Machine Shop Practice 2nd Edition

PracricalTask I ' Proied

Studenl Name & Malr. No

1)
2)
3)

E MEEE mEEr@

,,,1 rt -I
t-f -= I

tr -+1,,, rt--ITT--I- T I
k-;bLAu"h
- II
ji IIt,..".,t,h"d,",,,0D..
+/4
I

I

H-=L

I

aPractical Task 2 - Report !

rr e Goverasisnmert brue.oour) I

tathe Ma.hine,. *sli.at on and dhgmm.

u! neeooele whieoieates the m..hine

Ea.h neporworkshould he ncrudedwth dngram5/
Mun berhe dGwrhe proiedwrhAuto.ad
srudent ab e toop-qra5 rarha m&h,ie

E!;-!it E! : !!F t!6j!I
iE: !
r! crHis*E;g :!gt ;E
E

i!t!!r

E; i! YE ;; E:P ,
i!i:iEHi :i3!il
t 12 gi

i*"!: !;

33

E P Ei :.E

? i2 T3 !iEza:.:, gr ri, ;,ji :
-ist €:
i!E::g ;E!i :n

i;e !cP: E! is ,

; i: E-a i6g

?e

',..: iiE :; p: i"r!1l

; flnE ! j!_:i: E it! !:;E E q*

fl: f

€

E E5g!:! E
s a€ a-:
9 aii? t pt
!;.i-lF::E-i:;a-
:;E .g e

3E2 If il IIil

Til

I

Pradi..lTask-Gen€ricskilk lLpsl

tt ,ii.iii il ii!!:i .1i !:i.i ir ill;
!r
ti i.! il rN!iil; =Er !iir i*rli:t Eii

li i i!! i!ti t:i ili ii;i:

| ;! Ii l.iiil ilir ii!!ri:!!, i" i!!l i,ii!: tu,it iii;iir ?iiri.
iili!r ,:ii iittcc iiiii.!:tE: i
lI iE!:i: i:!tg: tt:;,t irli: :!E;

::i-E

li !t ii, ,iii; i- li !r E leii! ii; i
ti t: i:t!
ii: {!iitEr!E:i:ili!<i ii i, :i;: ii:;1::i
Ei;i
!ig! iiq!

liE ![! ii ;"=piitit t rii!:$: i isi I: ;31i;i::t9ii
!!i;! I
.E ?i!!5:i" iii r; ,i:::! iii!liii ::i9i

3 riii? ;t;ii

: !E l,fii i r!, ! ii
s ii E: E"9i I I !Eii;;E!l
;i E i.=_ itt .i?:.:ii t"!.;!a!;i"i !:Ir
li itEEr::l liii!, ! E
Eilr ii! t:i
sEr ii g
= i.
:i
iri3!i !qr ::rlri tH:i iI ! ;i3r tI Ei r;,t!i
iltEiil
:E! 1E 9!

in, !E 1! !: iti E i!: !i!ii;iiriii i!.

!;; fiEi :i:!i! !5;i: !E5l

I I Ii E u ii i: I

3 r !i

r !; 1i i!T: .:E

II ! I

I !I

!

_ ii- ,;

'L ; ia

I 3 lr
,]
Ir
il1il

I

$rork s genera ly machined on a hthe fortwo rcason:to.utlttoszeand
to produ.e a t.ue dameter work that must be.ul to rDe and have the same
dameler aons the entre leneth ot the workpece .volves th€ operaton of

I-I;;,"

I

Trrftri Eft, the Ed iraletErs

Fisure3 4, Paralle Turn ng

II

Fsure35 SteppedTurning

tid"o.;r.i.l*lo"ln.r."mas'ba.ohd*riofi,fnbe.s;,etnon;oterdler*,ee.nt"rd"ttOeo*u6"r,te,ehtn,"es.uaw,,rr.co.sher"ktrohpao'esiendon.seera'pmpsad,exlolat^eaB''lpovo(aero'.n6nb'd,atBa'chiiunat(sbmommaetoeofrdl6neog'n'poianrv^P!dio'irkni'"etohe-nord"ntl'modar"luesPdnEusr'df'loar"[ht^cdPsae'

Boring Machining

. Boring - cuttinq is done inside diameter of the work

Horizomal aoirng f4achining .

v€rticd sonno Machininq

F eure 3-6 : soring Pro.e$

t #I, J ti tE

\

7F gure 3 cutt ngloolN,liling Mach n€

Shoulder milling Groovrng Ranpina

Wide aoplication only by one tool

E

Pocket milling Drilling Helical milling

F gure 3.3: Miling Mach np Pro.e$

Grooves are miled re.e*er ln wo.kpie.es whi.h may have various

ceometricalshapes(prismat c, rotationa lysymmetri.a )and sDes.we disungu sh
berwe.n the folowin8 kindr ofgrooves:

' tooth{haped srooves kur et and .hip sroover).

Grooves are made wth dlferent ar.u/a.y specficarlons a(.ordiis ro ther

applicalion. 6rooves tor receiving oble.is or transmiuing torques (fitlnA key

not/rittns key, dsk key novdGk key or T sotltoncues) are made wth sma

to erances lpermissible deviationrrrotr tha s ze)aslitt nsste(e c.2oH?)
ns sizes sha lb€ lake^onmfrionma
The toleran.es for ftt conespondine standatus or

o of1)

oo@

fisure 3.9: Miline ofG.ooves

Spur Gear

Spur gears arc thc osr commonly uscd ged $!c. Thcy arc

characterized by tc.lh which a.e perpendiculrro rhe bceoflhe
geAr- Spurgcars are by l.rthe nosl comftonty ilailable. and
arc gcne lly the lcast cxpensivc.
iTcelh is parallel ro a'(isofrotado,
tTranshil powcr from one shail lo anorhcr parallclsiaR

Applications of Spur Gear

In mechanicnl systcms $hcrc wc ll rcqnirc simplr dcsign, more

cllcienr powcr rmnsfcr, and loN spccd applicarions whc.e

noisc docs no! maitcr. wc should 80 for spu gcars.
Spurgears have a $idc ransc ofapplications. Thcy are uscd inl

i Mclal c$tling machires > Gcar morors and Bcar

> M cchinic.l clocks and

> WashinA Machines > Aubmobilu lcarboxcs

> Sleci milh

> Rollingmills

FiEore 3 11 : App i.atiois Of Spur Gear

SPUR GEAR

diectio .h@8. is reqnn.d.

FiSure 3 12 : Advanbses& Disadvantages Of Spur Gear

Differential Indexing

Used when 40/N cannot be reduced to a
factor of one of the available hole circles
lndex plate must be revolved either
forward or backward part of a turn while
index crank turned to attain proper
spacing (indexing)

' Change of rotation effected by idler gear or
gears in gear train

F eure 313: ndexin€ ol Gear

Example:

Calcuiate the indexing and change gears required
ior 57 divisions. The change gears supplied with

the divid nq l-eao are as iorlows:. .

24 24 2a. 32. 40. M . 48, 56 64, 72, 86

the available index plate hole circies are as lollows
Plale 1: L5. 16, 17 '8. 19.20

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

Plate 3: 37, 39, 41. 43. 47. 49
40540 40
Choose plale 2: 21 holes
lndexing
N57 567 5/7 would be I5 holes

No 57 hole circle so selecl on 21-hole circle ]
number close lo 57

F gure 3-14: Example Ca.u ation lndexing ofGear

Pra.tl.a Task(r) PLo4,ct01
PradicarTask (ce^ericski s )(tD3) plo3, cro2

mMakea project usinE.onventona larhe, verticatand univeGa ng

mach ner. Followthe fo low ng pro.esser:

! 5etsu tabespeedandtransm $tonrorvartour ma.hinin€proceser.
! Perform dnect indexineoperet on to produ.e spurgear.
. Perform suda.e grndine proce$ to srnd a fat surface.
. Folow safety p.ocedureswhen opeGtin8 mach nes

Pradical Task 1 ' Proied 1

Studpnt Name & Man'. No :

1)
2)

r)

EffiE E E@EEq tEH*ir

t{5tri

IL!L IIIIII III III
s"l"ryi --- l

Gr"NG;;a

I III

:l I II I II
-I II
F F I II II I-

l3? II

3L Gea, ( te.sth ,o m.,

ReeodtRde t. @pon (ieha/ile a

=

rE



I

E!!!4

rne{rovera$iAnmenr bluecorou.

in3 Ma.h'i.9purcear .ra$dchon:ndd as am
sdd:.e6rndinsMrh,rs,drrh. onandd,asram

Us nB Boosle wh l.operate5 rhe ma.h ne

nepofworkrhortd be mduded wrh d aBGm!/
M6r b€ thedraw the prored wnh Auro.id

Meer rhe needs of tha obiedives

sudentabre ro opec'E tdrhe marh'ie
comme on!aretyprc.ed!r€s

! 3!

E ! -3 3 €€ E! i !!
iE
?p0 g !ii t

RR 25- c *E !t !:> ::P qi

i! i!. EIEi ii I

!gE; E+g

iE:.

I *€ 2E6i TE E" r I t
2 ;e
i5i!;, :t g
i:s3

:3,EEZPB..' :! F.'.

TP *:E: E3 7
EE, E3
;!:;'{is !:p: ?6F!

t ;E!I 8 E !;

e-!

;5q gr !.!

FP !;!B E

;3 z

,EO

igi

- 'e; ! ET;.Bi gi! -!i

;+ F :g E:Eg iE

EIil[I ia lil

Pr.dical Task-Geherk skilG lLDSl

:1.! ;::!tlt ,:i -li :l .ir .!
iE5,
izitt!iiiir i!i i;!iEiri ii:il
?!l E !!ii !!: i!l!
i;i ii

t ;l !rl ;r!r" r !! i55 .ii i
it:i
iEii 5 trl iilEi iiiii i!ri taail!!ri iiiriE I iiilir

It!i i{'!E:! iir" ;iiiE tiii F !:: !qt

l..Ei ii: E :ii, -i. !iii!: i!r !r! i;tiii ii3i
i!Ei!iiI-l:
r!?i iltii: !i:!:1 iri= it!i
ii:iit iEii:

! Itiir!ti - i,li --i ;{! c: !* ati Iei!.itil ii:t:cii!i;t i!iE
9!ii ilr ri ?9i, !tii
!i!! ,El i( iiui iil r iEilE,
E
rii i!!ti
!
!rl , iF. i
it; r:!i t, 'E .iiaE iir !i :r
?.ii liE iiriiE !lliiili
i:. ;iir:iiil
tli! I rEl
tE: i iri IE
!!Pi! !tl

1 ii ri! €t ;1i!i "ig. !
! !:. ::
t Ei lii i iiilri !i iE ii i!iii I
I ii;iii i ia ii;;.
i"! l.: !l!i ifi: ta iitii il
!5 rEt :.i

iI r5 e1 ii ir 9l !rr I

i !1 F Ii i1

lg !-E iE

ig

t 7i
!!

E

I

c E

! tg

T ;!

il E-

i;

+$

3i

+.

II

G

The cutting edge of the tool is used to
cut an angle on tl1e coruer of the
cylinder, tbrming rvhat is called a
"chamfer

Frgure4 1 chamfercuttns

Def ntonolvthread :ascrewthread havnBathreadansleof S0degrees
wth the bisector of the angle bery perpend cu ar ro the axis of the thread and

the (ests and rootsofthethreads be ng lines formed bv the lnlec€ctions of the

stoE vlEw

FBUre 4 z Trrread Cut! ngToo Bit

curuis V threads wnh a 60 degr.es rhread ange is the most commo^
thread cutrinS operaton doneon a tathe. v threads, with rhe 60 desree angt€,
are used for mot.ic thread cuttns and for Amercn (Narona ) threads and
Un fied threads. To propory cutV shaped th.eads,lhe sinCle point tooibit mu{

be ground for the exad shape of the thread fom, to ncud€ lhe root of rhe

F cure 4 3I V shapedThread cutter

!iD WH IT, B5E l+iz ACME

4trtt^.

60' I,ETFIC t

AMERICAN

Flgure 4 4I Ans eThread Cutt ns GaueeToo

I

.;fl

t

Flgure 4.5: S.rew P kh Gaugo Thread
Ai externa thread G cut on an e{e.nat surfa.e or .one su.h as o^ a cap

Job Rolqtion l

t Pilch+ ll*
D
t\ L;I

Tool\ Feed Direclion
Externdl Thredd cultinlF

risure4.6: Externa Ihread Cutt ne

COMPARISON OF THREAD CUTTING

ExternalThread lntemalThread

risure4 7 : Externa and lnternalThrcadCuttine

Pradical rask (2) - PLo4, cLol

Reoort 1(Generc Skils)(LD5) PlO5, CLO2
Repod 2 (Generi. skiLls)(LD7)- PLo9, cto3

. Fo ow the 5af€ty procedures in the ma'hinlngworkshopr
. 6rindtoo bitto rut metricv th.ead
! Seedsplndlespeed,feedandcuttingtooslor athnsworks
. Pertorn thelo low n3 Lathe works

Pra.tice.ult ns erterna met clhread on the lathe

. to low safely pro.edure5 ntheworkshopi
. dentfyto.kfor.uttincthread
! set up ma.hlne a.dtools
. Cutexternametrkthread

Pe orm indexingon mllLlng ma.hine

! FoLow 3afety pro.edureswh le nde,ngworks
r rnstalllnder nc head on the mllLln3 ma.hinetable
. Milsquare/hexaSonshapeonawo*pie'e
. (eep the workshop clean and safe

Pra.tical Task 1: work Pr...*

student Name & Matric No:

ffit,,,ll, -ffffi

il

I

i+-

]t

Practicar Task 2, Proied PRACTICALTAS(2. PROJECT

student Name & Maki. No: |,I.I,I.I.

1)

2l

3)

I II

IIIIII EII I

IIIIIIIIIIIIIII
IIII IIII



Re.od 1-ceneri. skitk l trpt)
neko( 'Bineft b !e(oou)

r.1 lMr igM&hin€ .65fctoi:idd:

61 Lfu 'd€rr'plmdse r4ss

R€pod 2- Generi.Skills2 ltOT)

ardo t hh p"khri Pehqhd:tan konpa :

td)qk t@nr dar nono percPrcr
rhedbiedveorse.ompoicrts/dsgn.

abtedl n4sh6itkdr kdhpon?r / rcto,etuk te6e6

htodrton orrhe@mPdne s/dsiBi
Ppnq.nataD bqi kanponzr / rt\dbentok
Adu d aBGm@mpdne /Bisissemred.
conba@jdh \eb?rdt bdtoaer / akob

Advlta3es/.ompoied design g.ie6led.
ketebir@ rnntuhd / rckabsttrk yons dihositka,

eart @mpdienb /daBis used ror

kpotuson konponen / dobentuk dBorakn lntut o@

i! E,E-!::, EiF !53s 3i;

: a! j!.s r!: ,:Ei! -*i96
!:i
c c ai r !: s::!E 9g;! PgT{ !i 5

i t;;

!P 5!I33: EEiI *! :i:E !;

€:

!t,E;3 !gE? TS ;i!6fei 3ir ECii : 2
3_:
2 iezi
: nl
i

!E ld : i e: ;s ,
iE i6Fl ;E
?i; 5E 1?
s? "s:Ei
.5;l !
E;,: 3
EE
, Ftr! ;ii!3;
!63 s
9 E]E! e
c E

€

EE

€!

E :!* t

I[ilIiE, :-q !, ,;p :r i: l ,[:r- 1I t -ic
F€
:sr! tx5.!:

ITe

Reoort 1-Generi. skllk ltDsl

li ;J :- !!!i .ii i!

!i iE! ?i, il
!i! E: iEi!
i_
i ;!5 i!!
; i; !: !iiitti:ii!,t
:ri; Eiiiiiiiii'
,ii,!iiiiiiii' siiiiiiii:i
il ia

i , ii, r, iEEi ii a! EB :li! ,iirEit! r lsE

!5E: Ei ?liliiiES; ;!ii: :<:? 5 eiriEi!

i:!i igE.:i, i r l,'$Eti !

I _!" ii! it _E!! i! plt:ii i riii!
Eitti:
2 :"5i:t:!t!E!!:ir E!: rr
?!i!ii
iiiEiiir .ir;:1! tE:i$i

t:i iiiit!i! i: !.:i! r!i.liiii:rE!ltt ! EEtrt:;t; !t!igil1ri ?iil!ii:
!!i
I Trii!ii ii r l! iii: a ti tr;15 .i

I i: i li ! ti tl!!l,1i 5tllE

l ;ii i!lll iq!?: ra9l!l!! iiiiE!!!

tiir"ri!r iifii;

.t

:!!i i!!t,!r ! E

il

".,i iE :!E

ili !Eii !iEE

!!1i!!!r:ili!ri! ;iitEiEE;:iiiiit,iEii!ii: 5 ! it 5

i!lE!i iiiii,iiiiii,iiii, iiii!ii;Ei
iii::9tiif:i

;; r,!1.

: Siiiit {
;iiii*:iiii,iiii,!!:fiir i":".i E

Ell ;itaAtEEi!iE!i!r:EtE!r;E.Er9r;.;!qa!E9;; =
ii! Ei Ei i ici ii

i. ii.i t;:t"
;!!i;ir ;tiii,':liili iti;i: i:r:
;iiiii*;i;
9irP!;;i ;it;i 5ii!i i; i i.E

!.5!it.!; !ii :i,i i:i,;

ai !;nE ! !r !:-
!ii*i:ciE;riilii
ii?r!

i,,,' ii!iF r!5
:E!Eti:iSi
i !t,'t! i?i:; gEEE

i:il!E iiE9i

;r
,.1 ir

it: Ei

Report 2-Generk Skalk ltDTl

i, :.iiil E

tr iiiii;'1, Eiii,ii !
i€iiiE!lr

BI gigi!iF!itiri:i"i:ii. EiIi" iq

!! ! i4'":9 a, iFi:;
iiiiiii?!
!;:i! lii!'iirtE! !i;.t1: :i5i!3i-0ii. !it i:il
li
iEi il i::!i aaririi:c:

r! . in iiEi i!i r!, ?i!E:!;i!iEi t:g! iiii
ll, !ii! il:
ii iir iig: Eii
iiiE"! i

:! E: +i9Ei r.l=i;i i: l! - Eii:! t-! s !i" lrEi
Er!:
!i E!i=ii i,!ii'i?EiEii ?i
ii: ! M;' iiii:; ;iii:: ;iii
i;Eii! Mi

! .1. :i;i"iir i!ir!i!; ! r! i ,i ,Ii il i iir,

! rll ;:ii !ir !Er t!: :i. ! i::ii i+!!!l

E tii!il,i iEt; Eir!E i i t,!'r

I

t. 5 ai- !!i I rft si" E I
iit:
iiliriii;?iE i Et; ii; iEt; iir!- ,!ti; ii

1,, llii r:E;g
:E;EE :n ig

I iE t 5$ I !r

t ti !E it il it l:!i
t l! 1i
T! a qc

i

T i! t : i:t E

i! itr !E t9 a I
rtE iE

E

!_

3

h

tE

,e

l:

il

**

T

Contour Milling (Profile Milling)

a Cdtlng alonsthe contour ofa workplecc whlch may
conslsts of linB ind arca.

r Oepth of cut r.mahs constant h 2D contou6.

Fiqute 4 3: Contauing Millinq Ptuc*s

A helx may be defi^ed as a resuar cutued path, such as G fomed bv
w ndinga cord a.ound the surface of a cyllnder. Helca part5 mon.ommonlv cut
onthemrlLngma.hnelncludehei.a g€a6,spra llutemiliig.utte6,twstdrlls,
and helca cam srooves. when miling a helir, a univetsa ndexheadGusedto
rotatethe workple.eatthe properrate ofspeed whiethe pieceisfed a8a nstthe

.utr.r A tra n olgea6 between the tablefeed s.rewand the indexhead setues

torotatetheworkpie.etherequ redamountforaglven oneiludlnalmovement
olihetable. M lnghe icalpa'ts requir.stheuseolspe.ia formed millne cutteu
and doube anse frlline cutte6. The .akulations and formu a5 necesary to
compute proper worktable anslet s.ar adiustmentr, and .utte. anget and

oositions for helica mi I nE are beyond the scope of th s manuaL

tl

#i$r'

Fsure 4 9: H€ rGearpro.e$

o
o

F€ure 4 10:Type of Gear

Practtallask(l) PIO4,CLOI

Practca rask{Generi.skihl)lLD3)-PLo3,clo2

Mak€a project using convent o^al iathe, venical, hor zonta and uiive6a
miling ma.hines. Fo lowthefolowing procesres

! set su tab e speed and tanrm $ on forvarous machln ng pro.e$.r
r Perform sjmple nder ns operation ro produ.e he ix sear
t Perforfr surfa.e Brlndinc proces togrind a llat surfa.e
. Fol ow satety procedures when op.raung machines

!E!!i!3LErLLlEi.c!!

student Name & Mat. No

1)
2)
3)

-'t*"

I

I

IIIIIIIII

=Frff+i -

I

8cp9B

riekovsrssimerr br,e.ooul
thdrsams/rgrs

a

2- f E'F !E6!
i;ijii"E JE
iE! ",! ! E { P: i: Eei.
: FFEst!
! !-* 3qs!i::eF!E;xc- i.:*€ 3 Ei qi5!n

;:E; E

!E :iv i
c E!J
Ei o *ei! ! .-t

ie;qF I t'2 gg

!t !: g

E: EA, t!:E

3i ! ;1iE: :a

t c_- '3

*E 1a 3it! gF ::tE Ex;EB;i;t9:!

."i *i

€E 5-t
PE: 4*

.8 ;i1 tlEii =gt

E!. E {C !.:

!; I

z

!Eq

Er! &-e E a{

t 3:5
IE ":!atE <g:-:i 3

E

PradiralTask-Generlcskills lLpBl

It ,il[!.t;r;"i 1 iii!l:i-i!i! !ii!i:!l!aiitc!a!i,tE ! !!- .:i -!i i!t1- !5:;i

,,i ! !t!l EE: Irl !ii. :lE!!i!! iiir

Ef: i!i; tlii

iiiiI ;i : ii, r rE,. rr-iiii ir9i !t '; ,i3 !

tEt: iii: i-: r r: i:: !. ti, ti!ai1;iEtEr!!!

?1!! : iiii$
iiiir: tii iii 53i; lii;iii il€5li

I:EEi!
i :!
5 :t !.'iiiit.! -E. iE:!!: ii: fuE ! i iii; t:.r;!i;i
!iiir irilii,
I! i,: { :i:ii i ii! :ar riiii
it: i::
ti iE::i !;E : E? ii- EiiE:

iirlr i ir 1i :1! i{E;Etitri ii: ata .: :. .. !!
t!; t;
iiFi i5 ili r ri i!
;ti3!
Er!; t5: !t 9[i i l!i€ iiiEir irilt i i; i,

r;i :,ri.ii!i!ii:i! ;iii.i i! t,tirtit,::!!:9tti !! i !:!tr d!1: ii,:! Ei

i!!i i:i !it ,ii:t;, ai;i!i at.

E 5If

;r! ii :i ,'i !" 5;
t- !;!: !!
iii it!i iiii:ii i it. :ti!tir!9 ig;i!t5! E!iEgr 1lii
ll ;i 6E I ?,' iii !E;t
::t iil !:IiiE! E:.

t! !i i IE ri ii ii ii r
;lil
!E !3 rr 'r! iP s! :i

t ! i i
9!
! t

!

il

l!

! i

a E

c

le

3 li

ir

tR

Gearsare used fora wde dnge of indunr a app icat on. Gea6 used in
aviat o^ rndunrres, lottile looms, automobile, industrial ma.hine, seared
mototr, agricuft ural machinery etc. To meet the $tote.onditions the geared
shoudhaverobust.onnrudion, reiabepertormance,hehefflciencv,e.onomy
and onc lfe.The gearshou d be fariguefree and lree irom a lnrerses to avoid

theirla lures TheseaE shouLd be fiee from ioise, chatter and shou d ensure
hish load varying.apa.ity atconsGntveloc ty rato. SpurseaE arethe monly
used in a ltypo ofgear.ll s used forthetransmitinsof power betw.en two

paralelshaft5 ln thBtype ofseaL the teerh.ut on the.vl.dri.a taceare

parale ro the ar6 ofth.Eear. n milinc, a mu t toothed.utteri rotaung at a

fixed posltion on the machine, shapes the workas iristraveued anosthe

cutrer. The work s lirmlysecored on the machine table which can be adjuned to
set the depth otcut and.an be moves dke.rions i^ the horironlalplane.ln

some ma.h nei, a vert .a hansv.6e ako is pos b e msnufacture of meta lic
.omponents us ng conventonaLmach netool5i cutterloo wear, its effects on

surla.e fin 5h, and.urtertoolfailure provide major limitauons to the
a.hievement of€.onomic product on. torm mlllns the rooth ofinvo ute rpur
gear invo ves specfi.ation oI the.uting spaad for the work piece materialand
feed rate ofthe miling cutrer The speed a.d feed rate seiedion loriu.h cutt nG
has a strons lnk with the completion period of the mach n nBexerise, which
ind rect y a so determlnes the.oslof producing the 3ear.ln cutting ofthesear,
most mportant s that mach nab lity. Machinabllityis deliied that to.urthe
marerra howeasilyoi a frach ne to 3er the des red shape with respecl to

Dividins p ate sthe host frportant pat ofthe dividinc head.The maror
ro e ofthe dividinE p ale sto keythe dividing c.c e The plare.ontai^s no of
ringsol holes. Th s means that one turn ofthe handle.an be divded intothe
numberof holes nthe padi.ularring.Dividngplatehavnsnoof hoLeso^rhe

ha f of plate drlled on one side and others de to be drilLed.The d v ding p ate k

ttted properlyallofthe'1ero'holes willhe ln lne and wil bevenicalyabove
the shaft ofth€ handle Usua lv, nextlo each ofthe zero hole5, s nanped th.
numberofhoesintherns

t

5e

Flgur€s.1r rndex Plate and secror

rndexingequipment is used to ho d the workp ec€, and to provide a meansof

rurnlns tsothara numberof ac.urateylocated 5peedcuts.anbemade,su.h

a..ro.c,"qr.cd n.. rl.3 roor\

and taps, and form nsteeth on m lLlns cutteE The workp e(e s he d in a chuck,
attachedtoa ndex i3 head sprndlp, or mounred nbetweena rve.e^terrnth.
indexiog head and dead center in the lootstock. The center rest can be used to
support lonE sle^derwor[.Ihe.enter ofthe footstock.an be raired orlowered
for setl ng up tapered workple.esthat requ re mach n nC.

Ihefollowins pr nciplesapplyto basic index ns ot workp eces:
(a)Suppose it is desied to m lla spurgear w th 3 equa lyipaced ieeth 5in.e 40
turns ofthe indexcrankwiL lorn the spind e one fu lturn, one eighth of40, or s
turn5 ofthe nank afier each cul, w llspacelhe cearfor Sleeth.

(b) rhe same princ p e applies whether or not the divisions re.tu .€d divide

ev.nlyrnto40. Forerample, I t i5 desned ro indexlor 6 divi5ion5,6 drvrded nro

40 equa s 6 2/3 turns; simi ar y, to ndex for 14 spa.es,14 d v ded nro 40 equah
2 6/7 turns Therefore, rhelolow ns ru e can be derived to delerm ne the
ndmberofturns ofrhe index.rank naadedto obtain one d v slon ofanvnumber
olequald v sion5 on the workpi€ce, d vlde40 bythe numberofequald v slons
desned lprov ded rhe worm whee has 40te€lh, wh.h is standard pmct ce).

The inder plate (fgure 5.1)is a round metalplate wlth a ser es of sir or more
.ndes ofequa lyspa.ed holes; the ndex p n on the nank can be lnserted in anv
hole nanycre.withtheinterchangeabeplatesreculadvlurnsh€dwithmost

ndexheads, rhe sracinss necesary for mostsea6, bohheads, milins.utteu,
splines, and so fofrh,.an be obtained. lhefo!lowlngsets of plares ar€ standard

(a)Brown and Sharpetype,3 p ar.s of6 circle5, ea.h driled aslollow5l

Phre 1 rs,16, r7,13,19,20 ho es

P ate 2-21,23,27,29,31,33 ho es
Plate3 37, 39, 4r, 43, 47, 49 holes.

1b)c nc nnatitype, one p ate dr led on borh sldes with circle5 dlvided asfo low5l

rnstsde 24, 25, 23, 30, 34, 37, 33, 39, 41, 42, 43 holes.

Se.ond r de" 45, 47, 49, 51,53, 54 57, s3, S9, 62, 56 holer.

NOTE

ll i5a Sood pract ce 3 ways ro nder.lo.kw se on the phte.

Spur Gear

Spurgenls iierhe nostcon]monly used ged twe. They arc

chamcteri2ed by left raich are pdpcndicular ro rhe ficc ofthe

ge!r- Spur Bears fie by h.lhe mosr confronly arailnble, and

arc gencrllly rhe lclst cxpcnsive.
,Tcerh is pamllel lo axis ol rootion

,TmBmilpo*er liom one shaR loanotherpanllel shall

rl

Applications of Spur Gear

In necharicil sysrems shdc se'llrcquirc sinple dcliEn, hore
clficicnt powcr lmnsfcr. and low sped applica(ions wherc

noisc does nol matlc.. we should go for spur gears.

Spurscd halc a widc rege of!r,plicariors. The) arc used inl

, MctllcufiinC tu&hinls > Gcar mo(ors and gear

;; Me.hiricalclocksand > Marcrial handling

; Wnshing Mrchincs > ulomobilc g.dboxes

, Slcel mills
; Rolli c mills

fisore s 3: App .at ons OfsourGear

SPUR GEAR

il DLSADVANIAGf,S:

C@"otb. r.d w1." uial

.fiMnot .heS. n .cqnirnl.

Fisure 5.4. Advantacps & D6trdvanrases OrtpurGear

Differential Indexing

. Used when 40/N cannot be reduced to a

factor of one of the available hole circles

. lndex plate must be revolved either

foMard or backward part of a turn while
index crank turned to attain proper

spaclng (indexing)

. Change of rotation eflected by idler gear or

gears in gear hain

hgure 5 5 ' rnde,inC ol Gear

Example:

Calculale the indexing and change gears required

ior5Tdvsions. The change gears supplied with
the dividinq head are as iollowsr--

24 . 24, 28, 32, 40. M, 4S,,.161 64. 72, S6

The available index plate hole circ es are as follows

Plate 1:15, 16, 17. 18, 19,20

Plale 2 21 . 23. 27. 29. 31 . 33

Plate 3.37.39,4 , 43, 47. 49
40 405lndexing
40 Choose p ale 2: 21 holgs

N57 5,:7 would be 15 holes

No 57 hole circle so select
number close lo 57

FiSure 5 6: Examp e Carcurat on tndexing ol Gear

I

Piacti.a raskl6en€rrskirr) lLDs) Pro10, cLoE

Practi.e on mi I ng mach ne

! Use indexinc headtomllaCear.

P.act ce on gr nd ng mach ne

! us. surfa.e grrndinS ma.hrne/.yindri.a 8.indi^s mach ne

Keep worltshop .lean and safe

!E!4

Student Name & Mati. No:

1)
2)
3)

IIIIIIIIIIIIIII
IIIIIIIIIIIIIII
IIIIIIIIIIIIII
IIIIIIIIIIcytrdttd 6thdhe Muhi" ne)

Mttkd Md.htre lsput 684 l2a4)

IIIIIEIEIIIIIIIIII(4onlRdtrr!qon(eii/rurd IIIIIIIIII