Mapa University

Muralla St. Intramuros, Manila

Department of Mechanical and Manufacturing Engineering

SHOP PRACTICE NO. 8

Milling Practice: Spur Gear and Bevel Gear

ANGELES, Marison C.

ME-2

ME137L/ A3 GRADE

2015100221

Group 04

Engr. Jose V. Hernandez

Instructor
OBJECTIVE:

1. To familiarize the students with the milling machine and its parts.

2. To familiarize the students with the basic operation of the milling machine.

3. To familiarize the students with the gearing operation of the milling machine.

4. To be able to manufacture a spur gear.

METHODS AND ANALYSIS:

The advent transformation of the wheel by adding teeth on its circumferential surface has
made possible the transfer of motion to another gear or rack. It is through the understanding of
the basic design computation and actual fabrication of gears that one can fully appreciate the use
of this basic spare part and the machine that produces it.

MATERIALS:

50mm diameter x 30mm Wooden Block

50mm diameter x 80mm Wooden Block

TOOLS AND MECHINES TO BE USED:

o Bolt and Nut

o Milling Machine
o Sandpaper
o Universal Chuck
o Wrench Driver
PROCEDURE:

1. Prepare the materials and equipment needed.

2. Compute for the simple indexing needed for the 13-teeth spur gear and zero bevel gear
which is 3 revolutions and 3 holes in a 39-set holes index plate.

3. Clamp the formed wooden material, for the zero-bevel gear, to the chuck of the index
head with the index pin at the top most hole of the 39-set holes and set the sector arm in
place.

4. Turn on the milling machine, then adjust the height of the saddle/table and the depth of
cut for the first gear.

5. Let the chuck travels horizontally with the table to complete each cut.

6. Rotate the index crank 3 times and pass 3 holes from the previous hole.

7. repeat step number five and six until the wooded gear is already finish.

8. Turn off rotating milling cutter and remove the newly cutter gear.

9. Clean it with a sand paper.

10. Insert the second wooden pattern to the correct sized bolt-rod and lock it with a
corresponding nut.

11. Adjust the inclination of the index heads chuck until it faces horizontally.

12. Clamp the bolt-rod with the wood pattern on it to the chuck and secure it with the tail
stock center.

13. Set the index pin again on the top most hole of the 39-set holes of the faceplate and
adjust the sector arm in place.

14. Turn on the milling cutter and adjust again the height of the saddle/table and the
depth of cut.

15. Let the chuck travels horizontally with the table to complete each cut.

16. Repeat stem number five and six until the gear is finished.

17. Turn off the milling machine and unclamp the bolt-rod with the wooden gear.

18. Remove the gear from the bolt-rod and clean it with a sand paper.

19. Write the section of the class of the gears and submit them.
QUESTIONS:

1. What is a milling machine?

- Milling machines are tools designed to machine metal, wood, and other solid materials.
Often automated, milling machines can be positioned in either vertical or horizontal
orientation to carve out materials based on a pre-existing design.

2. What are the two main kinds of milling machines and what are their differences?

- Horizontal milling machines have a spindle or cutters mounted on a horizontal arbor

above an X-Y table. Some horizontal mills have a table, known as universal table, that
features a rotary function for machining at different angles.
- Vertical milling machines have a spindle that moves in a vertical orientation over the
table, working on the top and bottom sides of the object being machined. Vertical
milling machines lend themselves to standing machinists and detailed work.

3. What are the main parts of a milling machine?

- Base, Column, Knee, Table, Overarm/Head, and Spindle. The base gives support and
rigidity to the machine. The column face is a precision machined and scraped section
used to support and guide the knee when moving. The knee is attached to the column
face and may be moved vertically on the column face either manually or automatically.
The table supports the vise and the work. The overarm provides for correct alignment
and support of the arbor and various attachments. The spindle provides the drive for
arbors, cutters and attachments used on a milling machine.

4. What is indexing?

- Indexing is the process of positioning a workpiece for matching it into equal spaces.
Dimensions or angles using an index or dividing head.

5. What is a gear?

- Gears are mechanisms that mesh together via teeth and are used to transmit rotary
motion from one shaft to another.

6. What does the circular pitch of a spur gear mean?

- Circular pitch is the width of a tooth and a space, measured on the pitch circle.

7. What does the diametral pitch of a spur gear mean?

- It is the number of teeth of a gear per inch of its pitch diameter. A toothed gear must
have an integral number of teeth.
 8. On gears that has the same diametral pitch, will they have the same size and
thickness of teeth on the pitch circle even if they have different outside diameters?
Why?

- Yes, because as define earlier diametral pitch is the ratio of the numbers of teeth the gear
has over the pitch diameter. This means that two gears can have the same diametral pitch
even though the other one is bigger. When this happen, their outside diameters can differ
from each other, but the size and thickness of the teeth on the pitch circle are still the same.
They may be increase in number, but the size and thickness are the same.

9. What is the addendum of a gear?

- Addendum is the radial distance between the pitch circle and the addendum circle.
Addendum circle is the circle bounding the ends of the teeth, in a right section of the gear.

10. What is the rule for changing diametral pitch to circular pitch?

- The rule for changing diametral pitch to circular pitch is the pi (3.1416) must be divided
by the value of diametral pitch in order to convert it to circular pitch.

DRAWINGS:

SPUR GEAR
Front View ( Scale 1mm : 1mm )
Right Side View ( Scale 1mm : 1mm )

Top View ( Scale 1mm : 1mm )

Isometric View (Scale 1mm : 1mm

BEVEL GEAR
Front View ( Scale 1mm : 1mm )
Side View / Top View ( Scale 1mm : 1mm )

Isometric View (Scale 1mm : 1mm )

DISCUSSION:

The milling machine performs a variety of operations, so it has numerous historical

predecessors, from the drill to the lathe. The first milling machines were developed to shape wood
in the 19th century, and as technology and the knowledge of metallurgy advanced, these wood
mills were modified to cut and shape metal.

Milling machines are an important industrial tool for machining solid materials like wood
and metal. They can perform a vast number of functions ordinarily done by hand, thus speeding
up and facilitating a faster and more efficient workflow. In order to be better informed about what
type of milling machine is best for one's needs, it is best to learn what the different classifications
of mills are and what each is best intended for. Knowing the difference between horizontal and
vertical machines is particularly useful. There are several types of milling machines, but usually
they are classified by the orientation of their spindles, which are positioned either horizontal or
vertical. Horizontal mills are optimal for machining heavier pieces because the cutters have support
from the arbor, as well as a bigger cross-section area than a vertical mill. Vertical milling machines
lend themselves to standing machinists and detailed work.

CONCLUSION:

Milling machines are important for cutting and shaping wood and metal, among other solid
materials. These machines are an invaluable resource for any business or individual seeking to
create precision pieces in a work or personal shop environment. There are several different types
of milling machines, but the two main types are classified by the orientation of their spindle:
horizontal and vertical.

In this experiment, students were able to familiarize themselves with the milling machine
and its parts. Also, students were able to familiarize with the basic operation of the milling
machine. Also, students were able to familiarize themselves with the gearing operation of the
milling machine. Finally, students were able to manufacture a spur gear and bevel gear.

RECOMMENDATION:

What I recommend is be careful of using the milling machine, by not make contact with
the revolving cutter, never adjust the workpiece or work mounting devices when the machine is
operating, Chips should be removed from the workpiece with an appropriate rake and a brush. hut
the machine off before making any adjustments or measurements, and when using cutting oil,
prevent splashing by using appropriate splash guards. Cutting oil on the floor can cause a slippery
condition that could result in operator injury.
REFERENCE:

http://www.thomasnet.com/articles/machinery-tools-supplies/how-milling-machines-work

http://www.ebay.com/gds/The-Difference-Between-Horizontal-and-Vertical-Milling-Machines-
/10000000177634484/g.html

http://www.kanabco.com/vms/mill_machine/mill_machine_02.html

http://www.sabah.edu.my/cwm019/Index_files/page0039.htm

http://www.engnetglobal.com/tips/glossary.aspx?word=Indexing

https://www.creativemechanisms.com/gears

https://www.cs.cmu.edu/~rapidproto/mechanisms/chpt7.html

http://www.ebay.com/gds/The-Difference-Between-Horizontal-and-Vertical-Milling-Machines-
/10000000177634484/g.html