ME6402 – MANUFACTURING

TECHNOLOGY – II

Dr. A.RAMAMURTHY.,M.E, Ph.D., M.I.S.T.E.,

PROFESSOR

DEPARTMENT OF MECHANICAL ENGINEERING

SAVEETHA ENGINEERING COLLEGE,

Dr.AR - SEC 1
 UNIT III SHAPER, MILLING AND GEAR
CUTTING MACHINES
Shaper - Types of operations. Drilling ,reaming, boring, Tapping.
Milling operations-types of milling cutter. Gear cutting – forming and
generation principle and construction of gear milling, hobbing and gear
shaping processes –finishing of gears.

Dr.AR - SEC 2
 BOOKS REFERRED
1. Hajra Choudhury, "Elements of Workshop Technology", Vol. II.,
Media Promoters.
2. Rao. P.N “Manufacturing Technology - Metal Cutting and Machine
Tools", Tata McGraw-Hill, New Delhi, 2003.
3. HMT, "Production Technology", Tata McGraw Hill, 1998.
4. Geofrey Boothroyd, "Fundamentals of Metal Machining and
Machine Tools", Mc Graw Hill, 1984.

Dr.AR - SEC 3
 SHAPER

1. A shaping machine is a reciprocating type of machine tool used for

producing flat surfaces in horizontal, vertical or angular planes on
small to medium sized workpieces.
2. It is also used for machining convex and concave surfaces, for key-
way cutting, slotting and grooving etc.
3. In shaper, the work is held on machine table and then ram carrying
the tool moves forward and backward over it during the cutting
action in reciprocating motion.
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 SHAPER

1. As each chip is cut-off, ram and tool return to the end of the stroke,
and the work is positioned for another cut.
2. This involves moving the table horizontally by an amount equal to
one chip thickness so that work is ready for the next cutting stroke.
3. The machining is performed during the forward stroke only and the
return stroke is idle.

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 PARTS OF A SHAPER – Base

1. The base is the necessary bed or support required for all machine
tools.
2. The base may be rigidly bolted to the floor of the shop or on the
bench according to the size of the machine.
3. It is so designed that it can take up the entire load of the machine and
the forces set up by the cutting tool over the work.
4. It is made of cast iron to resist vibration and take up high
compressive load.
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 Dr.AR - SEC

PARTS OF A SHAPER

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 PARTS OF A SHAPER – Column

1. The column is a box like casting mounted upon the base.

2. It encloses the ram driving mechanism.
3. Two accurately machine guideways are provided on the top of the
column on which the ram reciprocates.
4. The front vertical face of the column which serves as the guideways
for the crossrail is also accurately machined.
5. The lid on the left side of the column may be opened for inspection
and oiling of the internal mechanism housed within the column.
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 PARTS OF A SHAPER – Crossrail

1. The crossrail is mounted on the front vertical guideways of the

column.
2. It has two parallel guideways on its top in the vertical plane that are
perpendicular to the ram axis.
3. The table may be raised or lowered to accommodate different sizes
of jobs by rotating an elevating screw which causes the crossrail to
slide up and down on the vertical face of the column.
4. A horizontal cross feed screw fitted within the crossrail actuates the
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table to move in a crosswise direction. Dr.AR - SEC
 PARTS OF A SHAPER – Saddle &
Table
1. The saddle is mounted on the crossrail which holds the table firmly
on its top. Crosswise movement of the saddle by rotating the cross
feed screw by hand or power causes the table to move sideways.
2. The table which is bolted to the saddle receives crosswise and
vertical movement form the saddle and crossrail.
3. Table is a box like casting having T-slots both on the top and sides
for clamping the work.
4. In universal shaper the table may be swiveled on a horizontal axis
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and upper part of the table may be titled up and down. Dr.AR - SEC
 PARTS OF A SHAPER – Ram

1. The ram is the reciprocating member of the shaper.

2. This is semi-cylindrical in form and heavily ribbed inside to make it
more rigid.
3. It slides on the accurately machined dovetail guideways on the top of
the column and is connected to the reciprocating mechanism
contained within the column.
4. It houses a screwed shaft for altering the position of the ram with
respect to the work and holds the tool head at the extreme forward
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end. Dr.AR - SEC
 PARTS OF A SHAPER – Toolhead

1. The toolhead of the shaper holds the tool rigidly, provides vertical
and angular feed movement of the tool and allows the tool to have an
automatic relief during its return stroke.
2. The vertical slide of the toolhead has a swivel base which is held on
a circular seat on the ram.
3. The swivel base is graduated in degrees, so that the vertical slide
may be set perpendicular to the work surface or at any desired angle.
4. By rotating the down feed screw handle, the vertical slide carrying
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the tool gives down feed or angular feed movement. Dr.AR - SEC
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 PARTS OF A SHAPER – Toolhead

1. Apron consists of clapper box, clapper block and tool post is

clamped upon the vertical slide by a screw.
2. By releasing the clamping screw, the apron may be swiveled upon
the apron swivel pin either towards left or towards right with respect
to the vertical slide.
3. The two vertical walls on the apron called clapper box houses the
clapper block which is connected to it by means of a hinge pin.
4. The tool post is mounted upon the clapper block.
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 SIZE AND SPECIFICATION OF
SHAPER
1. The size of shaper is given by its maximum stroke length (175 mm to
900 mm) or maximum length of cut it can make.
2. shaper is specified by:
1. Type of drive 6. Type of feed (manual or power
2. Type of speed reduction feed)
3. Power input 7. Total floor space required
4. Cutting to return stroke ratio 8. Weight of the shaper.
5. Number and amount of feeds 9. Maximum movement of table,
tool etc. 15
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 CLASSIFICATION OF SHAPER

1. According to the type of mechanism used for giving reciprocating

motion to the ram.
(a) Crank type (b) Geared type (c) Hydraulic Type
1. According to the position and travel of ram
(a) Horizontal type (b) Vertical type (c) Travelling head type
1. According to the type of design of the table
(a) Standard shaper(b) Universal shaper
1. According to the type of cutting stroke
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(a) Push type (b) Draw type Dr.AR - SEC
 CLASSIFICATION OF SHAPER –
Crank Type
1. This is the most common type of shaper
2. In this, a single point cutting tool is given a reciprocating motion
equal to the length of stroke desired and the work is clamped on the
table.
3. The crank shaper employs a crank mechanism for converting a
circular motion of a large gear, called as a bull gear to reciprocating
motion of the ram.
4. The bull gear receives power from individual motor.
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 CLASSIFICATION OF SHAPER –
Geared shaper
1. In this shaper, the circular motion of an electric motor is converted
into reciprocating motion of the ram by means of a rack and pinion.
2. The rack teeth, which are cut directly below the ram, mesh with a
spur gear.
3. The pinion meshing with the rack is driven by gear train.
4. This type of shaper is not widely used.

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 CLASSIFICATION OF SHAPER –
Hydraulic shaper
1. In hydraulic shaper, reciprocating movement of the ram is obtained
by the hydraulic power.
2. Oil under high pressure is pumped into the operating cylinder fitted
with piston.
3. It first acts on one side of the piston and then on the other, causing
the piston to reciprocate and the motion of the piston is transmitted to
the ram.
4. The piston speed is changed by varying the amount of liquid
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delivered by the pump. Dr.AR - SEC
 CLASSIFICATION OF SHAPER –
Horizontal and Vertical shaper
1. In horizontal shaper, the ram reciprocates in horizontal plane.
Usually a plain table is provided in these shapers and are mainly used
to produce flat surfaces.
2. Vertical shaper has its ram reciprocating in vertical direction and has
the table of circular rotary type.
3. The ram of vertical shaper, in addition to vertical movement, can
also be adjusted from its vertical position to about 10° on either side.
4. The work table can be given cross, longitudinal and rotary movement
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5. Used for machining internal surface, key-ways, slots. Dr.AR - SEC
 CLASSIFICATION OF SHAPER –
Travelling head type
1. It is a specially designed shaper.
2. The ram carrying the tool, while it reciprocates moves crosswise to
give the required feed.
3. Heavy and large workpieces which cannot be held on the table are
loaded on the base or floor and then machined.

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 CLASSIFICATION OF SHAPER –
Universal shaper
1. In universal shaper, in addition to the two movements provided on a
table, the table can be swivelled about an axis parallel to the ram
ways.
2. The upper portion of the table can be titled about a second horizontal
axis perpendicular to the first axis.
3. This shaper is used in tool room work.

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 CLASSIFICATION OF SHAPER –
Push and Draw type shaper
1. In Push type shaper, metal is removed when the ram moves away
from the column.
2. In Draw type shaper, the metal is removed when the ram moves
towards the column of the machine.
3. In draw type shaper, cutting pressure acts towards the column which
relieves the cross rail and other bearings from excessive loading.

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 SHAPER MECHANISM

1. In a shaper, rotary movement of the drive is converted into

reciprocating movement by the mechanism contained within the
column of the machine.
2. The ram holding the tool gets the reciprocating movement.
3. In a standard shaper metal is removed in the forward cutting stroke,
while the return stroke gets idle and no metal is removed during this
period.
4. To reduce the total machining time it is necessary to reduce the time
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taken by the return stroke. Dr.AR - SEC
 Dr.AR - SEC

SHAPER MECHANISM

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 SHAPER MECHANISM

1. Thus the shaper mechanism should be designed that it can allow the
ram holding the tool to move at a comparatively slower speed during
the forward cutting stroke
2. During the return stroke the mechanism can allow the ram to move at
a faster rate to reduce the idle return time.
3. This mechanism is known as quick return mechanism.
1. Crank and slotted link mechanism.
2. Whitworth quick return mechanism.
3. Hydraulic shaper mechanism. Dr.AR - SEC
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 CRANK AND SLOTTED LINK
MECHANISM
1. The crank AB rotates about the fixed centre A, the end B having the
form of a sliding block which fits the slot in the link CD.
2. As B rotates about A, it slides up and down in link CD and causes
this to oscillate about the centre C (pivot point of slotted link) so that
as CD oscillates the ram is operated backwards and forwards.
3. When the link in the position CD1 tangential to the pitch circle of B,
the ram will be at extreme backward position of its stroke and when
it is at D2, the extreme forward position of the stroke will have been
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reached. Dr.AR - SEC
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 CRANK AND SLOTTED LINK
MECHANISM
1. The time taken by cutting and idle stroke of the ram is proportional
to the angles B2KB1 and B2LB1 respectively.
2. The ratio between cutting time and idle time may be determined
from the formula

3. The cutting speed and return speed is not constant through out the
stroke, which is minimum when rocker arm is at the two extremities
and speed is maximum when the rocker arm is vertical.
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 CRANK AND SLOTTED LINK
MECHANISM
Adjustment of the length of stroke
1. The length of the stroke can be varied by changing the distance
between bull gear centre and centre of the crank pin.
2. As the bull gear is fixed, the variation in the distance is achieved by
moving the slide block and crank pin away or towards the bull gear
center.
3. The sliding block can be moved by rotating the bevel gear and
turning the spindle, which rotates the adjusting lead screw and moves
the sliding block mounted on it. 30
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 CRANK AND SLOTTED LINK
MECHANISM
Adjustment the position of the ram
1. The position of the ram is adjusted by first keeping the hand wheel
tight and moving the ram back to extreme rear position.
2. Then hand wheel is released and slide the ram to the required
position.
3. With the help of clamping lever this position of ram is get fixed.

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 WHITWORTH QUICK RETURN
MECHANISM
1. In the whitworth quick return mechanism, driving crank 3 rotates in
clockwise direction with uniform angular speed.
2. The slider C which is attached at the end of driving link also
reciprocates in slotted link 1 and cause to oscillate the slotted link 1
about pivot B.
3. The link 5 is attached at the end of slotted link 1 which carries the
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ram and tool.
4. When the driving crank moves from position ac’’ to ac’ through an
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angle ϕ in clockwise direction, tool moves back from f’ to f’’.
 WHITWORTH QUICK RETURN
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MECHANISM

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 WHITWORTH QUICK RETURN
MECHANISM
1. Thus the angle turned by driving crank i.e. θ will be for cutting
stroke and return stroke will be for angle ϕ or (360° - θ).
2. Since driving link 3 rotates at uniform angular speed, the ratio of
cutting stroke to return stroke time will be given by,

3. As θ is always greater than 180°, therefore the ratio is always

greater than 1.
4. Hence time required for cutting stroke is greater then return stroke.
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 HYDRAULIC MECHANISM

1. The shaper ram moves from left to right.

2. The oil from the reservoir is drawn through the filter by a gear pump
which is driven by an electric motor.
3. Pump delivers a constant quantity of oil to the control valve and from
control valve, the oil can be delivered to the either side of the piston
in the cylinder situated under the ram.
4. To which side of the piston the oil will be delivered is determined by
the position of the control lever of the control valve.
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HYDRAULIC MECHANISM

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 HYDRAULIC MECHANISM

1. The same volume of oil is delivered on both sides of the piston, but
the intensity of pressure is different due to difference in effective
area of the piston.
2. Due to difference in pressure, the ram travels at a faster rate in the
return stroke than in the forward stroke.
3. The stroke length of the ram is adjusted by adjusting the distance
between the two stops.
4. The cutting speed is controlled by using the throttle valve during the
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cutting stroke. Dr.AR - SEC
 HYDRAULIC MECHANISM –
Advantages
1. Large range of cutting speeds are available.
2. Control of cutting speed is easy.
3. Due to oil present on both sides of the piston, there is smooth and
quick reversal of ram.
4. Because of high speed, there is saving in machining time.
5. Higher safety is provided to the machine and cutting tool.

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 FEED MECHANISM IN SHAPER

1. In shaper, both down feed and cross feed movements are provided
intermittently during the end of return stroke only.
2. Vertical or bevel surfaces are produced by rotating the down feed
screw of the tool head by hand.
3. Cross feed movement is given by rotating the cross feed screw either
by hand or power.
4. Rotation of cross feed screw causes the table to move sideways.
5. Automatic cross feed of the table is obtained by a Ratchet and Pawl
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mechanism. Dr.AR - SEC
FEED MECHANISM IN SHAPER

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 FEED MECHANISM IN SHAPER

1. It consists of a slotted disc which carries T-slot which is rotated by a

bull gear of the shaper.
2. In this T-slot an adjustable pin is fitted and to this connecting rod is
attached.
3. The other end of the connecting rod is attached to the lower end of
the rocker arm of the Pawl mechanism.
4. The rocker arm swings about the fulcrum and at its upper end carries
a spring loaded pawl.
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 FEED MECHANISM IN SHAPER

1. Adjustable pin is set eccentric with the slotted disc centre.

2. The slotted disc at its back carries a spur gear which is driven by a
bull gear.
3. As disc rotates, the adjustable pin being eccentric with the disc
centre, causes the connecting rod to reciprocate.
4. This in turn, makes the rocker arm to swing about the fulcrum, to
move the pawl over one or more teeth and thus transmit an
intermittent motion to the cross feed screw which moves the table.
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 FEED MECHANISM IN SHAPER

1. As the lower end of the pawl is beveled on one side, it facilitates the
power fed to operate in either direction.
2. To reverse the direction of rotation of ratchet wheel and
consequently the feed, a knob on the top of the pawl after removing
the pin is rotated through 180°.
3. The amount of feed may be altered by shifting the position of crank
pin with respect to the centre of dividing disc.
4. Greater the throw of eccentricity, more will be the rocking
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movement of the rocker arm. Dr.AR - SEC
 SHAPER – Advantages

1. Shaping machines requires less time for process setup.

2. Shaping process has higher production rate.
3. Shaping machine employs a quick return mechanism to minimize
idle time.
4. It uses relatively inexpensive tools.
5. It is suitable for light duty operations.

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 SHAPER – Disadvantages

1. The cost of machining is higher than milling or broaching.

2. Due to higher cost it confines to the small quantity production.
3. It is not suitable for machining of large parts.
4. It can not be used for heavy duty operations.
5. It can not be employed with heavy cuts and coarse feed.
6. It has less accuracy and rigidity than planer.

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 SHAPER OPERATIONS

1. The different operations which can be performed on shaping machine

are:
1. Machining horizontal surface
2. Machining vertical surface
3. Machining angular surface
4. Machining a V or Keyway curved surface
5. Cutting splines or gears.

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 SHAPER OPERATIONS – Machining
Horizontal Surfaces
1. Set the vice jaws length perpendicular to the ram movement.
2. Hold the job length-vise parallel to the tool stroke so that maximum
stroke of the tool may be utilized.
3. Adjust cutting speed and feed depending upon required surface finish.
4. Hold the appropriate tool in the tool head with proper inclination.
5. Give cross feed to the tool initially by hand till the cut start and then
employ power feed.
6. After the tool has cut the full width of the job, stop the shaper, inspect
the job and set the another depth of cut. 47
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 SHAPER OPERATIONS – Machining
Vertical Surfaces
1. The tool is fed downwards in vertical cutting as swivel the apron
from the face of the work to be cut.
2. The tool is fed downwards by rotating the down feed screw by hand
at the end of return stroke. Give the feed about 0.25 mm.
3. On the return stoke, the tool wings away from the work and gives
clearance which prevents the work from being scored.
4. Start cutting form highest point towards the bottom.

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 SHAPER OPERATIONS – Machining
Angular Surfaces
1. Set the swivel hand to the required angle for shaping angular faces.
2. The apron is to be swung away from the face to be machined.
3. The tool is to be fed by the slide hand wheel.
4. The tool head is also swivelled in the direction away form the surface to
be machined.
5. Feed the tool during return stroke.
6. Repeat the procedure to finish the work.

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 SHAPER OPERATIONS – Machining
Keyways and Grooves
1. For shaping grooves, slots and keyways, a square nose tool similar to
the lathe paring tool is to be used.
2. Fix the tool in tool head rigidly.
3. Avoid excessive overhung and ensure that the tool clearances are not
so great as to weaken the tool.
4. Start the machine and give feed during return stroke.
5. Repeat the cut till the end of the operation

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 SHAPER OPERATIONS – Cutting
Splines or Gears
1. Hold the workpiece between the centers.
2. Use index head for cutting equally spaced splines and gear teeth.
3. Cut the first spline or gear tooth on the workpiece exactly in the way,
a keyway is cut.
4. Rotate the workpiece by the required amount using the index plate.
5. Lock the index plate by engaging index pin with corresponding hole
in the circumference of the index plate. Cut the second spline.
6. Repeat the procedure, till the splines or gear teeth have been cut on
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the whole circumference of the work piece. Dr.AR - SEC
 SHAPER TOOLS - Types

1. According to the shape : Straight, cranked, goose neck, etc.

2. According to the cutting direction : Left hand and right hand.
3. According to the operations : Down cutting, side recessing, parting off,
etc.
4. According to the degree of finish : Roughing and finishing.
5. According to the shape of cutting edge : Round nose and square nose.

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 MILLING MACHINES - Types

1. Column and knee type milling machines :

1. Hand milling machine
2. Plain or horizontal milling machine
3. Vertical milling machine
4. Universal milling machine
5. Omniversal milling machine.

2. Planer type milling machines

3. Production milling machines :
1. Rotary table or continuous type milling machine
2. Drum type milling machine
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3. Tracer controlled milling machine. Dr.AR - SEC
 MILLING MACHINES - Types

1. Fixed bed or manufacturing type milling machines :

1. Plain type milling machine (having single horizontal spindle)
2. Duplex head milling machine (having double horizontal spindles)
3. Triplex head milling machine (having two horizontal and one vertical spindle)
4. Rise and fall type milling machine (for profile milling).

2. Special purpose milling machines :

1. Thread milling machine
2. Profile milling machine
3. Cam milling machine
4. Gear milling or gear hobbing machine
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5. Planetary milling machine. Dr.AR - SEC
 COLUMN AND KNEE TYPE MILLING
MACHINES – Plain or Horizontal Milling machine

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COLUMN AND KNEE TYPE MILLING
MACHINES – Vertical Milling machine

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 COLUMN AND KNEE TYPE MILLING
MACHINES – Vertical Milling machine with
Swiveling head

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 COLUMN AND KNEE TYPE MILLING
MACHINES – Universal Milling machine

1. Universal milling machine is similar to horizontal milling machine,

except that the table can be given one more additional movement.
2. Its table can be swivelled in a horizontal plane and for this purpose
circular guideways are provided on the saddle.
3. To read the angle of swivelling, a graduated circular base is provided
under the table with datum mark on the saddle.
4. Hence, workpiece can be set at an angle with the cutter for milling
helical and spiral flutes and grooves.
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Plain vs. Universal Milling Machines

Sl. No Plain Milling machine Universal Milling machine

In this, the table can be fed in Table can be given one more
three directions i.e. longitudinal, additional movement (Table can be
1
cross and vertical. swivelled on the saddle in horizontal
plane).
It is more rigid and consists of It is less rigid than the plain milling
2
heavier construction. machine.
For helical milling, spiral milling Helical milling and cam milling can be
3
attachment is required. performed without any attachment.
This machine is used only for This machine is mostly used in 61
tool
4 Dr.AR - SEC
 OMNIVERSAL MILLING
MACHINE
1. Omniversal milling machine is a modified form of a plain milling
machine, provided with two spindles, out of which one is horizontal
and other is carried by a universal swivelling head.
2. The latter can be fixed in vertical position or can be set at any required
angle up to 90º on both the sides of vertical.
3. special feature of this machine is that, it carries two more adjustments
in addition to all the adjustments provided in a universal machine.
4. Its knee can be swivelled about a horizontal axis to tilt the table and
can be moved horizontally also, useful for Tool room work. 62
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 MILLING – Work holding devices

1. For effective machining operations, it is necessary that the workpiece

should be properly and securely held on the milling machine table.
2. Following are the general method of holding the workpiece on the
table :
1. T-bolts and clamps
2. Angle plates
3. V-blocks
4. Vices.

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 MILLING CUTTERS

1. The milling cutters may have straight teeth i.e. parallel to the rotation
axis or in helical shape.
2. The angle of helix may be right hand or left hand which will decide
the direction of rotation of the cutter for cutting operation.
3. A milling cutter may be made of single piece of steel or having
cutting teeth inserted in a solid body.
4. Milling cutters are classified as: plain milling cutters, side milling
cutters, metal slitting cutters, end milling cutters, T-slot milling
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cutters, angle milling, cutters, formed milling cutters. Dr.AR - SEC
 MILLING CUTTERS

1. Plain milling cutters : 3. Metal slitting cutters :

1. Light duty cutters 1. Plain cutters
2. Heavy duty cutters 2. Staggered teeth cutters
3. Helical cutters 4. 4. End milling cutters :
2. Side milling cutters : 1. Taper shank cutters
1. Plain cutters 2. Straight shank cutters
2. Staggered teeth cutters 3. Shell cutters
3. Half cutters 5. T-slot milling cutters
4. Interlocking cutters
6. Woodruff key slot milling
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cutters Dr.AR - SEC
 MILLING CUTTERS

8. Angle milling cutters 10. Tap and reamer cutters

1. Single angle cutters
2. Double angle cutters

9. Formed milling cutters

1. Convex milling cutters
2. Concave milling cutters
3. Corner rounding milling cutters
4. Gear cutters
5. Thread milling cutters
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 METHODS OF MILLING

1. Following two methods are commonly used for performing this

operation by using cylindrical cutters

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Comparison of Up and Down milling

Sl. No Up Milling Down Milling

The cutter is rotated against the The cutter rotates in the same direction
1 direction of travel of workpiece of travel of the workpiece.

The chip thickness is minimum at The chip thickness is maximum at the

the beginning of the cut and beginning of the cut and or reduces to
2
reaches to maximum when the cut minimum when the cut terminates
terminates.
The cutting force is zero at the Cutting force is maximum when the
3 beginning of the cut and cut begins and it reduces to minimum
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maximum at the end of the cut. when the tooth leaves the Dr.AR
work. - SEC
Sl. No Up Milling Down Milling
The cutting force is directed The cutting force is downwards which
4 upwards and this tends to lift the tends to seat the workpiece firmly in
workpiece from the fixture. the fixture.
Difficulty in pouring the coolant The coolant can be poured directly at

5 just on the cutting edge, due to the cutting zone where cutting force is
typical nature of the cut. maximum.

Chips accumulate at cutting zone Chips are disposed off easily and do
6 and may be carried over with not interfere with the cutting.
cutter spoiling the work surface.
The actual cutting does not start at Improved surface finish is obtained.
zero chip thickness as teeth slide
7
through a minute distance which
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gives a slightly wavy surface. Dr.AR - SEC
 MILLING OPERATIONS

1. Plain or slab milling 10. Side milling

2. Face milling 11. End milling
3. Angular milling 12. Profile milling
4. Form milling 13. Gear milling
5. Straddle milling 14. Thread milling
6. Gang milling 15. Helical milling
7. Slot and groove milling 16. Cam milling
8. Keyway milling
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9. Slitting or saw milling Dr.AR - SEC
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 DIVIDING OR INDEXING HEAD

1. The dividing head is a mechanical device used to divide the

circumference or periphery of a job into a specified distance or
angular separations.
2. It is also used to hold the workpiece securely.
3. The dividing head rotates the workpiece through a certain number of
degrees or a certain fraction part of a complete circle for graduating
the part. This operation is called as indexing.
4. Types are (a) Plain dividing head (b) Universal dividing head (c)
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Optical dividing head Dr.AR - SEC
 PLAIN INDEXING HEAD

1. There are two types of plain dividing head.

2. The first type carries an indexing plate directly mounted on its
spindle and there is no use of worm and worm wheel.
3. The index plate carries 12 to 24 equi-spaced slots on its periphery.
4. The plate, together with the spindle can be rotated by means of the
hand i.e. provided on the left side of the dividing head.
5. In the second type second type of plain dividing head worm and
worm wheel are used. In this, the index plate movement is obtained
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due to worm, which is rotated by handle. . Dr.AR - SEC
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 UNIVERSAL INDEXING HEAD

1. For indexing the workpiece, this type of dividing head is very useful.
2. It consists of robust body and worm drive is enclosed in it, which is
having worm and worm wheel.
3. In this, the dividing head spindle carries a worm wheel, which
meshes with the worm.
4. The worm carries a crank at its outer end.
5. The index pin works inside the spring loaded plunger, which can
slide radially along a slot provided in the crank.
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 UNIVERSAL INDEXING HEAD

1. This plunger can slide, to adjust the pin position along a desired hole
circle on the index plate.
2. Index plate is mounted on the same spindle as crank, but on a sleeve,
hence crank and worm spindle can move independent on index plate.
3. To set a definite distance along a desired hole circle, sector arms are
used.
4. Sector arms are of detachable type and can be set at a desired angle
with one another. The index plates are available in a set of two or
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three, with a number of hole circles generally on both sides on them
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 UNIVERSAL INDEXING HEAD

1. The universal head is used to perform following operations :

1. To set the workpiece in a desired position, in relation to the machine
table.
2. To rotate the workpiece through a desired angle, after each cut and
hence, index the periphery of the workpiece.
3. To provide, a continuous rotary motion to the workpiece while milling
of helical grooves.

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 METHODS OF INDEXING

1. Indexing is defined as division of the job periphery into a desired

number of equal divisions, followed by a controlled movement of the
crank, workpiece rotates through definite angle after each cut is over.
2. The different methods of indexing are as follows :
1. Direct indexing
2. Simple or plain indexing
3. Compound indexing
4. Differential indexing
5. Angular indexing. 88
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 DRILLING, REAMING, BORING
AND TAPPING
1. Drilling is an operation through which holes are produced in a solid
metal by using a revolving tool which is called as drill.
2. With the help of drilling operation, perfectly true holes are not
produced hence it is also considered as a roughing operation.
3. Therefore, for accurate holes, drilling is followed by another operation
which is called as reaming.
4. In reaming operation, a multi-tooth revolving tool (REAMER) is used
to achieve required dimensional accuracy and fine surface finish
5. For enlarging an existing hole size, boring operation is done. 89
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 CLASSIFICATION OF DRILLS

1. According to the type of shank : 4. According to the applications :

1. Parallel shank 1. Core drills
2. Taper shank 2. Centre drills

2. According to the type of flutes : 3. Masonary drills

1. Flat drills 5. According to the material of

2. Twist drills tool :
3. According to length of drill : 1. High speed steel drills
1. Short series drills 2. Carbide tipped drills
2. Stub series drills
3. Long series drills 90
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TYPES OF DRILLING MACHINES

1. Portable drilling machine 1. Radial drilling machine

2. Sensitive drilling machine 1. Plain machine

1. Bench mounting machine 2. Universal machine

2. Floor mounting machine 3. Semi-universal machine

3. Upright drilling machine 2. Gang drilling machine

1. Round column machine 3. Multiple spindle drilling
2. Box column machine machine
4. Deep hole drilling machine 4. Automatic drilling machine
1. Vertical machine
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2. Horizontal machine Dr.AR - SEC
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 Gang Drilling vs. Multi-spindle
Drilling machine
Sl. No Multi-spindle Drilling Gang Drilling Machine
Two or more spindles are driven Series of single spindle drilling heads
1 from a common driving shaft by a driven by separate driving motors are
single motor. mounted on a common base/long table.
Number of holes are produced Number of drilling operations are
simultaneously as all the spindles performed in certain sequence, hence
2
are fed at the same time. the component moves from one
drilling head to the next.
All spindles are fed at the same Speeds and feeds of the spindle are
3
time. controlled independently. 94
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 Gang Drilling vs. Multi-spindle
Drilling machine
Sl. No Multi-spindle Drilling Gang Drilling Machine
The drill head has fixed tools. Each drill head is equipped with
4
different tools.

Feeding motion is obtained by Feed is normally given by lowering the

raising the table and eliminating drill head.
5
the movement of heavy geared
drill head.
As the number of spindles are Generally drill jigs are not used.
6
more, drill jigs can be used.
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 DRILLING MACHINE
OPERATIONS
1. Drilling 9. Grinding
2. Reaming 10. Trepanning
3. Boring
4. Counter-boring
5. Counter-sinking
6. Spot facing
7. Tapping
8. Lapping
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THANK YOU

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