

Symbol of surface texture in terms of

drawing.
 INFORMATION SHEET 6.2-2
Kinds and uses of work holding devices

Learning Objectives:

After satisfactorily completing this unit the students/trainees must

be able to:
a. Identify kinds of milling machines and its components.
b. Identify different kinds of milling cutters and its uses.
c. Differentiate the two types of milling process.
d. Enumerate the different kinds of cutting fluids or coolants.
e. Name the different kinds of work holding device and its functions.

Introduction/Overview

Milling Machines were first invented and developed by Eli Whitney in 1800’s
to mass produce interchangeable musket part. This machines assisted
manpower in maintaining accuracy and uniformity while duplicating parts
that could not fabricated by using files and other hand tools. While years
past, development and improvement of the machines continued that
resulted in innovating of heavier arbors, high speed steel(HSS) cutters and
carbide insert cutters. The operations of this machine are easier, faster and
accurate in removing parts than previous machines. In new era of
mechanical operations more special operation of milling machines are
developed and until computerized numeric controlled milling machines was
developed to alleviate or more lessen the errors and have good quality in
producing a components.

Milling machine is one of the most common form of machining in which the
material removal process that create a flat surface, helical surfaces and
contoured surfaces of various configurations. These are accomplished by
slowly feeding of the materials to the equispaced multi-edge circular cutting
tool that rotates to the workpiece while in feed.

Classification of Milling Machines

1. Vertical Milling Machine

The vertical milling machine can be recognized by the position of

its spindle which is vertical (normal to the work table). The table
can be moved in all the axes (X, Y and Z). The spindle head which
is clamped to the vertical column can be swiveled at an angle,
permitting the milling cutter mounted on the spindle to work on
angular surfaces. In some machines spindle can also be adjusted
up or down relative to work piece. The machine is adapted for
machining grooves, slots and flat surfaces. The end mills and face
milling cutters are the usual tools mounted on the spindle.
Machines Componets
 Base and column - The base of a
milling machine is simply the
platform that sits on the ground and
supports the machine. A large
column is attached to the base and
connects to the other components.

 Table - The workpiece that will be

milled is mounted onto a platform
called the table, which typically has
"T" shaped slots along its surface.
The workpiece may be secured in a fixture called a vise, which is
secured into the T-slots, or the workpiece can be clamped directly into
these slots. The table provides the horizontal motion of the workpiece in
the X-direction by sliding along a platform beneath it, called the saddle.

 Saddle - The saddle is the platform that supports the table and allows
its longitudinal motion. The saddle is also able to move and provides the
horizontal motion of the workpiece in the Y-direction by sliding
transversely along another platform called the knee.

 Knee - The knee is the platform that supports the saddle and the
table. In most milling machines, sometimes called column and knee
milling machines, the knee provides the vertical motion (Z direction) of
the workpiece. The knee can move vertically along the column, thus
moving the workpiece vertically while the cutter remains stationary
above it. However, in a fixed bed machine, the knee is fixed while the
cutter moves vertically in order to cut the workpiece.

2. Horizontal Milling Machine

This non – automatic

general purpose milling
machine of small to
medium size possesses a
single horizontal axis
milling arbor, the
worktable can be linearly
feed along three axes (X,
Y, Z) only. It is most
widely used for piece for
piece or batch production
of the job relatively
 simplierconfiguration and geometry.

3. Universal Milling Machine

This versatile milling machine
not only posses both
horizontal milling arbor and
vertical axis spindle, the latter
spindle can be further tilted
about one or both horizontal
axis enabling machining job of
complex shape.

Milling Cutters
The tooling that is required for milling is a sharp cutter that will be rotated
by the spindle. The cutter is a cylindrical tool with sharp teeth spaced
around the exterior. The spaces between the teeth are called flutes and allow
the material chips to move away from the workpiece. The teeth may be
straight along the side of the cutter, but are more commonly arranged in a
helix. The helix angle reduces the load on the teeth by distributing the
forces. Also, the number of teeth on a cutter varies. A larger number of teeth
will provide a better surface finish. The cutters that can be used for milling
operations are highly diverse, thus allowing for the formation of a variety of
features. While these cutters differ greatly in diameter, length, and by the
shape of the cut they will form, they also differ based upon their orientation,
whether they will be used horizontally or vertically. 

A cutter that will be used in a horizontal milling machine will have the teeth
extend along the entire length of the tool. The interior of the tool will be
hollow so that it can be mounted onto the arbor. With this basic form, there
are still many different types of cutters that can be used in horizontal
milling, including those listed below.

 Plane (helical) mill - The High Speed Steel

cutters are used for surface cutting and
finishing in all types of materials.
Furnished with right or left hand cut, 30°
Helix

 Form relieved mill

Convex Milling cutter – These High Speed Steel cutters are
form- relieved for milling concave half circles in all type of
materials

Concave milling cutter - These High Speed Steel

cutters are form-relieved for milling convex half
circles in all types of materials.

Gear cutter – these HSS cutters are form in tooth size

to cut the gears.


Metal slitting saw - HSS Slitting saws are used for
general slotting and sawing applications. Coarse
Pitch and Fine Pitch cutters are supplied in Plain
tooth, staggered tooth form to give chip clearance.

 Single Angle Mill and Double Angle Mill

Single Angle Cutters are designed for
chamfering or beveling parts and are
manufactured in Single Right and Left
Angle in 45° & 60°.Double Equal Angle
Cutters are generally used for milling
threads, V-grooves, serrations, and other
angular surfaces. Double Angle are
generally supplied in 45°, 60°, & 90°
Included Angle

Another operation known as a straddle milling is also possible with a

horizontal milling machine. This form of milling refers to the use of multiple
cutters attached to the arbor and used simultaneously. Straddle milling can
be used to form a complex feature with a single cut. 
For vertical milling machines, the cutters take a very different form. The
cutter teeth cover only a portion of the tool, while the remaining length is a
smooth surface, called the shank. The shank is the section of the cutter that
is secured inside the collet, for attachment to the spindle. Also, many
vertical cutters are designed to cut using both the sides and the bottom of
the cutter. Listed below are several common vertical cutters.

 Flat end mill - An end mill makes

either peripheral or slot cuts,
determined by the step-over distance,
across the workpiece in order to
machine a specified feature, such as a
profile, slot, pocket, or even a complex
surface contour. The depth of the
feature may be machined in a single
pass or may be reached by machining
at a smaller axial depth of cut and
making multiple passes.

 Chamfer mill - A chamfer end mill makes a peripheral cut along an

edge of the workpiece or a feature to
create an angled surface, known as a
chamfer. This chamfer, typically with a
45 degree angle, can be machined on
either the exterior or interior of a part
and can follow either a straight or curved
path.

 Face mill - A face mill

machines a flat surface of the
workpiece in order to provide a
smooth finish. The depth of the
face, typically very small, may be
machined in a single pass or may
be reached by machining at a
smaller axial depth of cut and
making multiple passes.

 T- Slot Milling Cutters - Used

for opening out the bottom of
previously milled slot to form a T-
slot. Alternate right and left hand
helical flutes, can be had in flatted
shank or threaded shank.
 Fly Cutters – is a tool where a
single cutting point rotates about
the axis of the tool holder

 Dovetails Cutters - Used to

produce dovetail slides for
machine tool tables, jigs and
fixtures. Regularly furnished right
hand with 45º and 60º included
angle.

 Woodruff key slot milling cutter -

Used for cutting the smaller Woodruff
Key seats. Alternate right and left
hand helical flutes, can be had in
flatted shank or threaded shank.

 Twist drill- A drill enters the

workpiece axially and cuts a hole with
a diameter equal to that of the tool. A
drilling operation can produce a blind hole, which extends to some
depth inside the workpiece, or a through hole, which extends completely
through the workpiece.

 Corner Rounding Cutters - These

cutters are used to produce convex
corner radii up to a quarter circle.
furnished with form relieved right or
left hand cut. Shank type cutters are
also available.

 Reamer - A reamer enters the workpiece axially and enlarges an

existing hole to the diameter of the tool. Reaming removes a minimal
amount of material and is often performed after drilling to obtain both a
more accurate diameter and a smoother internal finish.

 Tap - A tap enters the workpiece axially and cuts internal threads into
an existing hole. The existing hole is typically drilled by the required tap
drill size that will accommodate the desired tap. Threads may be cut to a
specified depth inside the hole (bottom tap) or the complete depth of a
through hole (through tap).

All cutters that are used in milling can be found in a variety of materials,
which will determine the cutter's properties and the workpiece materials for
which it is best suited. These properties include the cutter's hardness,
toughness, and resistance to wear. The most common cutter materials that
are used include the following:
 High-speed steel (HSS)
 Carbide
 Carbon steel
 Cobalt high speed steel

The material of the cutter is chosen based upon a number of factors,

including the material of the workpiece, cost, and tool life. Tool life is an
important characteristic that is considered when selecting a cutter, as it
greatly affects the manufacturing costs. A short tool life will not only require
additional tools to be purchased, but will also require time to change the
tool each time it becomes too worn. The cutters listed above often have the
teeth coated with a different material to provide additional wear resistance,
thus extending the life of the tool. Tool wear can also be reduced by spraying
a lubricant and/or coolant on the cutter and workpiece during milling. This
fluid is used to reduce the temperature of the cutter, which can get quite hot
during milling, and reduce the friction at the interface between the cutter
and the workpiece, thus increasing the tool life. Also, by spraying a fluid
during milling, higher feed rates can be used, the surface finish can be
improved, and the material chips can be pushed away. Typical cutting fluids
include mineral, synthetic, and water soluble oils.

Types of Milling Process

1. Up Milling(Conventional) Process

This is the process of removing

part of workpiece in form form
of small chips. The chip
thickness is minimum at the
start and maximum at the end.
The cutter rotates in a
direction opposite to the table
feed.

Advantages of Up Milling
 It does not require backlash eliminator
 Safer in operation( cutter does not climb on the
workpiece)
 Load on the teeth are acting gradually
 Built-up edge(BUE) fragments are absent from the
machined surface
 The cutter is not affected by sandy surface of the job

Disadvantage:
  Workpiece has a tendency to lift from work holding
device.
 Obtained poor finished surface

2. Down Milling Process

Milling cutter rotates in same

direction of the
table/workpiece feed. The
chip thickness is maximum at
the start of cut and minimum
at the end. Less heat
generated on the cutter
surface and the workpiece.

Advantages:
 Better surface finish
 Less tendency of vibration or chattering
 Fixture are simpler and less cost, downward cutting
force.
 Cutter with higher rake angle can be used, which
decreases the power requirements
 Suitable for computer numerical controlled(CNC)

Cutting speed, Feeds and Cutting Fluids

Cutting speed of milling machine refers to the distance the

circumference of milling cutter revolves in a fixed period of time.

Metric standard

RPM = cutting speed(m/min)

cutter circumference(m)
English standard

RPM = cutting speed x 12 (sfpm)

cutter circumference(inch)

Feedrate is a combination of distance and time. Distance represents how

far a workpiece moves during milling process.

Feed per Tooth = feedrate(mm)

Number of tooth x RPM

Cutting fluid must have atleast the following important properties:

 High specific heat factor, which relates to the ability to absorb

 heat.
 Sufficiently low viscosity which regulates the property of the fluid
to cling and flow.
 Maximum fluidity to penetrate rapidly to the cutting edge.
 Resist deterioration resulting from excessive heat

Kinds of Cutting Fluids

1. Straight cutting oils

2. Water soluble coolants
3. Synthetic and semi-synthetic coolant
4. Sulphurized Oils
5. Kerosene
6. Air as coolant

Work Holding Devices and its uses

In milling machines, before we begin in to mill work workpiece we must

securely fastened the workpiece to the milling machine table. Setting up of
the workpiece is one of the most difficult job in milling operation because it
needed of critical think not only that the workpiece be fastened to the
milling table but on how to be positioned for proper surface of milling
operation. If the setup is not properly planned and the accuracy is not
insured in the setup, the part will probably end up as scrap. To insure a
good setup, the operator must become aware of the types, proper and safety
uses of the work holding devices associated with milling machines.

1. Clamps - Work that is too large or has an

odd configuration is usually bolted directly
to the table. This method of work holding
takes the most ingenuity and expertise.
Stop block is used to align the work as
well as prevent the part from slipping. Step
blocks help to support the work piece.
Below are the sets of clamps:

Kinds of Clamps

1. Parallel Clamp - is a low reach

heavy duty clamping device, also
known as machinist or toolmakers'
 clamp. Clamping devices are used for safe handling and ease of
operation. Stronger and smaller than a C-clamp.

2. U-Clamp - U" shaped device for

holding down a work piece. It has a
continuous slot and for safe
handling and ease of operation. One
advantage of the "U" - clamp is that
it can be removed without taking
the nut off the T-bolt.

T-Bolts are used on

milling machines
tables and faceplates.
Head has a T-shape
and is used to fasten
work to the table

3. Gooseneck clamp - is a hold down

device used to fasten a work piece
to a table. The gooseneck clamp
allows the top of the clamping bolt
to be positioned below the surface
to be machined.

Parallels are pieces of steel bar stock

accurately machines so that the
opposing sides are parallel to each
other.

Parallels are provided in sets of two

with identical dimensions. Parallels are
used in order to provide clearance
under the work so the cutting tool
does not damage the machine table or
the vise base
Correct and Incorrect Direct clamping

*Place clamp stud close to the workpiece

*Do not place clamp stud closer to the

support

*Use shims between finished surfaces and

clamps

*Clamps in contact with finished surfaces

will mark the workpiece.

*Clamps that are level or with a slight decline

toward the workpiece will equalize the clamping
pressure.

*Angling clamps incorrectly puts pressure

on the support, not the workpiece.
*Place support parallels directly under clamps.

The spring caused by improper

parallel placement will cause the
part to bow.

2. Milling Vise - The milling machine

vise is the most common type of
work holding devise used on the
milling machine
The plain milling machine vise is
used for holding work which has
parallel sides. The vise is bolted
directly to the table using the T-
slots in the machine table. The
plain vise can be accompanied by a
swivel base.

The swivel base is graduated

in degrees and allows the vise
to swivel in the horizontal

plane. The swivel base gives the vise a

greater degree of versatility, but
should be avoided when doing heavy
rough cutting operations because it
reduces the rigidity of the setup.

Angle vise
For machining operations involving compound
angles, a universal vise is commonly used. The
universal vise allows the operator to tilt the
workpiece 90 degrees in the vertical plane as well
as swivel it 360 degrees in the horizontal plane.
Proper uses of Milling vises

Most of the vises used in milling operation are manually operated and
some of the vises are air or hydraulically actuated. It open or closed
manually and maintained the consistent clamping from one part to
another respectively. Improper uses of that workholding device can cause
cut or serious injuries. The proper uses of work holding devices can be
an avenue to a good results or outcomes of operations. Listed below are
the proper uses of vises.

1. When tightening a plain type milling

machine vise it is not necessary to
strike the handle of the vise. Striking
the vise handle with a hammer can
either cause the vise to become over-
tightened or cause the vise handle to
break. If it becomes apparent that
the vise is not holding properly,
check with your instructor for other
possible causes to the problem.

2. Locate the part in the center of the

vise. This equalizes the pressure on
the vise jaws.

Holding the workpiece off center

puts unequal pressure on the vise
jaws.  This can cause the piece to
loosen up.

3. The workpiece should always be

supported by the bottom of the vise
or by parallels.

Work pieces that are not supported

will move under the pressure of the
cutting forces.
 4. Keep the workpiece as low in the
vise as possible.

Work that extends out of the vise

has a greater chance of loosening
up under cutting conditions.

3. Angle Plates - An angle plate is an L

shaped piece of Cast Iron or Steel that has
tapped holes or
slots to
facilitate the
clamping of the
workpiece).
Angle plates are
used when
parts need to
have machining operations performed at a
90 degree angle to the axis of the table.

4. Rotary Tables - are devices most often used in precision metalworking.

They consist of a metal disc on a base that can in turn be placed on
another surface. The disc usually
rotates through the assistance of a
hand crank. The most common
areas of application for rotary tables
is machining, automation and
assembly. A rotary table is a
precision work positioning device
used in metalworking. It enables the
operator to drill or cut work at exact
intervals around a fixed (usually
horizontal or vertical) axis. Some
rotary tables allow the use of index
plates for indexing operations, and
some can also be fitted with dividing plates that enable regular work
positioning at divisions for which indexing plates are not available. A
rotary fixture used in this fashion is more appropriately called a dividing
head (indexing head).
The table shown is a manually operated type. Powered tables under the
control of CNC machines are now available, and provide a fourth axis
 to CNC milling machines. Rotary tables are made with a solid base,
which has provision for clamping onto another table or fixture. The
actual table is a precision-machined disc to which the work piece is
clamped (T slots are generally provided for this purpose). This disc can
rotate freely, for indexing, or under the control of a worm (handwheel),
with the worm wheel portion being made part of the actual table. High
precision tables are driven by backlash compensating duplex worms.
The ratio between worm and table is generally 40:1, 72:1 or 90:1 but may
be any ratio that can be easily divided exactly into 360°. This is for ease
of use when indexing plates are available. A graduated dial and, often,
a vernier scale enable the operator to position the table, and thus the
work affixed to it with great accuracy.
A through hole is usually
machined into the table. Most
commonly, this hole is
machined to admit a Morse
taper center or fixture.
Rotary tables are most
commonly mounted "flat", with
the table rotating around a
vertical axis, in the same plane
as the cutter of a vertical milling
machine. An alternate setup is
to mount the rotary table on its
end (or mount it "flat" on a
90° angle plate), so that it
rotates about a horizontal axis.
In this configuration a tailstock
can also be used, thus holding
the workpiece "between centers." With the table mounted on a secondary
table, the workpiece is accurately centered around the rotary table's axis,
which in turn is centered around the cutting tool's axis. All three axes are
thuscoaxial. From this point, the secondary table can be offset in either
the X or Y direction to set the cutter the desired distance from the
workpiece's center. This allows concentric machining operations on the
workpiece. Placing the workpiece eccentrically a set distance from the
center permits more complex curves to be cut. As with other setups on a
vertical mill, the milling operation can be either drilling a series of
concentric, and possibly equidistant holes, or face or end milling either
circular or semicircular shapes and contours.
A rotary table can be used:

 To machine spanner flats on a bolt

 To drill equidistant holes on a circular flange
 To cut a round piece with a protruding tang
 To create large-diameter holes, via milling in a circular toolpath, on
small milling machines that don't have the power to drive large twist
drills (>0.500"/>13 mm)
 To mill helixes
 To cut complex curves (with proper setup)
 to cut straight lines at any angle
 to cut arcs
 with the addition of a compound table on top of the rotary table, the
user can move the center of rotation to anywhere on the part being cut.
This enables an arc to be cut at any place on the part.
 to cut circular pieces.

Additionally, if converted to stepper motor operation, with a CNC milling

machine and a tailstock, a rotary table allows many parts to be made on
a mill that otherwise would require a lathe.

Worm

The worm is the term for the hand crank that operates some types of rotary
table. Rotary tables come in powered and manual types, however, so
powered rotary tables will not have a worm. Usually, the worm consists of
two parts: the worm screw and the worm wheel.

Worktable Diameter

Worktable diameter is a very important term to know when working with a

rotary table. It refers to the surface area of the rotary table.

Maximum Loads

Maximum loads come in two types for rotary tables: maximum axial load
and maximum radial load. The maximum axial load describes the amount of
weight that the table can withstand when the load is pressed up against it.
The maximum radial load refers to the maximum amount of weight the
rotary table can handle while it is running.

Indexing Accuracy

Indexing accuracy is an important technical term having to do with rotary

wheels. It describes how close the actual measurement on the wheel's
turning angle is to what the table's theoretical angle is.

Repeatability

Repeatability refers to the level of difference in the measurements of

indexing angles. Four different angle positions are measured five times, and
the difference between the maximum and minimum reading for each angle
is found. This figure is the rotary table's repeatability.

Clamp Torque

Clamp torque refers to the clamping mechanism, specifically the level to

which the clamp holds materials on the rotary table.
Allowable Wheel Torque

Allowable wheel torque is a measurement taken when the table is running at

one revolution per minute. The maximum amount of torque that the table
can handle at this rate of speed must meet specified standards.

Indexing Cycle Time

Indexing cycle time refers to the amount of time that is required for a rotary
table to slip into the proper position for a particular measurement.

5. Indexing Head

The dividing head is essentially a horizontal (though sometimes tiltable)

shaft with a wormwheel on it that can be driven round by means of a
worm. The shaft has various means of holding a workpiece.
This may seem very similar to a rotary table. It is different in that there is
no table to mount the workpiece on. Instead it is possible to mount a
center in the shaft or mount a chuck onto it. Usually dividing heads are
supplied with a tailstock. This is essential when using a center with the
dividing head. It can also be very useful for supporting the workpiece
when using the chuck.  Most professional dividing heads, regardless of
size, usually have a ratio of 40:1 between turning the handle and the
shaft rotating. Strangely, smaller ones often have higher ratios.

On all dividing heads the worm is turned by means of a handle. Each

turn of the handle can be divided by means of a dividing plate that
contains a number of rings each with a different number of holes in it.
The handle has a pin that can be moved to fit the holes in any one of the
rings of holes.

Dividing heads can be split into three types. These are closely related to
their size and complexity. These are the “plain”, the semi-universal and
the universal.

The Plain dividing head

On the plain dividing head there is

simply a fixed horizontal spindle that is
rotated using a worm mechanism.

The semi-universal dividing head

 The semi-universal dividing head is just like the plain dividing head
but the spindle can be tilted. On the semi-universal dividing heads the
spindle will tilt so its axis will move from about 5º below the horizontal
to about 5º past the vertical.

The universal dividing head

In this case, firstly the shaft can

be tilted. Secondly, and
what makes the universal dividing
head universal is that it has an
auxiliary input at the back of it.
When this is turned it rotates the
dividing plate. In the case of the
universal dividing head the dividing
plate can either be fixed or it can
be rotated by turning the auxiliary
drive shaft

The handle and dividing plate

On all dividing heads the worm is

turned by means of a handle. The
handle either contains a retractable
pin or the other end of the handle
contains an  pin that can be locked
into a hole in a dividing plate. This
plate has several rings of holes
spaced equally around the plate.
The indexing pin whether it is in
the handle or separate cab be set
so the pin will fit in any hole in any
one ring of holes on the division
plate. Using this means that movement of the spindle on the dividing
head can be made in single or multiple hole spaces

Dividing plate

The dividing plate is the key to dividing the circle.  Often a dividing
head is supplied with three dividing plates. Each plate contains a
number of rings of holes. This means that one turn of the handle can
be divided into the number of holes in the particular ring. Working this
out is covered under “Dividing the circle”.

When the dividing plate is fitted properly all of the “zero” holes will be
in line and will be vertically above the shaft of the handle. Usually next
to each of the zero holes is stamped the number of holes in the ring.

On a small dividing head there might two or three dividing plates.

Together these will cover rings of holes up to about 50 holes. The
 numbers selected in the rings of holes will be arranged so the division
by any number up to 50 is possible. Of course, it is possible to divide
by numbers way beyond fifty but not numbers whose factors include
one or more primes greater than 47 (amongst others). The number of
holes on a dividing plate depends on the manufacturer of the plate. For
example a Browne and Sharp dividing head uses a set of three dividing
plates. These plates contain rings with the following numbers of holes:

Plate 1     15, 16, 17, 18, 19, 20

Plate 2     21, 23, 27, 29, 31, 33      

Plate 3     37, 39, 41, 43, 47, 49

Cincinnati dividing heads use one dividing plate with rings of holes on
both sides. These are:    

First side  24, 25, 28, 30, 34, 37, 38, 39, 41, 42, 43

Second side 46, 47, 49, 51, 53, 54, 57, 58, 59, 62, 66      

We have to remember that one turn of the handle turns the worm by
1/40 of a circle. To go through a whole circle, therefore, requires 40
turns. Using just whole turns of the handle we can divide by any
permutation of the factors of 40, for example, 2, 4, 5, 8, 10, 20.

Many amateurs use homemade dividing head with a ratio of 90. In this
case, the factors become 2, 3, 3, 5     

In the simplest way of using these, the dividing plate is fixed in position.

If we can turn the handle by a fraction of a turn then the choices are
much greater. Suppose we pick the ring of holes with 15 holes in it. It
will also have 15 spaces in it. To turn the spindle through a whole circle
involves the handle going past the number of spaces in the currently
selected circle, say, 15 times 40 turns. That is 600 holes.     

With this ring of holes we can divide the rotation of the spindle into any
number of equal parts where the number is a factor of 600

Suppose we want to divide a circle by 30. In this case the number of

spaces will be 600/30 which is 20. Since this is greater than 15 this
means each step will be one complete turn, that is, 15 spaces, plus
another 5 to make 20 spaces altogether. The sector arms would be set
to cover 5 spaces between holes. Between the sector arms would be 5
spaces but it would start with a hole and end with a hole so 5 spaces
would have the arms encompassing 6 holes. As we have just seen,
dividing by any number less than 40 will need one or more complete
turns of the handle plus a certain number of spaces. Dividing by 40 will
require one whole turn of the handle. Dividing by any number greater
 than 40 will involve less than one rotation of the handle, i.e., just so
many spaces. All the possible ways of dividing a circle in up to 150
parts. It will be seen that to divide a circle into 6 parts can be done with
the ring with 15 holes (and, therefore, 15 spaces) in it. The total number
of holes in this circle is 15 x 40, that is, 600 holes. Divide this by 6
gives the number of holes for one sixth of a circle, that is, 100 holes. If
we divide this by 15 it gives the number of whole turns for each
division. It comes out as 6 turns but that only does 90 holes. So we
have 10 holes left over. In this case one division will be 6 whole turns
and 10 spaces.      If we look at the numbers of holes in the rings on the
Brown and Sharpe dividing plate above we can see that the rings of
holes give us the following factors:

Ring Holes Factor Ring Holes Factor

15 3 5 31 31
16 2 2 2 2 33 3 11
17 17 37 37
18 2 3 3 39 3 13
19 19 41 41
21 3 7 43 43
23 23 47 47
  

It can be seen that with this dividing plate we can divide by any number
up to 49. What we often cannot do is divide a circle where 40 times the
number of spaces in a circle does not contain the factors required for
the division we want to do. For example we cannot divide a circle by 51,
whose factors are 3 and 17, because we cannot get a ring with both 3
and 17 at the same time. Similarly we cannot divide by 81 because it
has 4 three’s as factors and we can only get a ring with 3 three’s. Apart
from these sorts of problems we can divide by most numbers up to 49 x
40, nearly 2000.       Remember that, at any time, we also have the
factors that divide into 40, that is, 5, 2, 2, and 2.

Dividing by degrees

The reader might have noticed that dividing heads seldom use degrees.
But if it is necessary it can be done. Since there are 360º in a circle, one
degree is simply a whole circle divided by 360.      

To do this requires that the number of spaces on the dividing plate

times the number of turns to do 360°, ie, 40,  must be divisible by 360.

Find the factors of 360. They are 5, 3, 3, 2, 2, 2. All of these factors

have to be in the product (multiplication) of 40 and the number of
spaces in the ring.      

Find the factors of 40 are 5, 2, 2, 2.      

The difference in the factors of 360 and 400 is 3 and 3.      

 The smallest ring of holes that includes 3 and 3 as factors is 18.      
Using this ring gives 40 x 18 as the number of spaces in a whole circle,
that is, 720.      

Divide this by 360. The result is 3.      

This means one degree is equivalent to three spaces on the 18 hole ring.

For n degrees the number of holes is n x 3.      

One space is equivalent to 20 minutes of one degree.

The choice of ring      

With a small dividing head with only one handle, if there is more than
one ring that contains the required factors it is best to choose the larger
ring. It is easier to turn the handle.       In the above example the 18
ring was chosen for having the factors required. But the 27 ring also has
the required factors and would, therefore, be easier to use.       With a
dividing head with two handles it does not make much difference.

Differential indexing

   More complex type of

dividinghead, which is
sometimes referred to as
being universal, has an
auxiliary input at the back.
This input can be used to
rotate the dividing plate. The
dividing plate is on a shaft
that contains the shaft with
the worm on it. This worm
rotates the wormwheel etc.

Usually the dividing plate is

locked in position. The worm
is rotated by the handle and
is locked to the dividing plate by means of a pin.       

In differential indexing the dividing plate is not locked. If the auxiliary

shaft rotates it rotates. In differential indexing the main shaft of the
dividing head is connected via a gear train to the auxiliary input.
If we turn the handle from one hole on the dividing plate to another the
workpiece turns. But doing that feeds through to the auxiliary input
which, in turn, rotates the dividing plate.      

This enables us to divide by numbers we could not do using just the

dividing plates. In this method of indexing we cannot rotate the
workpiece from the leadscrew – we cannot do helical milling but then
that is not why we are using this set-up. Also it is not possible to have
the dividing head tilted at an angle.     

The merit of this is that it makes it easy to divide a circle by

unpleasant numbers. Suppose we want to make a gear with 127 teeth.
The number 127 is of great interest because it is the factor that
converts from imperial to metric but it also happens to be a prime
number.      

The method is to set things up to produce a gear with something near

the number of teeth we require.      

This number is a number that is easy to handle. In the case of wanting

127 teeth a good number would be 120. The closer this number is to
the required number the smaller the gear ratio needed to correct it.

Since the ratio built into the dividing head is 40 this means each tooth
will need only one third of a turn of the handle. Therefore we have to
use a ring on the dividing plate that contains a factor of 3. If we use a
ring with 27 holes then each tooth will be 9 spaces.      

This arrangement is called differential because the ratio is determined

by a difference, i.e., two numbers added or subtracted. It is easy to see
that this technique is a very powerful way of dealing with ratios with
intractable factors.

Formula for differential indexing

D   -  ratio between handle and spindle

A   -  convenient number near to the number required

N  -   required number

R   -  required gear ratio

        R = (A – N ) x D /A            

in the above example            

R = ( 120 – 127 ) x 40/120            

R = – 7 x 40 /1 20            
 R = – 7/3

If top and bottom are multiplied by 8 this gives a ratio of 56/24 which
are gears in the standard Browne and Sharpe gear set.      

If the number chosen is too big then the ratio will be negative. If it is too
small the ratio will be positive. This means that the dividing plate will
have to turn one way rather than the other. This can be changed by
adding an idler gear in the gear train to change the direction of rotation.

Compound indexing

For the sake of completeness some mention will be made here of

compound indexing. This can be used to divide by odd numbers. The
trick here is to rotate the main shaft by a certain number of holes on
one ring of holes on a dividing plate and to add or subtract from this a
different number of holes from another ring. It is necessary that both of
the rings being used are on the same plate. In “Practical Treatise on
Milling and the Milling Machine” published by Brown and Sharpe in
1927 refers to this as being of “little practical accuracy”

The sector arms

The two brass parts in the above photo are the sector arms. These can
be set so as to encompass any particular number of holes. But when set
like this, these arms as a pair can be rotated as required.

In general the pin is set to one hole. The left arm is to the left of this
hole. The handle is rotated clockwise so the pin is to the left of the right
arm. This has moved the arm by the number of holes between the sector
arms. The sector arms are rotated clockwise till the left arm is just to the
left of the new position of the pin.

Indexing ring

As a completely separate feature a dividing

head often has an indexing feature that is
separate from the division plate. This
means that if the worm is disconnected
from the shaft the dividing head can be
used as a simple index head.

In this case, the holes for indexing are on

the side of the wormwheel. The indexing
pin is the black knob on the top of the
dividing head.

Engagement of the worm and worm

wheel
 On all types of dividing head there is always some
sort of mechanism that means that the worm can be disengaged from
the wormwheel. This has two uses. It can be used to adjust spacing to
minimise the backlash between the worm and the worm wheel. But it
can also be used to completely disengage the worm from the worm
wheel. On the plain dividing heads the shaft with the handle is fitted so
the worm can be moved away from the wormwheel

On dividing heads that can be tilted the shaft the handle is mounted on
is fitted eccentrically in a sleeve that can be rotated. This not only
enables the spacing between the worm and wormwheel to be adjusted it
can also be used to disengage the
handle from the shaft driving the worm.
The fig. shows the arm for controlling
the engagement of the worm and worm
wheel.

Control of engagment of worm and

wormwheel on universal head

If the shaft with the worm is moved so

the worm is not engaged with the
wormwheel then the gear that links the
division
plate and the series of gears that led
back to the auxiliary input is also
disengaged.

Gearing between auxiliary input and worm shaft

In the above photo, the dividing plate and the

lower gear are permanently connected
together. The handle which is to the left of
the dividing plate is connected to the shaft
which is fitted with the worm. When the
worm is disengaged the bottom gear in the
photo is disconnected from the gear above
it.

This top gear is connected to the auxiliary input. In this situation the
dividing plate is free to rotate but when used like this the dividing plate
is locked by means of a small tab which is the black bit

When the auxiliary input is in use this tab is withdrawn. The auxiliary
input drives the top gear. The worm is engaged with the wormwheel. So
the top gear drives the bottom gear. This rotates the dividing plate. The
pin on the handle is in one of the holes on the dividing plate. As this
handle rotates so does the worm and hence the wormwheel.
The spindle

The spindle always has a hole all the way through it. At the front end,
the spindle, on larger dividing heads, often has a taper and/or a thread
or some other means of holding a chuck.

On larger dividing heads the spindle has at the back end a thread so
that an extension shaft can be screwed into it. This enables the dividing
head spindle to be driven directly. But this will only work is the worm
has been disengaged from the main shaft. It also enables the rotation of
the spindle to fed back into the auxiliary input to enable differential
indexing.
Though this is a rather unusual feature it is, surprisingly, one that is
very easy to implement on any homemade dividing head.

Locking the spindle on the dividing head

Rather like the rotary table the dividing head always has some means of
locking the spindle in the same way as the table can be locked on the
rotary table. And it is used in a similar way. If the workpiece is being
machined between two points the lock has to be off. But if the
workpiece is to be machined at one point, as when cutting a spur gear,
the spindle should be locked. .

Handedness

It might seem odd but dividing heads can be either left or right handed.
That is, with the dividing plate facing the user, the nose of the spindle
can be either to the left of the dividing head or to its right.

The only time this is significant is when a universal dividing head is

driven by the leadscrew on the milling table. If the auxiliary input is on
the left then access to the leadscrew will have to be on its end on the
left.

Size/Weight

A key feature of a dividing head is the center height. This is the height
between the axis of rotation when in the horizontal position and the
base. In general, the higher the center height the better. But this is no
use if the largest diameter will not fit between the milling table and the
bottom of the cutter being used.

Even more important is that it is too big if it cannot be safely and easily
moved on or off the milling table. The weight goes up far faster than the
center height. A center height of
100mm could easily be the most that
many model engineers could safely
manage.
Use of raising blocks

If the dividing head is in the horizontal position, the maximum

diameter workpiece it can hold is bit less than twice its center height.
This can be increase by mounting the dividing head (and the tailstock
if used) on raising blocks. But whether this is useful depends on
whether there is still enough space between the cutter and the milling
table.
If a tailstock is being used this will also have to be raised by the same
height. In the figure another use is shown. In this case the dividing
head is raised so its axis is near the height of the spindle when it is
nearly horizontal.

The auxiliary input

Universal dividing heads have an auxiliary input at the back of the

head. This is used for helical milling.
This is where as the milling table
moves along the leadscrew is used, via
a gear train, to rotate the workpiece
being held by the dividing head.

Notice that the exposed part of the

auxiliary input is only the near end of
the shaft. The large diameter bit is a
boss. This is used for fitting the
quadrant arm onto the dividing head.

Quadrant arm

Often when the auxiliary input is

being used this will involve a gear
train. The gears are mounted on an
arm that fits a boss round the shaft of
the auxiliary input. An arm like this is
often used for a similar purpose on a
lathe. On the lathe it often is designed
to rotate through 90° and so is known
as a quadrant arm. On a dividing
head it is usually just a straight arm.
It rotates simply by the angle it is fitted on at. (Quadrant arm fitted to
dividing head head)

Stub axles

A gear train often starts with a gear on one shaft such as the end of the
leadscrew. At the other end it is often on
the auxiliary input to the dividing head.
Gears in between are usually fitted to stub axles that fit in the slot in the
quadrant arm. It is use in helical milling.

Extension pieces

It will be seen that the arm usually supplied does not meet all the uses
the user might wish to use it for.
Firstly it is not always long enough.
This can be dealt with by small
extension pieces.

Secondly there is often not enough

space this can be dealt with by using
the extension pieces as shown.

Where an extension piece is used a

special stub arbor is needed so that
the gears on it are in the same planes as those on the ordinary stub
axles on the arm.

Feed through

Thirdly, it is sometimes useful to

have
the drive coming from the front of
the arm and going through to the
back. This can be done with an
extension piece that has a special
stub axle fitted to it.

Self Check 6.2-2

 Kinds and uses of work holding devices

This brief self-test will help you measure your knowledge and
understanding of in work holding devices and its uses. Please answering the
ff. questions.

I. Enumeration: Enumerate the following.

1. Three classification of Milling machine?

________________________________________________________________

2. Two milling process.

_________________________________
_________________________________
6. Five kinds of milling cutters and its uses?
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
4. Four correct and incorrect clamping.
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________

II. Explain the following:

1. Why workholding devices are important in milling operation.

_________________________________________________________________
_________________________________________________________________
_________________________________________________________________

2. Why milling vise handle is not necessary to strike by a hammer when

tightening or clamping workpiece?
__________________________________________________________________

Answer key 6.2-2

Kinds and uses of work holding devices

I. Enumeration.

1. Classification of Milling Machines

1. Vertical Milling Machine
2. Horizontal Milling Machine
3. Universal Milling Machine
2. Two Milling Process
1. Up cut Milling Process is the process of removing part of workpiece in
form form of small chips.
2. Down cut Milling Process a milling cutter rotates in same direction of
the table/workpiece feed. The chip thickness is maximum at the start of
cut and minimum at the end.

3. Correct and incorrect clamping

 Place clamp stud close to the workpiece
 Do not place clamp stud closer to the support
 Use shims between finished surfaces and clamps
 Clamps in contact with finished surfaces will mark the workpiece
 Clamps that are level or with a slight decline toward the workpiece
will equalize the clamping pressure
 Angling clamps incorrectly puts pressure on the support, not the
workpiece.
 Place support parallels directly under clamps.
 The spring caused by improper parallel placement will cause the part
to bow.

II. Explaination:

1. Workholding devices are important in milling machines because in milling

operation it is needed to securely clamps or fastened the workpiece for
surface cutting.

2. It is not necessary to strike the handle of the vise. Striking the vise

handle with a hammer can either cause the vise to become over-tightened or
cause the vise handle to break.

INFORMATION SHEET 6.2-3

Procedure in setting up work piece

Learning Objectives:

After satisfactorily completing this unit the students/trainees must

be able to:
a. Know how to set up workholding device into worktable of milling
machines.
b. Set up workpiece using different workholding device.

Introduction/Overview
One the critical aspect in milling operation is proper setting up of
workpiece in work holding device. Holding workpiece by clamps, vises,
rotary table and indexing head will prevent from moving along one or more
of three axis. On this unit, will discussed the proper way of setting the
workpiece into vises, worktable using clamps, rotary worktable and indexing
head.

METHODS ON HOW TO SET UP INDEXING HEAD/DIVIDINGHEAD

First Method:
The

workpiece in the chuck is normally

aligned with the axis of the feed table (left to right). To position the dividing
head, place a straight piece of round stock in the chuck. It needs to be
about 300 mm long and 20 mm minimum in diameter. Make sure that the
jaws of the chuck are clean. The stock will show the centre line of the
chuck/dividing head. You can check if the stock is straight by running a
dial gauge against the top surface of the stock at the end furthest from the
chuck. If the stock is straight, when the chuck is rotated the dial gauge will
give a consistent reading.
To align the dividing head with the table feed, first mount the dial gauge on
the machine head so that the gauge can touch the top of the stock. Feed the
table (left/Right).

If the stock is horizontal, (parallel to the

table feed), the reading on the dial gauge
will be the same at each end of the stock.
If not, check that the tilting movement of
the dividing head is set to zero and that
the underside of the dividing head is
clean. If the problem persists then the
calibration of the tilt needs to be re set.

Resetting the Tilt

On the line of the arc you will see an

engraved scale and a set point. This engraved
scale in relation to the set point will tell you
what angle the dividing head is set for. The
dividing head need to be at zero for it to be
parallel to the bed. Ensure that this is so prior to going any further. If it is
not you need to adjust the angle. To do this you undo the bolts that secure
the dividing head in position and tip the chuck up in relation to the base.
An easy way of doing this is to use the piece of stock for measuring as a
lever. If the number of degrees the dividing head is off by is not very much it
is probably better to tap the stock slightly until the dividing head is in the
correct position.

Once you are happy that the angle is zero re-

tighten the fixing bolts. The second alignment
is parallelism with the feed table in plan view.
To measure this leave the dial gauge mounting
where it is and run the gauge against the side
of the stock. When the workpiece is parallel
with the table feed, (front to back alignment),
the gauge will have a consistent reading for the
whole length of the stock.

To align an existing flat on a workpiece so that

further machining may be done, (e.g. on the
opposite side), first place it in the chuck.
Clamp a short piece of flat bar across the flat to widen the surface to be
measured. Mount the dial gauge on the machine head and run the clamped
bar under the gauge. When the flat on the workpiece is horizontal the dial
gauge will have a consistent reading along the length of the clamped bar.
Rotate the handle of the dividing head clockwise to position the workpiece
correctly.

Second method:
First find an engineer’s square, and set it
against the rear of the bed. Use this to align
the dividing head so that it sits parallel to
the bed. You can also use the dial caliper
for this as well. Set up the dial caliper so
that it is attached to the spindle of the head
and resting
the probe on
the surface
of the dividing head. Then adjust the dividing
head so that when the bed is
moved from side to side there
is no lateral movement in the
head itself. Next replace the
chuck in the spindle with a
"live centre" using the method
you used when setting up the
rotary table.
In addition locate another
smaller "live centre" and place
this in the chuck of the dividing head. On
the side of the dividing head you will see the
 mechanism for altering the pitch of the
chuck. This basically forms an arc of metal.

Place two bolts in the beds "T" channels and

slid them so that they are in position in the
cut outs in the base of the dividing head.
Bring the dividing head, with its attached
"live centre" up to the "live centre" that is in
the spindle.

Make the two points on the ends of the

cones touch each other. Once this has
been done, ensure that the dividing head
is still square to the bed with the
engineers square as previously. Tighten
the fixing bolts to fully secure the dividing
head to the bed of the milling machine.
The dividing head is now ready to be used.

Footstock – it serves two basic functions :

a. To support one end of the workpiece and
b. To position the workpiece in a horizontal
plane or in an angle position.

Different way of Setting up workpiece

Holding the workpiece in the vice

When it comes to holding a workpiece in a vice the same principles apply

to holding it using clamps. The workpiece must be stopped from moving
along one or more of three axes. The workpiece must also be prevented
from rotating about any one or more of the three axes. Consider a small
block held between the two faces of a vice whose faces are in the x/z
plane. There are two types of force resisting movement of the workpiece.
There are those forces we can assume to be completely fixed – they do not
rely on the friction between the workpiece and the faces of the vice. It
cannot move against either face. It cannot move downwards. It cannot
rotate about the x or the z-axis. Then there are movements that are only
restricted by the friction between the workpiece and the faces of the vice.
These are movement upwards in the z direction, movement in the x
direction and rotation about the y-axis. However tight, within practical
limits, the vice is done up these frictional forces can be overcome.
Usually even if the workpiece moves only by the smallest amount the
tendency is for it to become even more exposed to the force of the cutter
and something will have to give. The workpiece might eventually be
moved right out of the way of the cutter. If this happens it will probably
be severely gashed by the cutter. Alternatively the cutter might break.
These outcomes are the better ones. It would also be possible for gears in
the drive to the cutter to get broken. Though we cannot eliminate this
risk completely with a little thought the risk can be reduced to acceptable
levels. When horizontally milling, if the vice is lined up so the forces
applied to the workpiece are right angles to the faces of the vice, then the
workpiece will not slip. This might seem to be a good thing but if we
consider the worst case what is going to give? Will it be the teeth on a
gear in the gearbox? The real problem is with vertical milling. Here the
cutter imposes different forces on the workpiece at different times and in
different directions as it rotates. The main risk is the workpiece rotating
about the y-axis (if the jaws are along the x-axis). This risk increases as
the length of the workpiece in the vice in the x direction gets less and less
and as the height of the workpiece increases. I.e. a square will easily
rotate about the y-axis. Similarly when the overall height of a workpiece
is greater than the length of the workpiece being held in the jaws. These
are very rough guides. The tougher the material being cut the higher the
forces and the greater the risk. The rate at which metal is removed will
increase the forces and will increase the risk. A blunt cutter will greatly
increase the force required to cut the metal.
In the end, most things can be machined safely if the rate at which metal
is removed is slow enough. If we need to machine the end of a workpiece
sticking out of the side of the vice then the workpiece should be long
enough to at least reach to the center of the vice. But if we are machining
across an end of a workpiece sticking out of the side of the vice it does
happen that all the forces ever applied to the workpiece are against either
of the faces of the vice which will not move.
To sum up, generally when using a vice we want to machine along the
length of something. There are other means of holding workpieces if we
need to machine the ends of them.
As far as possible the workpiece should be in the center of the vice. This
ensures the two jaws of the vice will be parallel. If this is not the case
then the force holding the workpiece will be at one end of it only and it
will tend to swivel found this point. If the workpiece is short and has to
be held at the side of the vice one way is to put a piece of scrap metal the
same thickness in the same place on the other side of the vice. Doing this
the workpiece is held at a point and can still rotate. After tightening the
vice just tight, tap the workpiece with a hammer to make sure it is sitting
firmly on the bottom of the vice. Then tighten hard.
If the workpiece is sitting on one or two parallels then it/these should
now resist moving when wiggled by hand. Generally the force of one arm
is sufficient to tighten a vice. Never use a hammer or extend the handle.
Too much force can bend the leadscrew in the vice.
In principle the resistance against the workpiece in the vice moving
should be dependent solely upon the force applied to its surface. In
practice it would seem the larger the area touching the vice the more
sure the hold on the workpiece. The reason for this can easily be seen by
trying the following experiment. Clamp a bar about 150mm (6 inches)
long along the x-axis of the milling table. Tighten clamp hard. Hit end of
 bar along the x-axis with a hammer. It will not move. Without altering the
tightness of the clamp hit the bar with the same sort of force at the
unclamped end at right angles to the x-axis. It will rotate about the
clamped point.
The same applies with a workpiece held in a vice that is sticking up.If the
workpiece is held on the end of a round or square bar different effects
can be achieved by milling with this set-up with the end in the horizontal
plane and by holding it so that the end is in the vertical plane.

Jaws lifting
The assumption when holding a part with parallel sides is that the jaws
of the vice are also parallel and therefore hold the workpiece securely. It
will be noticed that the vices used for milling have a long moving jaw. The
reason for this is that it reduces the chances of the moving jaw lifting
when pressed against the workpiece. Vices without long moving jaw
cannot do this and are not suitable for holding workpieces for milling.
One way of avoiding this problem is to hold the workpiece on the moving
jaw side with a round rod.Holding short workpieces in the viceHolding
short workpieces in a vice is not always as simple as one might think. It
is rather as if it is being held by just one clamp. It will not moved
sideways or up or down. If the force is high enough it can rotate.If the
workpiece is sitting on the bottom of the vice or on a parallel this reduces
the tendency to rotate.Often, if the forces being applied are low enough
the job can be done.If all else fails the four-jaw chuck fixture usually
works.

Alignment of a workpiece in the vice – horizontal

The most usual way of aligning a workpiece in a milling vice is to place it on
the bottom of the vice assuming that
this is horizontal. For this to work
both the workpiece and the vice
must be clean.
The vice should be tightened up but
not really tight. A softheaded mallet
should be used to hit the top of the
workpiece. It should soon be clear
from the sound that the workpiece
is in contact with the bottom of the
vice.
If the workpiece is much wider than the vice as more accurate way is not to
rely on the bottom of the vice at all. Instead, the workpiece is supported on
1-2-3 blocks at either end of the bottom of the workpiece so that it is just a
bit higher than the bottom of the vice.
Alignment of a workpiece in the vice – vertical
Usually a workpiece is aligned with the bottom of the vice. But if a workpiece
is held vertically and the end is not flat it has to be aligned using a square.
It is very useful to have a square
which has an adjustable T-piece to
get the most accurate vertical angle
possible. It would also be possible to
check this with a DTI.
It can be a bit difficult to set a
workpiece vertical using the square.
One trick is to close the jaws to just
before they start gripping the
workpiece. At this point the edge of
the workpiece is aligned, using the
square, so its edge is at right angles
to the edge of the vice. When this has been done the workpiece is pushed at
the front top backwards so it is tight between the top of the back jaw and
the bottom of the front jaw. Like this it will not move left or right. With it like
this the vice can be tightened up and the workpiece will not have slipped.
Setting a workpiece at an angle in a vice
This can be done using a bevel protractor as shown.

Setting the angle of a workpiece in a vice

Notice the narrow arm of the protractor is touching the top of the jaw of the
vice. The wide arm is touching the surface of the workpiece.
Of course, this is only going to work properly if the jaw being used by the
protractor of the vice is horizontal.

Alignment of a workpiece in the vice – use of stops

Suppose the vice has its jaws parallel to the milling table. If two similar
workpieces are put in it one after the other they will both fit in the vice in
exactly the position in both the y and z directions but not in the x direction.
If we have some method of fixing them in the x direction the position of the
workpieces is the same in both cases. If there are many of them they will all
be held in the same position relative to the milling table.
The simplest way of exploiting this is to fix a stop mechanism to the vice.
This can be seen in the following fig.

It is also possible to make a more

general purpose stop as shown:

It is also possible to set an angle

plate at the side of a vice but at right
angles to the vice. This acts as a stop
along the x axis.

Use of Parallels
A parallel is simple a piece of metal with parallel sides. Often they are sold
in sets about 150mm long. In a set of parallels all of the parallels will be of
the same thickness but the heights will vary. For each height there will be a
pair of identical parallels.
Parallels are usually hardened. If they are homemade and are not hardened
they are very venerable to being knocked and a ding will form. This happens
most easily along the corners. These can be removed with a fine file.
In this case, the two pairs of sides will be of equal thickness, so these sides
will be parallel – hence the name parallels.
One of the main uses of parallels is to lift a workpiece up in a vice so it can
be machined. This means the maximum height of a pair of parallels that is
going to be useful for doing this is a bit less than the height of the jaws of
the biggest vice that will be used.
Except when the workpiece is not much wider than the parallel it should be
supported using two parallels of the same height spaced well apart.
Even so, within limits, there are few sizes of parallels that will be found be
useless. You can never have too many parallels.
Whatever system of parallels is used the vice should be firmly tightened and
then the workpiece should be banged down onto the parallel(s) with a copper
headed hammer. Then the vice should be tightened hard.
If the workpiece is truly tight against the parallel(s) then, if the parallel is
pushed with a finger you should feel some resistance to its movement. Also
it should not be possible to wiggle it at all in the vertical plane.
Often it is necessary to raise the workpiece using a parallel on its side but
the workpiece is wider than the parallels available. In this case if the
workpiece is raised using the parallel required but the moving facing of the
vice uses another parallel to clamp the workpiece against the fixed jaw.
It is possible to buy sets of very thin parallels but the above trick usually
makes these unnecessary.
Apart from this common sort there are endless varieties of parallel. They can
be longer or shorter. They can be very thin to very thick. They will usually be
supplied in pairs.
If a workpiece is setup using parallels and then is another similar part is
made using the same setup then all of the surfaces of the vice and the
parallels should be cleaned between one job and the next.
Parallels should always be cleaned before use and cleaned again when
putting them away.
Thin workpiece and Long workpiece. Parallels can also be used to hold thin
material so that it is rigid enough to be milled along an edge. Since the
parallels are often about 150mm long this also extends the maximum length
of the material that can be machined.
Though the workpiece is held rigidly along its length the risk is that it will
bend in the vertical plane. It is worth remembering that the rigidity of the
workpiece in the vertical plane is, at its top, is a lot less than it is half way
between the top now and halfway down to the top of the parallel supporting
it.
The parallel vertical on the left provides a strong backing to stiffen the
workpiece. The parallel under the workpiece raises it to the required height.
The parallel bottom right merely lifts up the final parallel, top right. This
clamps the workpiece and supports it along its length.
Sometimes, if the workpiece vibrates when cutting it is possible to clamp the
ends of the parallels on either side of it using toolmaker’s clamps.
Use of thin parallels
It might be thought that thin parallels would be good for holding thin
workpieces. But they are not. The problem is that they fall over.
The easiest solution to holding thin workpieces is the trick described above.
Use of wavy parallels
One solution to the thin parallel not staying upright is the wavy parallel.
This is a thin parallel but instead of being flat it is wavy. It is also springy so
it can be flattened but will spring back when the pressure is released. These
are even thinner than the thin parallel, but will stand upright without any
trouble. As the vice is tightened up they will flatten but they will always be
upright. They are useful for holding very thin workpieces.
Use of short parallels
Sometimes a workpiece has something projecting on it that means it cannot
be clamped in a vice securely enough to machine it. The way round this is to
use short parallels on end to clamp it on surfaces not near the moving vice
jaw.
It will be found that though the end surfaces of a pair of parallels are often
not accurately ground those on short parallels usually are so the ends of
these parallels can be used to hold the workpiece.
Use of blocks
Similar to parallels in their possible uses are blocks. One common sort of
block is the 1-2-3 block. These are so called because a common size for
them is 1in x 2in x 3in. Blocks can be used to hold a workpiece rigidly when
the workpiece would otherwise be too high to hold safely in the vice.
Blocks are also useful to hold very long workpieces. It is often difficult to
ensure they are parallel to the milling table but the use of blocks ensures
they are.

Use of soft jaws

All vices are provided with hardened jaws. These are screwed to the body of
the vice. It is quite possible to change these hardened jaws for ones made of
softer material.
Soft jaws can be machined to support workpieces that are very thin or made
of soft material like plastics so they can be machined without being spoilt.
They can have dowels in them to fit workpieces and so hold them. They can
be cut to hold parts at angles to the base of the vice.
All of these require the hardened jaws taken out and then replaced. This will
need the jaws to be readjusted to make them horizontal.
Sacrificial parallels
Sometimes a workpiece is to be machined along the edges of the top surface
but is too thin to be held sufficiently above the jaws. In this case it can be
held lower in the vice but with some parallel pieces of stock material
between the workpiece and each of the vices jaws.
However unless the workpiece is in contact with a reasonable width of the
vice it is very easy for it to swivel about the point where it is held in the vice.
This is particularly true if the workpiece sticks out of the vice by more than
the width of it being held in the vice.
Use of other types of jaws
It is usually possible to remove the hard jaws from a vice. They can then be
replaced with jaws made of some softer, i.e., machinable metal, – mild steel
or aluminium. One use of this is that the jaws can be machined to provide
level surfaces to hold thin workpieces that would not project above the top of
the jaws.
These jaws can be machined to hold round shapes better, either vertically or
horizontally by machining a v-shape in the jaw. These jaws can also be
machined into strange shapes in order to hold strangely shaped workpieces.
If the jaws are temporarily replaced then it does not necessarily mean that
when the usual ones are put back they will be horizontal. This can be a
serious nuisance.
One way round this is to use “parallels” made of rectangular steel bar
against the existing hardened jaws.
Holding round sections in vices
Though it is not obvious why, it does seem that a workpiece held along two
lines of contact, for example a round bar is never as secure as one might
expect.
Vices for use on drill presses often have v-shaped grooves in their jaws to
help them to hold round sections. Milling vices never seem to have these
grooves.
The solution might seem to be to use a V-block between the workpiece and
the fixed face of the vice. Clearly the height of the bottom of the V must be
well below the top of the faces of the vice. Most commercially made V-blocks
are often too big to be useable.
One way of holding a round bar in a vice is to use a spacer between the
round part and one face of the vice
with a V-shape in it.
It is quite easy to make V-blocks
whose width is less that the height of
the face of the vice just for this
purpose. Whereas on a V-block the
angle of the V is always 90º this
severely limits the smallest size of
round shape that can be held
It is very probable that you will need
a set of these because one that holds
the biggest round shape will be too
big for small round shapes. It is desirable that the intersection of the two
sides of the V is parallel to the bottom of the vice and parallel to the fixed
face of the vice.
Though it seems possible to hold longish round sections horizontally in a
vice so they can be machined it is not possible to hold a shortish section
without a risk of it slipping though this could be done with a square section
of similar length.
Where the diameter of the workpiece is large compared to the length it is
often possible to turn the ends flat (on a lathe) and then hold it on the
milling machine by holding the flat faces in the jaws of the vice. This sort of
shape is risky. If however a long V-shape is used to hold it then it is not a
frictional force holding it and it is no longer a risky shape.
Collet blocks
One way of holding round and some other shapes – square and hexagonal is
by using collet blocks.
Collet blocks used as rotating collets are covered elsewhere. Collet blocks
are covered here because they are often used in vices where they are only
rotated in a very simple way.
Collet blocks are blocks of steel designed to take a specific style of collet.
One of the most common is the Hardinge 5C collet. Usually there are two
blocks – one is square and the other is hexagonal. Since both have parallel
sides either can easily be held in a vice though the hexagonal one might not
fit well in some smaller vices. The collet block should be held in the center of
the vice’s jaws.
Square collet block

Hexagonal collet block

One way to hold a hexagonal collet block

The beauty of the collet block is that it
turns a round shape, the collet, which
can be hard to hold into a square or
hexagonal shape, which is easy to hold. 
Of course, only the end of the workpiece
can be machined but if the part in the
collet is not needed it can easily be
turned off in a lathe.
But the collet block can be used to do
more than this. This is because the block can be rotated in the vice to give
90° turns with the square block or 60° turns with the hexagonal block. This
allows for a very simple and cost effective form of indexing.
If a large number of bits are being machined by holding them in a collet
then it can be useful to have a collet stop. In the case of the 5C collet this
screws into an internal thread in the end of the collet. This ensures that
each part in pushed into the collet by the same amount.
The only problem with this is that the position of the collet block laterally in
the vice is not well defined. This can be done using a stop fitted to the collet
is the case of the 5C type collet, or a stop fixed to the vice or a separate one
bolted to the table of the milling machine.

Making spur gears

One of the most common ways of making spur gears is by using a dividing
head on a milling machine. The dividing head makes it possible to cut a gear
with almost any number of teeth. It is possible to use either a horizontal
milling machine or a vertical milling machine . Either way the workpiece is
held using a dividing head. The whole point of using a dividing head is that
it is designed for dividing a circle into an equal number of parts. When gear
cutting, determines the number of
teeth to be cut. This leaves one
more choice. This is whether a
horizontal or a vertical milling
machine is available. Given the
choice the horizontal system is
more rigid and would enable the
user to cut bigger gears or cut any
gear faster than would be possible
on a vertical milling machine.
 Cutting a spur gear using
the horizontal arbor

Most home machinists do not have

horizontal milling machines but have a
vertical one. In this case the gear cutter
is held on a stub arbor held in the
vertical spindle’s socket. In this case, the
cutter cuts into the workpiece in the
middle of the front side.

cutting a spur gear with the cutter on a

stub arbor in the vertical head

Use of spur gears

Spur gears can be use to transfer power. In doing this they can also be used
to shift the axis from where the power comes from to any other axis parallel
to the first. They can also be used to convert the speed of one shaft to a
different speed on the other. Of course the power stays the same but the
torque changes. Where two shafts are connected by gears then the
relative speeds of rotation will be directly proportional to the diameters of
the gears. If a gear with, say, 20 teeth turns one with, say, 40 teeth one turn
of the first will only make half a turn of the second. If one gear is rotating
one way the next gear will rotate the other way. If there is a third gear
between the other two, it will not affect the speeds but it will reverse the
direction of rotation of what was the second shaft.

Where two spur gears are in mesh with each other, if one is bigger it is the
gear and the other is the pinion. A rack can be seen as being a small part of
a spur gear with an infinite radius. Where a spur gear is used with a rack it
is the pinion.

Spur gears – parameters

There are still a few key features of gear we need and have to be defined. For
two gear of any size (i.e. for any number of teeth) to mesh properly, there are
several conditions that must be fulfilled:

A. Metric or Imperial

The dimensions of the gear will be either imperial of metric. Standard sizes
of metric or imperial gears cannot be used with imperial gears and vice
versa. Used means two gears whose teeth are engaged properly.

B. Tooth form

For gears to work properly the teeth have to roll over each other. Otherwise
they would rub and this would lead to rapid wear and friction. Also this
shape must have the property that as one gear rotates the other always
rotates at every point in the circle at the same rate. This is known as
constant velocity. There are two common shapes that have this quality the
first is the cycloidal. This used (a very long time ago) to be popular but is
now superseded by the involute form. Watchmakers still use a variant of the
cycloidal form.

C. Size of teeth

For two gears, with any number of teeth, to mesh properly the size of the
teeth on both gears must be the same.

The sizes of metric and imperial gears are defined differently.

In the imperial system tooth size is called diametrical pitch or DP. The
diametrical pitch is the number of teeth a gear has for each inch of its pitch
circle diameter. For example a gear of 1 inch pitch circle diameter and 10
teeth would be 10DP.

In the metric system the tooth size is MOD. The MOD of a gear is the pitch
circle diameter in mm divided by the number of teeth.

D. Pressure angle

Where two gears touch each other the angle relative to a normal on the pitch
circle diameter to the tooth face at this point can vary. In the past the
fashion was for a pressure angle of 14.5º. The current fashion is for 20º. For
special applications this can be even higher.

For involute gears to mesh properly it is also necessary for the teeth on both
gears to have the same pressure angle.

Because in the past 14.5º was the standard this was often not marked on a
cutter. Because modern cutters have different pressure angles they are
usually marked as having a pressure angle of 20º. Consequently a cutter
that is not marked with a pressure angle is probably a 14.5º one.

E. Depth of cut

The depth the cutter needs to cut is always marked upon the gear cutter. It
includes an allowance of 10% at the bottom of the cut so the top of one lot of
teeth will not clash with the bottoms of the other gear. This makes no
difference to the user – just cut to the depth marked on the cutter. Because
of the essential that the gear blank has an outside diameter that is correct
because this is the reference point for determining the depth of cut.

The above variables define a tooth of a certain size. If this is fixed the only
other variables are directly related to the number of teeth
X. Number of teeth

The number of teeth is important since this determines the gearing obtained
with other gear of this or other numbers of teeth.

Y. Pitch diameter

Though a gear has an outside diameter this is not as important as the pitch
diameter. This is the distance between the two centers of two identical gears
meshed together. It is roughly the distance from the middle of a tooth on one
side of the gear to the middle of a tooth on the other side.

Z. Outside diameter

The gear will have an outside diameter. This is the size the blank has to be
turned down to. Some gears, for example 16DP will have pitch circle
diameters and outside diameters that are both multiples of 1/8 inch. But,
this is an exception. Since gears are usually defined by their tooth size and
the number of teeth. These set the outside diameter. The result is usually a
very non-standard size.

Outside diameter = (pitch circle diameter + 2) / diametrical pitch

Cutters for cutting spur gears

It might be thought that a cutter

that was made for a tooth size
would make any gear with that size
tooth. But, unfortunately, for any
given size of tooth, pressure angle
etc the shape of the tooth will vary
depending upon the number of
teeth on the gear being made.

This means that to be able to cut a

gear with any number of teeth but
for a given size of tooth a set of
eight cutters is required. In order to
cope with this it is necessary to
have a cutter for each of a range of
teeth numbers.

Browne and Sharpe first devised this system in 1865. Their cutters are:
 Cutter Number Number of teeth
1 12 teeth- 13teeth
2 14-16
3 17- 20
4 21- 25
5 26- 34
6 35- 54
7 55- 134
(These only apply to involute gears. One snag with cycloidal gears is that the
number of cutters needed is much larger.)
It will be noticed that there are no cutters for cutting less than 12 teeth. As
the number of teeth gets this low a true involute form starts to clash at the
bottom of the tooth against the top of the other tooth. Cutters for small
numbers of teeth are modified to prevent this. What happens is that the
base of the tooth is thinned. To do this for even less teeth would need so
much thinning that the strength of the teeth would be compromised.
It is interesting to note that a rack, which is just a part of a gear of infinite
radius, has sides to the teeth that are straight lines. These sides just
happen to be at an angle that is the same as the pressure angle for this
tooth. This is a property of the involute tooth form.
It will be seen elsewhere on this site that similar cutters are used for making
bevel gears. The technique recommended here produces what are known a
parallel teeth. These can be cut with the standard cutters as used for spur
gears. For making bevel gears where the teeth vary in both height and width
special cutters are needed. They look just like the cutters for making spur
gears but they are marked “bevel” and are not suitable for cutting spur
gears.
Marking of gear cutters
The bore of the cutter is never marked. Those for use on milling machines
will usually be 1 inch and upwards. But smaller bores sizes are used for
gears cutters used for making gears for clocks and watches.
The outside diameter is usually not more than 75mm so they will fit all but
the smallest milling machine.
Most cutters will be marked with:
the size of the tooth – mod or DP,
the number of the cutter
the range of teeth sizes it can cut,
the depth of cut,
the pressure angle (not always.)

Buying gear cutters

It should be clear that given the number of parameters which define a gear
cutter the number of different gear cutters is very large. If one buys gear
cutters on the off chance they might be useful and one bears in mind how
seldom any gear cutter is ever going to be used then the conclusion has to
be that it is a waste of time buying gear cutters unless there is good reason
to believe they will be used or they are very good value.
If you are the sort that just cannot help collecting things on the off chance
they might one day come in useful then rather than buy any cutter simply
because it is cheap make a point of collecting ones that you are likely to use.
The first set of cutters to collect has to be those needed to make gears of the
form of the change wheels on your lathe.
If you think you might need others go for relatively standard sizes. An
example of this are the sizes taken from the catalogue of one well-known
supplier of gears.
DP          4, 6, 8, 10, 12, 16, 20, 24, 32, 40, 48, 64 (smallest)
Metric      0.5, 0.7, 0.8, 1.0, 1.25, 1.5, 2, 2.5, 3, 4 (biggest)
Spur gears – Mathematics
Many books on cutting gears are full of maths. But there is a simple
solution to this. There are several suppliers of gears who provide catalogues
with details of every gear they supply. Suppose you need a change gear to
match some you already have. For any gear you have from a set of change
gears it will have a certain number of teeth and a precise outside diameter.
In the catalogue there will only be one gear that fits these two parameters be
it metric of imperial. Having found it you will now know whether it is
imperial or metric.
There is a slight chance this is a fluke. If the same procedure is done with a
second gear from the set of change gears, if it confirms the first, then it is
probably right.
From this we know:
Whether it is imperial or metric
The size of the teeth
Though manufacturer’s catalogue will tell us the pressure angle we cannot
tell what the gear we have is. If it is British made and old then it is probably
14.5°. If it is continental or far eastern of any modern date it is probably
metric and the pressure angle will be 20°.
If the pressure angles are wrong the gears will not mesh properly. But for
the use in gear trains on lathes and milling machines this is not a problem
because they will be in use for very little time, the loading will be limited and
the spacing is easily adjustable.
Knowing this we can then look up in the same table the outside diameter of
any gear for any number of teeth directly.
Or we could work it out from scratch. From the number of teeth we want we
can work out the number of the cutter. That’s all there is to it.
Variable
Metric
PCD   =no of teeth + mod (mm)PCD
O/D   =(No of teeth + 2) * Mod
Imperial
PCD   =no of teeth/DP ins
O/D   =(no of teeth + 2)/DP
Module      CP / Pi                       25.4/ DP
No of teeth PCD/Module                    PCD * DP
Other factors
Apart from all of these parameters there are others that will affect the
gears possible performance.
Material the gear is made from:
Plastic
Metal Length of the tooth
Fitting to a shaft

Making the workpiece

The first step is to make a blank. It is important that the outside diameter of
this is as accurate as possible. It might seem odd because when the gear is
in use the outside does not touch anything. The importance of the outside
diameter is that it is used as the reference from which the depth of cut is
taken. If it is undersize it will introduce backlash between the gears. If it is
oversize the gears will not rotate freely.
While turning the outside of the blank to the required diameter it is worth
putting a small chamfer on the two corners.
A gear has to fit a shaft accurately. Usually it has to be fixed in some way to
the shaft. The easiest way is to machine the blank so the gear has a boss on
it. This is drilled and tapped to take a grub screw to hold it in place. A better
arrangement is to have two grub screws. These should be at 90º round to
each other on the boss. The shaft should have a flat milled on it where the
screws touch it.
The next simplest way is to cut a keyway on the shaft, and a keyway in the
bore of the gear and put a key in when fitting the gear to the shaft. The
simplest type to get right easily is a Woodruff key. This is covered
elsewhereThis can be done with the simplest of slotting tools. A good fit is
essential.
The ultimate way is to put splines on the shaft and matching splines inside
the bore of the gear. This is a bit more than most home workshops can
manage. (Covered elsewhere).
The center hole is center drilled, drilled and reamed or bored on the lathe. It
is essential that this hole is concentric with the outside of the gear. If it is
not there might be backlash when the gear is in one position but it will stick
in the opposite position.
The gear blank can be made on the end of a bar and then parted off. In this
case the blank would then be mounted on an arbor or mandrel.

Holding the workpiece

There are three ways of holding the
workpiece.
It is also possible to hold the
workpiece with an arbor with a
shoulder and parallel shank and
hold the workpiece on with a washer
and nut arrangement.
It can be held on a mandrel.
Having done this it is possible to turn
the outside to the required diameter by
turning between centers on the
lathe. If this is done it is possible to
transfer the blank whilst it is still on the mandrel straight onto the dividing
head and tailstock though the dog might need changing. The “wider” end
should be at the dividing head. Cutting should then  be done towards the
dividing head.
This needs to be bolted very tightly. It only works because there are no
forces attempting to turn the workpiece round. All of the cutting forces are
parallel to axis of the arbor. It is possible to use a drop of Loctite 603 to hold
it from rotating. After the gear has been cut the gear and the arbor can be
heated up and the glue will loosen its grip.
If just one thin gear is to be made it needs a dummy blank on the side the
cutter is cutting towards to support it. The outside of the dummy it needs to
be at least as large as the outside diameter of the gear being cut. Thin gears
cannot be held properly on a tapered arbor. Neither can very wide ones …It is
also possible, especially with smaller gears for the axle of the gear and the
gear to be part of the same piece of metal. In this case the end of a bar is
turned down to the outside diameter of the gear. But a length of the bar is
turned so it is concentric with the end but this part is for holding it in a
chuck. This method is useful if several gears of the same size are to be
made. After they have been cut they can be cut to length by parting them
off in the lathe.
It is also useful if very thin gears are needed. They are cut altogether in one
go. Then they are parted off to the thicknesses required.

Alignment
1. The dividing head must be aligned along the x-axis of the milling
machine.
2. The dividing head must be horizontal.
3. If using a tailstock it must be at the right height .
4. If using a mandrel it must lie along the x axis.
5. If in horizontal mode, the cutter must be above the blank and the
centerline of the cutter must be in line with the axis of the spindle of the
dividing head in the vertical plane.
6. If horizontal milling:
7. Then the y axis should be locked. This should remain locked for the
entire job. If vertical milling.
8. If in vertical mode the cutter must be in the center of the side of the
workpiece.

Setting and using the dividing head

The way the the dividing head is set up and used determines the number of
teeth that will be cut.
The handle on the dividing head has to turn, say, 40 times to go through
one circle. But one turn of the handle can be divided further by using the
holes in a ring on the division plate. The result
will be that for most numbers for each tooth (ie gap) to be cut it is need so
many turns of the handle and for the indexing pin to pass so many
spaces on the appropriate ring of holes. The number of spaces is set by
using the sector arms.
When starting it is important that the index pin is in the top hole in the ring
being used and the sector arm set .
After cutting the first tooth the sector arms are moved as shown (fig sector
arms moved).
The handle is then turned by however many turns is required plus the holes
shown on the division plate( fig final position of the indexing pin)

Where the teeth cannot be cut in one pass

If the teeth are cut in one pass then the whole process of making the gear is
done with the milling table at just one height. This means it can usefully be
locked in the Z direction all of this time. If the teeth are cut in two passes
then the table is locked in the z direction for one pass. It is then raised and
locked for the second pass.

Cutting gear

Fit the gear blank on an arbor in the

chuck on the dividing head. Rotate the
dividing head through one circle without
the cutter touching the workpiece. This
is to check that there is nothing that is
going to compromise the job before it is
finished. In this photo the cutter is
cutting away from the dividing head.
This is simply because this is the way
this spindle usually rotates
When cutting a gear on a horizontal
machine the cutter will normally turn so that it cuts towards the dividing
head. When using a mandrel the wide end of the mandrel should be at the
dividing head end and cutting should be towards the dividing head. Here, it
is this way because it is easier to see what is happening. This is true
whether the dividing head is left handed or right handed.
The dividing head should be set so the sector arms are spaced as needed for
the number of teeth being cut. The whole gear cutting process starts with
the dividing head set to zero.
As the dividing head is driven round it can happen that you lose
the position. The trick to prevent this is to have a starting point that is
reproducible. The way this can be done is before anything else is done, is to
set the dividing pin to the zero position on the dividing plate. Then mark the
indexing ring as closely as possible to the indexing pin. If the surface is
black it can be marking by using Snowpake
One problem that can cause confusion is where the number of holes is
greater than the number in the current circle. This will occur whenever the
number of teeth is less that the number of turns needed to turn the spindle
by one whole circle. For example, if the movement for each tooth is x turns
of the dividing handle and then y spaces on the dividing plate.
The dividing head should always be rotated one way when one tooth has
been cut and you are moving to the next tooth. If it should happen to you go
too far you must come back past the position required and then move
forwards to the position required. This is to allow for any play in the dividing
head
If at any point during the cutting of the teeth the position is in doubt then it
is necessary to go back to a point where the setting of the dividing head is
known to be right for a given tooth. In the worse case this means going back
to the first tooth as closely as possible by sight and then set the dividing
head pin to the zero position. However it is necessary to go back past this
and then forwards to this point to counter any backlash in the dividing
head.
Of course a mathematician would be able to compute where the pin should
be for the last tooth cut properly and set the diving head to this position and
to continue from this point.
If cutting has started at the wrong point the whole job is usually completely
screwed up. The main cause of this problem is interruptions in the cutting
process. It is best to do this when there is time to complete the whole job in
one go. It also helps if no-one is around who might interrupt. Mobiles must
be turned off.
for the cutting of any one tooth (ie gap) the dividing head should be locked
It is very desirable to cut all of the teeth in one pass if at all possible. If the
teeth have to be cut in more than one pass then it is best to cut all of them
to one depth with the z-axis locked. Then the process is repeated for a new
depth. To do this the axis is unlocked and then locked again for the new
depth. This continues till the right depth is reached. This reduces the
possibility of confusion or error. For each tooth, whilst it is being cut, the
dividing head spindle should be locked
If the teeth are cut in two passes with half the depth on the first and the
second half of the depth on the second, then most of the metal removal will
occur on the second cut. For this reason cut two thirds of the depth on the
first cut and the last third on the second.
The end of cutting a gear

The job starts with cutting the first tooth, i.e., the first gap. If there are n
teeth to be cut, then when the last tooth, i.e., the last gap, is cut the gear
wheel will not have done a complete circle. At this point it is useful to check everything by turning
just one more tooth position. If everything has gone to plan then the
indexing pin should be back on the zero position on the dividing plate. And,
of course, this tooth, i.e. gap, should have already been cut and the cutter
should fit perfectly into this gap

If it does not it could be that:

 the indexing was not done properly,
 the workpiece slipped in the chuck,
 the milling table was not locked in the Y direction,
 the cutter moved on the arbor.
Or any one of many other reasons.
If the workpiece is mounted on a mandrel it should be removed from it using
an arbor press
 Self Check 6.2-3
Procedure in setting up work piece

This brief self-test will help you measure your knowledge and
understanding of in procedure in setting up work piece. Read carefully the
questions and write True if the statement is correct and False for the
incorrect statement in the blank space provided.

__________1. In milling machine, setting up of both workholding device and

the cutting tool the spindle or machines must be stop or turn
off.
__________2. Milling cutter/s should be put in the worktable of milling
machine when it is not in use.
__________3. The gear blank outside diameter is essentials because it will be
the depth of cut referrence point.
__________4. In cutting of blank gear, the blank gear must be set or hold it
by mandrel for rigid fixture of work.
__________5. For safety procedures of setting up workholding devices in the
worktable of milling machine, it must me near the spindle
cutter.
__________6. An accessories of milling machine that hold the workpiece to
prevent movement of work?

a. vise c. clamps
b. rotary table d. all of these
__________7. The workholding device that are suitable for making gears or
splines?

a. Vise c. Indexing head/footstock

b. Angle Vise d. clamps

Answer key 6.2-3

Procedure in setting up work piece

1. True
2. False
3. True
4. True
5. False
6. D
7. C
 INFORMATION SHEET 6.2-4
Safety Practice in Milling Activity

Learning Objectives:

After satisfactorily completed this unit, the students must be able to

learn milling machine safety operations and environment concerns.

Introduction

In machine shop practices, most of the accident occurred in an

improper use of hand and power tools. In this topic will discuss the milling
machine safety practices and it categorized in to human error and
mechanical failure. If either is prevalent, it can cause to potentially
hazardous situations.

Human Error is mostly cause by ignorance because of lack of knowledge on

how to properly use a particular tool. Ignorance can be overcome by proper
education.
Mechanical error involves lack of maintenance operation and not knowing
the machine specifications. To prevent the mechanical failure, follow the
proper procedure of using, maintenance and knowing its specifications or
limitations.

Basic Rules in Shop Safety

Wear eye protection. In machine shop, operating tools are required or

must wear eye protection. Flying debris may come directly to the operator or
anyone else on the shop.
Wear proper clothing and footwear. Don’t wear loose clothing, it
could get caught by moving part of machines. Safety shoes are required
because many small, hot, sharp pieces that may fall from the tool and onto
the floor. And can cause burns/ cut to the exposed part of our lower body.
Jewelry, watch and ring etc are not advisable to wear and it may also
get caught by the machines.
Pre-caution Before using Milling Machine

 Before using the milling machine, plan – out exactly what are you going
to do the operations.
Planning-out involves the following:
 make sure the workpiece is not too long or large to properly fit on
worktable/workholding device.
 Carefully calculate the angles/dimensions of the cut to me made.
 Choose the appropriate cutting tools for the operations.
 Choose appropriate speed for tooling the workpiece. Table of
materials and cutting speed specification also available in shop.
 Calculate the speed of worktable. This will depend on the
materials to be worked and cutter being to be used.

 Make certain worktable and immediate area are clear from debris and
unnecessary objects.
 Make certain to properly secure the workpiece to the worktable by
workholding device. And the clamping arrangement does not lie along
the line to be cutted.
 Before turning –on the machine, the coolant flow is set to the desired
flow rate. Never adjust the flow rate of the coolant while operating. The
motor is geared for the desired cutting tool speed. Never adjust machine
speed while it is operating.

Causes of Injuries are the following:

 Failure to draw the workpiece back to a safe distance from the cutter
when loading or unloading into worktable.
 Leaving the cutter exposed after the work has widrawn.(operator could
easily rub arm against the cutting tool and resulting to a deep cut)
 Leaving hand tools loose on the worktable.
 Failure to clamp the job securely.
 Reaching around the cutter to remove chips when the machine is in
motion or uncompletely stop in motion.
 Removing chips by hand instead of brush.
 Measuring the workpiece while it is operating.
 Using rag in cleaning/removing oils while cutting tool is turning
 Wearing gloves, ties/ loose clothing.
 Using improper cutting tool for the job
 Improper storage of cutting tools and other accessories.
 Attempting to remove a nut from the arbor by applying power motor.
 Striking the cutter with your bare hand while setting up or stopping the
machine.

Environment Concerns

Our nature are exposed to the different kind of elements that can
cause to destroy other living things in our environment.
 The coolants or cutting fluids used in machining a job is called
cutwell 45. It is universal lubricant that is used on the most processes
requiring cooling and it is water soluble oil & renewable.
The chips that are milled away from the piece can be recycled, depending on
the cost of material and size. If they are deemed worth recycling they are
place in bins where scrap are resold. Other scrap materials are deemed not
worth recycling is thrown into garbage/ landfill.
Cutting tools of milling machines can be re – sharpened when they
get dull like high speed steel/ insert carbide. Other insert bit are not
advisable to re- sharpened because of the element compositions that are not
suitable to human health. Those insert bit are recommended to return back
to the manufacturing when the bits get dulled.

Milling machine safety

Most workshop accidents would simply not occur if the operator had
followed basic safety measures. Follow these guidelines for safety for the
milling machine:

1. Clean the milling machine, like all machine tools, after each work period.
2. Never use an air hose to remove the chips. The flying particles might
injure you or someone standing nearby.
3. Make sure that you are thoroughly familiar with the machine before you
attempt to use it.
4. Wear proper clothing and approved safety goggles.
5. Stop the machine before you make adjustments or take measurements.
6. Stop the machine before you remove chips.
7. Never reach over, or near, the rotating cutter.
8. Make sure that the work-holding device is mounted solidly to the table
and that it is firmly holding the work piece. Spring or vibration can cause
thin cutters, like the slitting-saw, to jam and shatter.
9. Do not talk to anyone while you operate the machine, nor allow anyone
to start your machine for you.
10. Keep the floor around the machine clear of chips and wipe up spilled
cutting fluid immediately.
11. Place sawdust, or oil-absorbing compound, on slippery floors.
12. Be thoroughly familiar with the position of the stop lever.
13. Treat any cut and skin puncture immediately.
14. Make sure that you turn off all power to the machine before you open
the door to the motor compartment. Take care to prevent running the
saddle, or work, into the column.
15. Use a piece of heavy cloth for protection when you handle milling
cutters. These are very sharp, so never use your bare hands.

Self Check 6.2-4

 Safety Practice in Milling Activity

This brief self-test will help you measure your knowledge and
understanding of in safety practices in milling operations.

1. What are the errors causing hazardous injuries of the operator? Explain.
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________

2. In general machine shop operations, the_________ must be wear to

protect the eyes from flying debris or chips.

a. Sun glass c. Safety goggles’

b. Reading glass d. All of these

3. Handling of milling cutters must be handling using ___________?

a. Barehand c. Vise
b. Heavy cloth d. clamps

4. True or False. Coolants, chips and used insert/cutting tools

should/must be disposed in the ricefield.

5. Enumerates aleast 5 cause of injuries using machine shop.

______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________

Answer key 6.2-4

Safety Practice in Milling Activity

1. Human Error is mostly cause by ignorance because of lack of knowledge

on how to properly use a particular tool. Ignorance can be overcome by
proper education.
 Mechanical error involves lack of maintenance operation and not
knowing the machine specifications. To prevent the mechanical failure,
follow the proper procedure of using, maintenance and knowing its
specifications or limitations.

2. C

3. B

4. False

5. Causes of Injuries are the following:

a. Failure to draw the workpiece back to a safe distance from the cutter
when loading or unloading into worktable.
b. Leaving the cutter exposed after the work has widrawn.(operator
could easily rub arm against the cutting tool and resulting to a deep
cut)
c. Leaving hand tools loose on the worktable.
d. Failure to clamp the job securely.
e. Reaching around the cutter to remove chips when the machine is in
motion or uncompletely stop in motion.
f. Removing chips by hand instead of brush.
g. Measuring the workpiece while it is operating.
h. Using rag in cleaning/removing oils while cutting tool is turning
i. Wearing gloves, ties/ loose clothing.
j. Using improper cutting tool for the job
k. Improper storage of cutting tools and other accessories.
l. Attempting to remove a nut from the arbor by applying power motor.
m. Striking the cutter with your bare hand while setting up or stopping
the machine.

OPERATION SHEET 6.2-2

Title Set up work holding device( Indexing Head) and workpiece
Given the necessary tools, materials, equipment and
Performance
supplies, you should be able to properly set up the work
Objectives
holding device in milling machine worktable.
Tools/Supplies/Materials:
wrenches
Rags and brush
T-bolts and nuts
Dial indicator/L- Square
Equipment:
Indexing Head/footstock
 Milling Machine
Personal Protective Equipment
Steps/Procedure:

1 Prepare the materials to be use in the activity.

2 Clean the worktable surface and the indexing head base.
3 Place the indexing head on the top of the worktable
4 Insert the T- bolt at the T- slot of the worktable.
5 Positioning the indexing head, place a straight round workpiece
about 25mm diameter and 300mm long in the chuck. Make sure
that the chuck jaws are clean or free from debris. The workpiece
will show the indexing head center line.
6 Check the workpiece by running a dial gauge against the top
surface of the workpiece at the end furthest from the chuck. The
dial gauge will give a consistent reading if the workpiece is in
straight position. If not,
7 Check that the tilting movement of the dividing head is set to zero
and that the underside of the dividing head is clean. If the problem
persists then the calibration of the tilt needs to be re set.
8 To reset the tilt or angle of indexing head. On the line of the arc
you will see an engraved scale and a set point. This engraved scale
in relation to the set point will tell you what angle the dividing
head is set for. The dividing head need to be at zero for it to be
parallel to the bed. Ensure that this is so prior to going any
further. If it is not you need to adjust the angle. To do this you
undo the bolts that secure the dividing head in position and tip the
chuck up in relation to the base.
9 Use a piece of workpiece for measuring as a lever. If the number of
degrees the dividing head is off by is not very much it is probably
better to tap the workpiece slightly until the dividing head is in the
correct position.
10 Once you are happy that the angle is zero re-tighten the fixing
bolts. The second alignment is parallelism with the feed table in
plan view. To measure this leave the dial gauge mounting where it
is and run the gauge against the side of the stock.
11 When the workpiece is parallel with the table feed, (front to back
alignment), the gauge will have a consistent reading for the whole
length of the workpiece.
12 To align an existing flat on a workpiece so that further machining
may be done, (e.g. on the opposite side), first place it in the chuck.
Clamp a short piece of flat bar across the flat to widen the surface
to be measured. Mount the dial gauge on the machine head and
run the clamped bar under the gauge. When the flat on the
workpiece is horizontal the dial gauge will have a consistent
reading along the length of the clamped bar. Rotate the handle of
the dividing head clockwise to position the workpiece correctly.

Pre Caution:
Make sure the milling machine must be shut – off before setting up
the machine.
The milling cutter be away from or remove from spindle
Assessment Method:
Written Exam, Actual Demonstration/Direct Observation and Interview

PERFORMANCE CRITERIA 6.2-3

CRITERIA Yes No

Did you……………………

1. Interpret according to the component specifications?

2. Sequence of operation is followed according component to

specifications?
3. Cutting tools are selected according to the requirements of
the operation?
4. The workpiece was set up to required level of accuracy using
instruments/equipment according to work site procedures?
5. The set up operations are applied knowledge on safety
procedures and using personal protective devices?
 Definition of Terms
Diameter - The distance from one edge of the circle to the opposite edge
that passes through the center.
Drill - A tool with multiple cutting edges used to make round holes in
workpieces.
Drilling - A holemaking process in which a rotating cutter (the drill) makes
a round hole into the workpiece to a certain depth.
Engine Lathe - The original and most basic type of lathe.
Face - A turing operation that moves a cutting tool at a right angle to the
centerline axis of the workpiece, creating a flat end in the part.
Faceplate - A flat, round workholding device often used to mount flat-
bottom workpieces. A faceplate is the most basic means of mounting a
workpiece on the spindle.
Facing - An operation performed on a lathe that feeds a single-point tool
into the end of a cylindrical workpiece to create a flat surface.
Fastener - A device that holds two or more objects together. A fastener can
be a button or a zipper as well as a bolt or a screw.
Feed - The rate that the cutting tool travels along the surface of the
workpiece.
Gear-Driven Lathes - Lathes that are driven by a series of belts that
connect the motor to the power input.
Graduated Rule - A straightedge with calibrated lines used to measure
distances with up to 1/64 inch accuracy.
Headstock - The end of a lathe that holds the spindle and the drive that
rotates the workpiece.
High-Speed Tool Steels - A group of tool steels used to machine metals at
high cutting speeds. High-speed tool steel stays hard at high temperatures
and resists abrasion.
ID Grooving - An operation performed on the lathe that creates a circular
channel or passageway around the interior of a workpiece.
ID Threading - The process used to machine a long, spiraling ridge along
the inner surface of a workpiece.
Inch Per Revolution - A measurement that indicates the amount of inches
that the cutting tool moves along the rotating workpiece.
Indexes - Rotates into position. On a turret lathe, the required cutting tool
indexes into position when required.
Inner-Diameter Operations - Cutting operations performed on the inner
surface of a workpiece.
Jaws - Holding devices on the chuck that clamp down on the workpiece.
Lathe - A machine tool used to create cylindrical parts. A lathe holds a
cylindrical workpiece on one or both ends while a cutting tool is gradually
passed along the surface of the rotating part.
Lathe Centers - The centerline axis (z-axis) distance between the spindle
center and tailstock center. The maximum length for work mounted on the
lathe.
Lathe Dog - A workholding device that clamps around a workpiece and
transfers rotary motion from the spindle to the work, allowing work
to be held between centers.
Leadscrew - The long threaded device that controls the precise movement of
the carriage on a lathe.
Morse Taper - A hole in the sleeve of the tailstock that narrows to a point
and holds tools or a center. A Morse taper allows for easy locking
and removal.
OD Grooving - An operation performed on the lathe that creates a circular
channel or passageway around the exterior of a workpiece.
OD Threading - The process used to machine a long, spiraling ridge down
the outer surface of a workpiece.
Outer-Diameter Operations - Cutting operations performed on the outer
surface of a workpiece.
Parting - Also called cutting off, a shearing operation that separates a
finished part from the bar stock.
Quick-Change Gearbox - A set of controls mounted to the front of the lathe
bed that engages the leadscrew to drive the carriage.
Quick-Change Tooling - A set of toolholders that consists of several tool
blocks or bars that help to speed up the production of parts.
Ream - The process of removing small amounts of material from the inner
diameter of a hole with a multi-edged cutting tool.
Reaming - The process of using a cutting tool with straight cutting edges to
enlarge or smooth holes that have been previously drilled.
Roller Element Bearings - A component containing one or more rows of
rollers used to reduce friction in a machine.
Round-Cut Grooves - Outer-diameter grooves on a workpiece that are
round-shaped.
Saddle - A cast iron frame, shaped like the letter H, that rides on the ways
and locates and houses the cross-slide and apron.
Single-Point Tools - Cutting tools that have a single cutting edge.
Speed - The rate at which the cutting edge of the tool moves past the
workpiece surface at the point of contact.
Spindle - The device located in the headstock that rotates the workpiece.
Spindle Bore Diameter - The diameter of the hole through the length of the
spindle. The larger the spindle bore diameter, the larger the workpiece the
lathe can machine.
Square-Cut Grooves - Outer-diameter grooves on a workpiece that are
square-shaped.
Surface Feet Per Minute - A measurement of speed describing the distance
that the tool tip travels in one minute. It is used for operations requiring an
adjustment of spindle speed as the tool moves toward or away from the
centerline. Surface feet per minute is abbreviated as sfpm, sfm, or fpm.
Swing - The maximum diameter of a workpiece that can be rotated on the
lathe.
Tailstock - component located opposite the headstock that supports the
end of longer workpieces.
Tailstock Indexer - A type of toolholder mounted in the tailstock that holds
up to six different cutting tools.
Tailstock Sleeve - Tubing that fits over the tailstock. The tailstock sleeve
moves towards and away from the headstock.
Tapered - Uniform change in the diameter of a round workpiece along the
centerline axis. Tapered parts make tool holding and tool changing easier for
the operator.
Tapping - The process of cutting internal threads in a workpiece with a
multi-point tool.
Threads - Helical ridges cut into the inner or outer diameter of a round
workpiece, allowing the workpiece to be used as a fastener.
Tool Geometry - The collective angles formed by the dimensions of a
cutting tool that make a tool unique.
Toolholder - A tool used to rigidly hold a cutting insert in place during
machining. Toolholders are classified so that they can be paired with the
correct style of insert.
Toolholders - Devices used to rigidly hold cutting inserts in place during
machining. Toolholders are classified so that they can be paired with the
correct style of insert.
Toolpost - A component that sits on the compound rest and contains a slot
for positioning the toolholder and cutting tool.
Turning - An operation performed on a lathe that feeds a cutting tool along
the length of a cylindrical part to reduce its diameter.
Turning Centers - Lathes that are controlled by a computer running
programs driven by numerical data. Sophisticated turning centers can
also perform a variety of drilling and milling operations.
Turret - The component of a lathe that holds a number of cutting tools. The
turret rotates to place tools in the cutting position.
Turret Lathe - A lathe machine with a mounted device that holds multiple
cutting tools. The turret rotates to position a specific cutting tool in place.
Universal Jaws - A set of synchronized jaws that open and close together
when they are tightened or loosened.
V-Cut Grooves - Outer-diameter grooves on a workpiece that are V-shaped.
Ways - Two precisely measured, parallel tracks that support and guide the
movement of the carriage and cross-slide.
Workholding Device - A device used to support, locate, and hold a
workpiece. The workholding device references the tool performing the
operation on the part being held.
Workholding Devices - Devices used to support, locate, and hold a
workpiece. The workholding device references the tool performing the
operation on the part being held.
Workpiece - A part that is being machined