TMENT,

20, 1942.

RS

milling machines 1- 4-

and

pers and

NG

ts 4

metal by means of a

. With the aid of various

aching, circular milling,

ks, and gears; and the

ines may be di-

ch is particularly adapted

s class of machine has

saddle is supported on

mped rigidly to the column.

would place them in this

so arranged that the

, 1941.
may

ure

ork

e swivel
RS 2-3

n adaptation of the

aracteristic, as com-

utomatic control of the

stable dogs.

g. 2) has the spindle

uction and operation to

hat the cutter and the

end milling and face

shed on this type of

ne.—This type of ma-

constructed that the spin-

g the cutter to the proper

machine is automatic

et up.

ne is similar in appear-

s carried on a long

er as on a planer table. The

or more cutter heads that

ousing uprights. These

tion manufacturing of

—Machines in this class

eading, gear cutting,

nes are similar to ver-

e guide mechanism which

e a predetermined outline

ufacturing compound

machines should

operator to have plenty

solid concrete 6 inches

he machine may be ac-

the four corners of the

th shim stock. Additional

e base at various points

e. After leveling, the

or by means of lag screws

e lag screws to the floor

and pour molten lead

ent has been maintained

chine should be given a

g

the
RS

ovable parts must be

ginner should start a mill-

bserve all moving parts

ntrol handles, stops, feeds,

actual operation.

red by a periodic check

chine.

d by placing a dial indi-

he spindle back and forth

ng. When play is found,

dle thrust nut as shown

be observed by chucking

and using it as a lever to

cturers have incorporated

hell bearings, which allow

4.

spindle

ay

pindle

aces

indle

ny
RS 3

test indicates improper

adjusting the gibs of the

f the table knee or column,

and are

nt

he

ed

e to
RS

e swivel vise (fig. 9) is

h makes it convenient for

ane. The universal vise

uipment, is designed so

tical angles. This type

d angular milling.

imilar to a screw

spring away from the

is used to lubricate

ubes have flexible joints

required point. A typical

71.

open end or socket

hine.

ench

ng

st,

ed for

sted

mes

nt

driven

ot
RS

achine and is driven by

ndle.

This device is one of

al milling machine. Its

sible to mill a helix of

It can also be used for

n installed, it is clamped

his attachment con-

ndle. It is clamped to

spindle. It incorporates

, from the vertical to the

machine spindle. End

e easily accomplished
rface

table

nd

illing attachment.

mas-

i-

the
RS

chment may be used

e. It changes the mill

ne in which the tool has a

ent is securely clamped

machine spindle. This

he head at various angles

keyways, splines, and

e of a universal and circular milling attachment.

ypical operations involving

spindle of the rack

al plane at 90° to the

convenient for cutting racks

wed

d to

ny boring

parallel

h-

so con-

achine.

nt.

driven
RS

turn pipe, coolant tank,

system gives a greater

fore, higher speeds can

RS 4
RS 4
RS

may be classified

rotation, or the method

utters.

rinding on the pe-

s obtained by grinding a

own in figure 20, are pro-

egular or curved shape

called shaped profile cut-

of the cutting edge, that

ers.

of

at the

nter-

er a

The

t or

cutter

31,
RS

and are mounted in collets

(T)) are attached to either

ne spindle.

erally made from

emented carbide. The types

f rotation.

ration to which they are

ed for milling flat sur-

his cutter is a cylinder

ace only. Plain milling

Helical cutter with nicked teeth.

and widths. Although plain

al, the latter type are gen-

-inch wide. A cutter tooth

along its entire width

oth starts to cut. It is to

ters

being

e work

s un-

ured

g and

eatei

ks

he

un

achine

b and

as to

nown

ed

sed.

can

s. The
RS

type for milling slots where

more milling cutters

gure 27, for the purpose

on.

gular form. The cutters

ng or overlapping teeth,

d.
se

cutters.
RS

he center for clearance,

lots are cut. They are

lots. Slitting saws are

re 28®.

saws with staggered

nerally used. Cutters of

k.

e 29, are used to cut

These cutters have com-

l surface and are made in

can Standard Gage

tters, and metal slitting

h, size of hole and diameter

th side teeth.

fications would be: plain

th, 4-inch diameter, and

ces that are not parallel

s. The single angle

for plain arbor

w arbors. The "screw

ate arbor interference on

specifying angular cut-

eter, thickness, hole size,

r cutters are of two

th forming an oblique

s and the other usually

pe are manufactured for

sed for milling the edges

ng

ch

uded

f each

cut-

one

or mill-

uting
RS
d

e. End

her

rated

ved.

rilling
RS 6

ecessary to secure the

used for milling

t exceed 1/4 inch in width.

should be set for a fine

bular construction,

with internal clearance.

ducing bosses or cy-

dered at the front

m to the arbor. A slot

key which prevents the

tter is cheaper to
ver

They

with

bush-

sides.

th.

are

ndard

ain

nd

h their

n iy2

ut-

ace

ot

ways

epi-

8, which

type

nter

e
RS

e a single unit

aced together and used

g one pass.

rm cutter, the teeth

es. Due to the chip-

utters.

avy cuts can be taken at

taggered in such a manner

ub toothed gears

volute tooth gear.

he gear spaces on

signated by the diametral

and

ed

for
RS 6-7

ars, worm wheels, etc.,

ets and spline shafts.

be used on work where

in figure 91, the cutter

by the milling machine

y desired shape and is

work slowly into it, or as

which is fed past it.

trated in figure 32,

eel, Stellite, or carbide

n a body of less expensive

ment and therefore re-

e usually made to cut

e as in the case of the

lied to an arbor or

ndle end.

dered in the choice of

d steel, Stellite, and

advantage of being capa-

chine which can reach the

e, 90° angular cuts

ter, while the work is held

e work is set at the re-

harder the material,

tting. Cutters should be

oarse-toothed cutter

an ordinary spiral milling

ng operations.

e, when milling stock

f straddle mills or a side

pieces to be cut.

ons can be accomplished

mple, milling the square

e a side milling cutter,

owever, for the majority

d named for the operation

used should be small

e the

shorter

act is

ge.

re

pped

d.

peed

to wear

ed

rheating

wer

e cut-

e for

of
RS 8-9

er from striking the hard

uts.

nd lightly coated with

ns in such a manner

other. Small cutters that

n hooks or pegs, while large

aight shank cutters may be

rovided with suitable sized

e arbors.

may be mounted di-

ched to it by means of

ollets and spring chucks.

s of cutter arbors in

d to certain operations.

hree tapers shown in

by mill-

om

ecessary

ng

ent

ich

e-

vice

dle.

ch

ndle

bor's
RS

this way, it is necessary

nd tap the head of the bolt

is applied to the spindle

d drawing it up tightly

of arbor is accomplished

yed types.

cribed as follows:

h the exception of

o the spindle, is of

t arbors.

d portion on the end

One or more cutters

of

s and

for

p-

nec-

sses

rbor

the

he

ate

his

tening

ed

ded

have

be

st
BS 9

used to prevent spring-

rbor, although one is not

e cutter near the column

the overarm of the milling

the cutter as possible. At-

re of the following ways:

shown in figure 46(T),

bushing in the arbor

ove method, the arbor

pport, which has a 60°

e of the arbor, as shown

rface cut on the end

urface fits into a bearing

®.

to assure correct

be thoroughly cleaned.

s burred or scored, it

ove the burred or scored

n be inserted in the

in place by the taper

ghly cleaned before

d provide a sliding fit

m operating the cutter,

ible and as close to the

will permit. Attention

the arbor.

bor by means of

g the cutter, the arbor

bor support (if required)

nut is then drawn up

or support while

he arbor out of alinement,

generally used to drive

red

in-

ure

hole,

m of

r.

ng

us-
RS

a tapered hole to accom-

ften used in combination

p" or increasing taper

drill press sockets, the

are unlike. Figure 49

of a collet adapter

ndle, a spring collet,

e to close concentrically

orces the jaws against

be held in spring chucks

in figure 48®. Adapt-

ns, such as a set screw,

al, large face milling

n the milling machine

es use of a flanged

milling cutters may be

ned keys are arranged

The back of the cutter

spindle, providing a

milled in the back of

the spindle, The cutter

crews

he

ely

by

peak-

om-

of

opera-

er

ctional
BS

oduced.—These factors

onal heat generated is

rial being removed.

d 40 to 80 percent higher

e to their heat resistant

00 percent faster than

dercut teeth cut more

e they may be run at

may be operated at a

g lubricant on most

that it will not overheat

may be used as a guide

or finds that either the

suitably operated at these

made.

and hi(,h speed steel cutters

ions per minute

ameter from 14 to 8

inch cutter and a

ired, the cutter revolutions

RS 10

he proper revolutions

f the following formula:

nute (table I).

he work passes the

ting a job. In selecting

ould be considered. These

e cutter and their

The force exerted varies

and can be regulated by

orrect amount of feed

n are dependent upon

hines are limited by the

and the amount of

feeds and deep cuts.

upon the type of cutter

se feeds should not be

d mill, as such an attempt

tters with strong cutting

ause the chips may be

cant.

be used on a frail piece

hat its holding device

he amount of feed.

moved more rapidly but

face being cut may not

product. Because of this

used for finer, more accurate

ce to use a comparatively

are made on the side of

eeding may be detected

sound. If vibration (re-

ng machine during the

ed and the feed increased.

d work, or a machine

of "chattering."
f the

nes,

her.

hes per

e in feed.

of

against

o this

ng

is

@,

ent (down method).

cutter

utter,

the

ness,

h the

nt

ace

ity of
 S 10-12

ely used because of their

may be mixed. If such a

e may be made by thor-

ne quart of lard oil to one

r the machining of most

sene should be used as a

machined dry although

ool the work and the cutter.

ans of the coolant drip

e cutter strikes the work.

olant should be allowed to

ethod of holding work

the machine tool is to be

he method used in holding,

erved in every case. The

st be secured to prevent it

tter and it must be so

several T-slots which

he work itself or for mount-

ments. These T-slots extend

s line of travel. Most

and index heads, have keys

so that they may be located

rious methods of

he type of work and the

used methods are described

work to the milling

e free from dirt and burs.

ly

the

work

otected

ss the

eld

uld

f
BS

pport should be provided

vent springing or possible

nd of the work where

heavy cuts are being

g procedure.

s of clamps in general

of application.

amping work to the

allel, perpendicular, or
ng

ed for

aline-

ber

ng

o-

ned.

ork

ucted

inimum

for

ure
RS 12

ex centers are used to

ds. When the work has

e pressed upon a mandrel

shown in figure 101.

mounting work between

atisfactory for many op-

to fit into the index head

latter type, the outer

stock center in the regular

1, prevents springing

ld between centers or

chuck.

by means of a dog as

should be fastened

ving center clamp, in such

springing of the mandrel.

g machine dog (fig. 56)

s dog is held in a flexible

of the dog or the work.

og to move in a radius

ularly useful in the rapid

wing the chuck to the

d any burs on the spindle

ith a smooth cut, three-

uld be accomplished with

d to fit the angle of the

he chuck should not be

rench or bar is required

niversal chuck, may

cator mounted upon a base

indicator point should

r work, or the circumfer-

ork. While checking, the

ex head spindle. Should

worn, they may be ground

ne spindle, and proceeding

a steel ring with a

allow a jaw opening of

e,

ed

held
RS 12

k of small diameter,

e spring chuck and collet

ld be inserted into the

placed in the chuck,

et and the cap nut tight-

ered seat and clamping

he collet lies in the

nd accurately.

mentioned, three types

r holding milling ma-

r tongues on the under

correctly in relation to

o the milling machine

cular to the arbor by

aduated circular base

le and located by means

he bolts which clamp

y be moved to hold work

wivel vise accu-

cator should be clamped

determine the setting by

inal feeds, depending

ation as shown by the

ng the vise on its base.

d in 'such a way as

zontally or vertically,

Due to the flexibility

ing.

d surfaces is to

erial should be placed

any marring of the jaws.

e the vise jaws, parallels

hould be used. These

w the required cut as

of the jaws. When hold-

be used to tap the top

e been tightened. This

els cannot be moved by

ghtening of the vise should

tendency to raise the

 ii

r the

gure 58,

having

e bottom

eans

he paral-
RS

p surface of the work fully

mped in the center of the

a short piece of work which

ng block of the same thick-

pposite end of the jaws. This

event the work from slip-

od of holding work in

end of vise.

d is used primarily

uired in the cutting of tooth

in reamers and taps. The

sting that is provided with

milling machine table. As

provided on the sides of the

ted. These bearings allow

gle from 10° below the hori-

duations on the side of the

egrees. A clamping device

 be

ck

nd is

e end,

red hole.

s, while

ndex

indle

g, or by

cal
RS 14

ed by means of the

ods. Of these methods,

y used, the compound and

ound method which was

becoming obsolete, due

xact results cannot be

urate, is not widely

does, however, become

yond the range of plain and

not be attempted with-

ook as the various manufac-

ing the operation.

ndexing, makes use of

t back of the work end of

has a number of equally

the index pin may be in-

ex pin out of contact

be disengaged and index-

hand. To divide work

e disengaged and the

a 24-hole circle have

inserted into the 12th

roper position. During

be clamped by means

ndex pin.

e universal index head,

ex crank must be turned

Charts specifying the

urn and giving the

furnished by index

charts are not available,

urns may be determined

the mechanism contained

main spindle is attached

m mounted on a shaft.

nk is located for revolving

worm is single threaded

0 turns of the index crank

ete revolution. Therefore,

uired to index a fractional

ng 40 by the number of

ed to make 40 divisions
ne com-

lete

dex

he

re-

of a

x or

holes

oned

houses,

eratoi

isions

at th<

nomi

ecl

indej

nator
RS 14

inator of which repre-

x plate is available. To

d the denominator must

mple, the calculation for

having a 27-hole circle

2 holes in a 27-hole circle.

f the fraction is

ailable in an index plate,

hould be divided by a

hich the denominator

n index plate is available.

g 76 divisions when an

ble, is as follows:

sed in the foregoing

mall that no available

presented by the de-

an available number.

g 52 divisions when an

, is as follows:

degrees or fractions

emembered that 1 turn

circumference of the

0° in a circle, one

rcumference of the

he index plate and

ole circle equals 1°, 1

n a 54-hole circle equals 1°,

es in a 54-hole circle

quals l/s°. To determine

he index crank for a

degrees should be divided

mber of complete turns

should be rotated.
 circle

rcle,

th<

of

e!

hole

circl

h wil

abli

ei

oll
RS

ndex plate.

te the proper move-

rts of a complete turn

figure 62, consists of two

a set screw is loosened.

ed to bear on the left side

rst hole in the circle that

d and the right-hand arm

number of holes will be

king the adjustment, the

tion. When setting the

ted from the one in which

zero. By subsequent use

es after each division is

evolve the spindle it is

unlocked; however, before

he spindle should again

with standard plates,

and including 60, all

cluding

nnot

vable

ment

es

mall

enter clamps.

ock

ent

idly,

gle

a
RS 15-16

d the tailstock

machine arbor with

of the test bar.

ndesirable deviation

stment may then be

ally.

ay be defined as a

winding a cord around the

he helix as being

s been coiled about

t on the milling ma-

twist drills, and helical

ersal index head is

f speed, while it is being

aced between the table

rpose of rotating the

tudinal movement of

is often used to mean

s a curve having a con-

watch spring.

tors involved, and the

x:
 x

eing

lead

ng the

ad

i by

of

he

ad.

he

meter

nce to

he

nal

ht-

worm,

ud

geai

ears,

s maj

ating

ed

helis

the
RS 16

must be remembered

on all standard milling

t 40 turns of the worm

s, if change gears of

e 10 inches longitudinally

herefore, the helix will

lue is the lead of the

lculations required

the numerator

the denomi-

hus:

factors to repre-

by a common

and denomi-

er of teeth

hine. Thus:

ent the number

minators rep-

ears; there-

respectively,

ectively.

ained by multiply-

nd dividing

ears. If the

s selected are
RS

nder no cir-

e exchanged.

anges its direction, the

cannot be perpendicular to

al milling—Continued.

ork brought about by a

n end mill, must be wider

An end mill is used when

hel-

ed

angle

52°,

ent.
RS

and set the milling ma-

d set it centrally with

r depth when it is

n a milling

d of the blank

d to the height

n inscribed,

ne inscribed

and cutter,

he 12° cutter

quare.

and cutter the

utter angle or

sversely and

s close to the

proper width

by measur-

and the line

th. The lon-

rmined by the

rbor collar, as

square rests on
les

e.

tc.,

d to

ve-

fluting.

or

is the
RS 17-18

more milling cutters are

the same time.

te typical face raili-

ned below.

face milling operations,

the type and size of cutter

mill.

ry of the cutter do prac-

e cutter is properly

mall amount of stock left

by producing a finer

e cutter securely placed

spindle is eliminated.
hin^

againal

ork

uli

o:

, thi

ui

ay b

yp

es 6

exec

ers

n th<

shoulc

s
RS

f the table should be

l movement.

ned warrants the addi-

milling cutter.

e held in a vertical position

25.

s should be used, which

c«

to us

th

of th

agon

above

red

rectioi

tori

maj
RS 19-20

55 times the distance

om a given cylinder

es 0.866. Thus: H=GX

at (r) is equal to

4 times the distance

om a given cylinder

es 0.707. Thus:

s equal to one-half

cylinder (G) and the

advisable to take

work, after which the work

cutter stopped and a

nished dimension should

the work moved toward the

rence. The remaining sides

by direct indexing.

uld be measured

ut down.

ylindrical surface,

described for flat sur-

der to eliminate losses

ould be taken with the

e grooved or fluted,

ges and channels for

g edges produced by

e that is smooth, round,

in unless they are

Common causes for

th, too much rake, or

ause of the rake of

eeth or teeth with nega-

oth

dial

cutter,

d in

oubles

orm

s. The

types,

anging
RS

h for a number 8 cutter,

various diameter ream-

a groove having

work laterally as illustrated

k

the

he

ular

dge

figure

in-
RS 20

idth of land is provided.

as shown in figure 66,

nch reamer, %6 inch

h reamer. It must be

eased, the table must be

emain radial.

ter should be set ahead

e rake on the tooth. To

et as outlined above, the table

cutter ahead of the radial

ffset required to produce

arious size reamers

with helical or straight

er of irregularly spaced

ocedure discussed

s operation, the angle

s make an angle of from

th is illustrated in

lutes. The difference

ould be very slight, not

aking up of the flutes

re or

on

t their

red

trically

nk

refer-

rs,

width
RS 20

e reamers

quired for positioning index crank when using above

and

able,

d to

to

ne,

ead

e proper

per

ts of
RS 20-21

so that when testing with a

ered portion is a trifle

tting is accomplished by

e index head set below center,

th the taper of the reamer.

eth to a depth slightly less

width of land, and readjust-

t the tailstock is raised

revolved, the tail of the

but also along the axis.

ling machine dog illus-

o use a regular bent tail

dog in the driver must be

eliminate springing of

aps the grooves or

wn in figure 75. These

he cutting edges and also

g chips. The number of

r of the tap, the standard

four flutes are generally

er, six flutes are gen-

g cutters may be used

ed, and produces what

he convex cutter for fluting

e selected with a width equal

depth of the flute should

e VI gives the sizes and

lute taps. Specification

g to machinists' handbooks.

vely in the past, due

cutters of a like size. An

range of tap diameters

s a cutting edge that

vex forms. This type of

ap

ex

bed

t from

cut-

ly

utter

l marks

ermit

ot

sely to

nt

one by

r index

ner

para-
RS 21-22

e milling machine table.

g cutter.

s and, with the cutter

st touches the tap.

osition and, using it

depth of cut (see table VI).

the longitudinal feed

maining flutes, bringing

are generally

fusion when referring

designate the cutter being

mill, number and kind of

upon the size and type of

n 4 inches, it is better to

ections.

e generally fitted with

mined by the diameter

aving 14 teeth, and

o the diameter.

aving 22 teeth, and

he diameter.

es up to 1 inch in diameter.

h on 1%-inch mills, and

ve milling operations

t teeth should be milled

should be cut with a

slightly rounded point.

proximately 15° when

be cut with a 70°

the use of an 80° cutter.

of milling cutters,

d held between the index

Mounting the work di-

us

76

me

ed

top

osition

er.

bring

d,
ooth spaces. Adjustment

gh the first tooth

the operation at the

ately increased in depth

nd the remaining
RS 23

are grooves of dif-

drical surface of a shaft,

ive method of locating

A keyway must be

e the key.

eat to be used depends

ed. The most com-

raight, round end

ustrated in figure 77, and

0 steel.

ure 77® may be

e purpose of inter-

usually proportioned with

g rules are widely used to

meter.

diameter.

y2 times the shaft

width of the key.

ney keys, as shown in

except that they have

re designated by a num-

rring to machinists'

ts width, while the

of key to a maximum

nd have a taper of

y is made ^4 the shaft

6 inches. Due to the

struction, no illustration

ar in shape, and are

knesses. The circular

is milled in the shaft

key.

ed by a system of

mensions. The last two

f the key in eighths

indicate the width of

number 404 key would

ch wide, while a number

 ind

ey anc

nd

value

th<
RS

utter, the shaft should

is tangent to the circum-

y moving the shaft

ng.

t to tear a thin piece of

r side teeth, as shown in

l on the transverse
ng

e^

e-half

bove

ei

ng a

this

revolu-

e is

edge

der

ated

ving

the

quare

trated

ners

he

dard

ng

n be
RS 23

keyseat and measuring

e position and the

scribed and center

r in the cutting operation.

size shafts
per

ed

utter

ed

y.

tter

work

ving
RS

een the peripheral teeth

graduated dial on the

p on the table set. Using

a guide, the work is

cut, completing the opera-

cut not be available,

eans of the following

are usually cut by means

neral shop, internal

e by using a slotting

ure 14, is used to cut

g single point tool and

ol is either horizontal or

mount of visibility ob-

must be held. The slotting

crank which allows the

ould be adjusted to per-

nd care must be taken

e set-up when mak-

se required for shaper

pecial shapes is illustrated

anks which permit them

rious shapes.
parts

y to
RS

plines used in trans-

and propeller hubs are

special machines. How-

r job, the operations may

a manner similar to that

al gear.

Two standard splines are

determines their dimen-

r the parts are to have a

whether or not, they are

mensions for the cir-

the size of the shaft and

values are given in table

es.
ter (D)

ade to figure 83.

.015
RS 24
g

cored

which

tion is

or

Figure

be

f the

must be

g of

utter.
RS

ial such as sheet

the table with the line of

e the work should be

to prevent it from being

ry precaution should be

rder to prevent climbing

ated in figure 86,

s and are particularly

liding movement, yet pro-

rs. The angular sides of

ne or shaper to any desired

- fift° io <mnfvra.llv nsftH

 be

plate

punch

n.

es-

ll rods

ure,

eter d

de-

ension
RS
s

ght of

e a.

etail

o 12

r buttons

holes.

our

m%

mmon

of

he

s may

eeth,

r line.

eir

ry

deep
RS

pilot so that the body of

dth of cutting edge. The

ouble angle type.

hine may be used

urate location of the hole

w graduations. The spac-

oles in an index plate,

d in the milling ma-

machine collets. Vari-

ed for boring on the

vided with either straight

taper shanks to fit collets.

for boring are the fly

d in figures 16 and 91.

hi

l and

er

ted

en

blank

2(1).

s text.

ainst

nge

rs

fferent
RS 32

an be obtained, if needed,

, and other specific data

utter and perform the other

he following definitions

ved in cutting an involute

e illustrated in figure 94.

e angle.

meter
RS 38
(J

the

mber

eter

ngth

itch

ed

y
RS 32

pace allowed between

by dividing the thickness

ngth of the tooth from

th, excluding the clearance.

he number 2 by the

g depth plus the clear-

e constant 2.157 by the

ircle is determined

requently employed

angle whose value is

cular pitch. This value

umber of teeth (N).

vernier tooth caliper

oth addendum (s) plus

hord to the top of the

und by adding the

ment, must be added

ments of the gear teeth are

the pitch circle. If the

t of

ear

which

ne 6)

s the

hat

the

und

be

ears

?')

he
RS 32

the above listed

ch

machine table and aline

al milling machine, the

tter arbor so that the tooth

gear.

t this point, it is im-

o that all teeth cut upon the

s.

of the gear blank. To

s the centers and inscribe

ear blank.

f a revolution to bring

es the line directly

blank until tool marks

er and lower the blank

scribed line.

mark, move the table

the center of the cutter,

g this adjustment is a

tailstock center with the

ing

l the

l feed

tooth

ng

tical

the

f the

mpared

acy by

to the

ound

into the
RS 32-33

rk must be lowered. For

ecessary to work to chordal

determining the chordal

(«").

blank. The method

of indexing other

te gear teeth.

h gears are largely

strength. This type of

short and thick, as the

ared to the standard

stub tooth gearing

Fellows, and the

g bases the tooth di-

he addendum being made

%0 of the circular pitch.

-

ng

by

oth

number

the

ng

er

ne

ed

he

to

be

for

olute

-
RS

y adapted for use in

f their compactness. This

e to the fact that one gear

the gears CD uses their

nabling more teeth to be in

smooth action and great

sizes for internal gear-

ear, except that in the

ence between the pitch

ng internal gears, care

may occur when the inside

ter of the pinion are too

the cutting of an

g attachments.
eption

Np)

a-

ure

al
RS 34

4+0.0112)

ircular attachment,

he axis of the circular

o hold the blank, which

l proper clearance. To

should be fastened on

ontact point of the dial

gear blank, and the gear

of the circular attach-

as registered by the

tapping the gear blank.

index head, eliminating

nsversely, scribe a

he top face of the blank

. Revolve the gear blank

l and repeat the process

he two inscribed lines

hine should be adjusted

he blank repeated until

the longitudinal feed

be two lines parallel to

d an amount equal to half

ne. These lines assist

en inscribed, the grad-

o adjust the milling

center line was drawn.

ed.

pe of a No. 1 involute

tachment. The cutter

h the gear blank by

s discussed in the

se feed until it just

o that it may be used

e

wit

spac

ot

pu

dina
RS 35-36

, any one of three

ing and indexing

are to be cut is fastened

exed by using the indexing

ay be held on a com-

a vise, parallel to the

indexed by hand,

ine.

ailable, and the

e interference with the

mping the bar to the

achine spindle. The

the universal milling

e bar. The tooth spaces

al feed of the milling

he rack teeth, the

ular pitch of the

whole depth of tooth,

e same as the correspond-

s to mesh. In all cases,

n in figure 92® are

m of the gear blank at

a screw. Helical gears

ause of the sliding

teeth that are in contact

a right- or a left-

cutting helical gears

posite helix angles when

mesh.

e same helix angle when

esign of the gear and

ed to cut gears up to

mounting the cutter in

greater than that which

ed i

ml

f:

he gi
RS 38

gear teeth, it is not

nd number as is used for like

hich has a thickness at

pitch would cut tooth

It is therefore, necessary

l diametral pitch (/*"),

6 (pi) by the normal cir-

cal gear cutter ia

e number of teeth in the

e of the cosine multiplied

tch surface is deter-

angle into the product of

ntial circular pitch (P').

ch interchangeable

universal index centers,

date the exact lead to

o are usually very

y cutting the tooth space

te lead of the helix (Z2)

with index centers, the

n gears must be multi-

he number of teeth in the

n gears

d by dividing the

pi) by the number of

*

h<

gl

rc
RS 36

oth angle

50 =3.962 inches

3 =0.2696 inch

elected ( T)

64 teeth (driven)

32 teeth (driver)

_ 28 teeth (driven)

h (driver)

e milling machine table

t right angles to the

cutter on the arbor and

on "helical milling."

mount it on the spiral

d driven by the head-

gear blank while being

cutting than are spm*

gear blank be pressed

blanks held on lathe

 oweve

tt<

tape

d fc

spind:

ia

e open

ng (

hi

cutti

e ri

ar

e helici

thrus

wo hel:

havin

eai

bor

m6t

er

wo

d on

he

orm
RS

ployed are illustrated in

eel is determined by

ance desired.

nclature.

eel is determined by

in the gear (N) and the

 the

and

by

alf the

on its

taking

s the

ce
RS

machine table should

m wheel is the angle whose

of the worm (L) by the

er of the worm (d').

ch as shown in figure

wheel.

utter, for a corresponding

a worm wheel is finished

hob selected should cor-

ch, and lead.

xample in the calcula-

strated in figures 101

wheel
RS
ble

ead-

cutter

cut

de

clear

knee

ns-

is

el
RS 38-39

slowly until the hob

nee is raised slightly

wheel until the distance

center line on the vertical

m and worm wheel. The

cates the position of the

at the same height as the

center distance may be

of the knee.

igure 92®, are used

not parallel and may be

ten called miter gears

th have the same number

e form of tooth with either

being the more commonly

d by a generating process,

ever, when only small

is commonly used in the

mbols and formulas in-

el gears whose shafts meet

strated in figure 103.

s the angle whose

ber of teeth in the pinion

).

the angle whose tan-

of teeth in the gear (Ng)

h cone angles, the

uals 90°, the calculations

ned by dividing the

(P).
he

tch (P).

P) .

x).

radius

ter-

s and
RS 39

the tooth at the large end

gear or the pinion is

dividing the major adden-

of the pitch cone and

the Brown and Sharpe

m of the tooth is made uni-

In this system the cut-

ng the addendum angle

ermined by multiply-

of the pitch cone angle (a) .

mined by adding twice

ameter (D').

ined by multiplying

ngent of the face angle (8).

f the tooth (j) may be

om the pitch cone radius

ne radius and multiply-

ce (/).

t the cutter may be

h in the gear (N) by the

of a

itch

")

one

the

the

ust be

sing

ear

ce (F)

itch

depth

st be

the

ect
RS 39

e of such a thickness that

nd too wide. Cutters,

gears, are similar in

ng spur gears. However,

nd, bevel gear cutters are

pur gears. Since the cut-

oth at the large end, the

e small end. The general

ng the small end of the

re 104. Rules used in the

e large end of the tooth.

small end of the tooth.

y be given as follows:

r cutters (numbering

ng bevel gears from a 12-

o the large end of the

r which the cutter

ollowing manner:

gear and pinion to be

B and BC at right angles

lines of the gears.

tance AB is the

onsidered the radius of a

the required bevel gear.

radius of the pinion and

ical spur gear of the same

n mul-

teeth.

illus-
RS

1.125X2X8=18

for the width of the

is necessary to set the cutter

blank, as illustrated in fig-

dth at the large end of the

o determine the amount

offset values, the ratio

e must be found. To

hould be divided by the

otation.

bevel gear cutting.

rizontal scale of the

tio calculated, is the offset

bstituted in the follow-

ffset the work table.

ch line
RS

to rotate the gear blank

amount of rotation may

ethod, as outlined below.

e gear blank with the

uired amount, as cal-

ne table transversely, and

aduated dial on the trans-

in an opposite direc-

ff center, allowing the

the gear to cut the entire

h.

cutter, the table offset

center, and the operations

The gear tooth so

nd by using the gear tooth

e such as shown in figure

basis of the vernier read-

o remember that a cutter

end of the tooth too

ves the small end too thin.

th

a-

ut

e of
RS

ndrel and insert the

dle as illustrated in

angle, as shown in

e number of teeth to be cut.

oper pitch, as shown

ometer, inscribe a line

e end of the tooth will

nsverse feed graduated

ndex arrangement,

tooth space.

el gear.

a guide, set the gear

y means of the index

y discussed.

made to produce a

remaining tooth spaces.

d adjust the machine

e of the teeth.
RS 40

ERS AND

d planers 43

d principally for the

h of these machines

the cutting tools used

n of size. The chief

nd planers lies in the

modated; the shaper being

hile the planer is suited

machine tool, utiliz-

ter. With the exception

the tool is on the

d at a slower speed than

in this way are paral-

ce that may easily be

rk is held on an ad-

at right angles to the line

ogress across the sur-

ss tool pressure against

e, making it particularly

The size of a shaper is

roke; thus, a 24-inch

length.

d and is especially

ere long cuts are required.

red as being the reverse

rocating motion is pro-

ool is caused to feed

ut to advance. As in

on the forward stroke,

uick return to bring the

of a planer is desig-

an be clamped and
is one

agraphs.

other
RS

those in which the

rank arm connected to a

crank pin. This driving

tion of figure 113.

o types, the plain and

k table that may be both

able can only be moved

ut

ries

n. The

side

ilable in
RS 41-42

is type of shaper is

range of the crank

bed upon which two

a saddle which feeds

of the ram, allowing

rk tables are adjustable

the tool is drawn

d instead of being pushed

uts to be made and

e conventional ram

ine is similar to that

14) is one in which

motion, the driving

ar type. The work table

icularly adaptable for

ensively in the air-

id production of gear

sing a hardened cutter,

e face of the gear blank

ine is used in pro-

uch as those in gears,

s of a base which houses

g motion to a cutter bar.

rnished in different widths

equired.

ded into two general

de, each of which is

the work table moves

ross rail and head are

r or helical gear, which

The larger machines are

ounted to the cross rail

using. With this set-up,

h the side and the top

de type have but a

ail is attached. The ad-

ng

ec
RS

m to give a wider range

he table. •

s and planers.—

rs and shapers should

r and carefully leveled

ld be made with heavy

necessary.

s must be made to insure

y means of an accurate

uld be made on the

e table, ways and cross

as illustrated in figure 115.

he

ments

lots

raper,

olvent.

bri-

be

liding

com-

ssories

ment

ra-

ufacturer.

per and
RS

sed to hold work on the

olts to the table T-slots.

ated in figure 117 while

ods of clamp application.

hown in figure 53© are

ilitate the holding of

rent sizes and are used

w (fig. 118@) replaces

xtension bases (fig. US®,

fective height of the jack.

h as described in the

se the work to the required

the table.

ngular type with the

te angle. These paral-

ing narrow surfaces to

"grippers", of the

ble in the holding of thin

adjustable angle plates,

are used extensively in

RS

— Several work holding

nt slippage of work being

these accessories while

methods of application.

ced in front of work

of the cut.

p pin.

screw plug. ® Toe dogs.

plug (fig. 1200) are

de during the cutting

or use in holding work

nction with screw plugs

work table.
g accessories.

ot

uired

s of the

e
RS

on and high speed steel

high production speed

el is becoming obsolete.

re required for the

ed on the shaper or planer.

e, the same general rules

case of lathe tools,

ast. Tool holders and

rgely replaced forged tools

of tool steel required

de and end of the tool

dge. This is termed side

work

o«

educes

side

oo]

ck

ft-

sed.
RS 46

s cutting toward the

the operator.

rd tools are illustrated

s:

very efficient for

xtremely heavy cuts in cast

ground for left-hand

al applications, the angles

ck rake is given this tool

20° for soft metals. Fin-

be performed with the

wn cutting tool may

and operation and is used

ction. The tool is sub-

scribed above with the

may be used for down

on. A small amount of

s made the widest part of

o give them longer life.

ft-hand side tools are

ols may also be used for

rs after a vertical cut has

s.

en relief on both sides

the cut is increased.

similar to the cut-off

. The squaring tool is used

shoulder cuts, keyways,

le cutting tool is

erally used following a

tting tool. The tool may

ation.

d to produce a high

a fine feed. The cutting

ches; twisted to a 20° to 30°

a small radius.

—This tool is used for

at the cutting edge is behind

e allows the tool to spring

 01

nd

s. The

be

positions.

, or

ing

mount

med

k.

extension

osition
RS 47

8®, is only used for

unt of metal is required

ssively deeper, multiple

machine. Figure 128©

he cut-

e length

or

s use.

or

endent
RS

s per minute may be

d by 7 and dividing the

s. Thus:

e formula:

ute for rough cutting

determined.

as nearly as possible

s for various metals

epth of cut of a

he type of work being

Where considerable

depth of cut should be

oid overcrowding the

e depth of cut is increased.

work does not re-

o any great extent. Its

inal operations in the

described in the section

purpose.
tion

ssary

any

efore

lting

ir

ing

on-

e
RS

t speed.

complete one stroke

e.

able parallel with the ram.

so that it bears

While adjusting the

a

ry

zero
RS 51

r contacts the rear end

icated, adjust the tilting

of the tilting table,

rther adjustment neces-

e top.—This adjustment

are to be taken. The follow-

e alinement, the set-up

that its sides are

nd adjust the tool

or is in line with the

r, bring the contact

rallel and set the dial

ower the tool slide to

he reading of the indicator

al to that at the highest

and no adjustment is

between the readings,

olts that bind the swivel

ment. Should it be de-

ing the vise, the parallel

e vise and the above

m.—This alinement is

parallel to the vise jaws.

31, and the necessary

et the reference line

d base, clamping it lightly

st, as shown in

incn less than the

t the indicator contact

nd.

contact point of
 the

d,

rection

with
RS 51-52

s. The set-up is illus-

y be outlined as follows:

swing it until the

uation on the base.

and open the vise

indicator to bear against

nt of the indicator

andle, adjust the tool

o position near the face

bring the contact point

, as illustrated in

jaw by turning the

e until the point of

he vise jaw and note the

se an amount equal

vise jaw and, when the

vel base.

een locked in position,

ral.—The length

usted to accommodate

e working dimensions is

ed, a considerable amount

hereas too short a stroke

he surface.

sts simply of shifting

chine. This may be done

dogs to the required

e shaper stroke depends

adjusted as follows:

travel and loosen the

th
RS 52-54

roke while the ram is

h as shown in figure 111,

for speeds, feeds, and

stroke is set by turning

d setting has been ob-

l. This dial is placed

graduated to read in

s equipped in this

n any position.

the stroke should usually

ngth of work. This over-

at each end.

he planer, the

positions the stroke and

r stroke must, how-

. In making this adjust-

in the preceding

ool clears the work % inch

ront. The following pro-

nd the adjustment should

stroke and loosen

ositioning shaft and

e rear of the work.

of overtravel at the

nt.

The clapper box as-

nge. The rectangular box

hed to the tool slide by

s a swivel adjustment in

s closely fitted into the

ool post extends through

ol.

e top of the clapper box

t. This setting is illus-

ts the block to hinge

ool to clear the surface

r box in the vertical

most

se

s.

st be

he

ded

vely
RS 55-56

e danger of springing is

d work, it is a factor

nging of work may be

ed as follows:

essure or faulty appli-

e may be overcome by the

g the set-up.

ains when the outer

ble may be minimized by

nishing cuts are taken.

thickness is many times

uld be left on a level table

he roughing and finishing

r planer is very similar

e. Due to the reciprocat-

mps, etc., are used as an

a. In this and fol-

s to machining operations

duction of parallel and

peration and may best be

ure outline for squaring

tion of the stroke.

of its largest surfaces,

st planed against the

134(2). After making

upper surface. More posi-

the stationary vise jaw

between the movable

re.

s or against the bottom

s against the stationary

block solidly in place

lane the upper surface.

be used between the work

seating.

s or against the bot-

nd after clamping and

ods:

et

ped

de

ping

quared
RS

ning right angular

angle plate mounted

he face of the angle

jaw. After one surface

clamped to the anglei

posite side.
en

ference

table,

ed

work

ng.

om of

hold-

ma-

form-

ce is

that

o pro-

erably

errun

the rear

h the

feed

ock

l from

d out

n,

ces

n and

ers,

lar

left-

s
RS 59

gle from 90°. Thus: Com-

gular cut, care must be

the column as the ram.

the dovetail sir 'ild be

nd prick punched to pro-

© Method used for keyways terminating In

ning.

e clamped in the machine

hing should be accom-

ng tools such as illustrated

the work should not be

machined.
er

w-

actory

pera-

ell

nd

lus-

per

ate

of

then

eration.

mi-

width

p of

ade to

the

cent

ped out
RS 6O-61

position at the beginning

ing operation should be

nate interference.

etal, extreme accuracy is

the stroke to prevent

pulleys, etc., a radial

t in the alinement of the

on on the machine, by

as a reference.

may be held in the

so that the keyway is at

ing upward which tends

bit. Before starting

t touches the work. In

slide is locked and used

of cut.

slots are cut on the

nerally used for those of

bed, the work is set

o the desired depth with

tly narrower than the

rcuts of the T-slot

and T-slot tools, as illus-

s finished to the required

lot, the tool must

e cutting edge is made

ce is ground flat. When

ck the tool so that it

rk on the return stroke.

he tool to lift against the

or breaking the cutting

ot on the return

e lifting the tool by hand.

141, can be quickly

er may be locked

by using a piece of ma-

RS

nd the tool slide, as

ay be cut, using the

ol can usually be of a

n.

machining of non-

uction of taper keys,

ure. Several methods

on, the use of each

piece, as well as the

practice, the work is

in such a position that

o the table top.

to the same taper, the

required angle. In this

 h

unte

di

hi

nvei

roi

uire

re

Tl:

ind
RS 63

owever, the shaper or

necessary.

be the same as that

as that of a gear tooth

lowing are standard

f the tooth for involute

>" + /) equals the linear

als one-half the linear

nd of the rack tool,

P') multiplied by 0.31.

qual 0.066 multiplied

ooth with a vernier

he tooth to the pitch

0.3183.

space is indexed a dis-

acing or indexing may be

dial on the cross feed

ed movement corre-

cturer's charts may be

icrometer or dial indi-

sly in one direction when

ors, due to lost motion

may be held in the

After the work has

ace is generally roughed

ve with a roughing tool,

specified above.

he planing of a rack

e.

in width than the

tered with the first tooth

screw to zero, and

h.
k

ut

down

he

this

or.

rk

he

of

uld

to

e by

urved

h, in
RS 65

nch. Internal planing

, however, when such a

horizontal shaper or planer

holder. In any case, the

directly to the table top.

age

52 171

9 165
ge

n.)

n.)