INTRODUCTION:

Milling is the machining process of using rotary cutters to remove material

rom a workpiece advancing (or feeding) in a direction at an angle with the axis of
the tool. It covers a wide variety of different operations and machines, on scales from
small individual parts to large, heavy-duty gang milling operations. It is one of the
most commonly used processes in industry and machine shops today for machining
parts to precise sizes and shapes.

Milling can be done with a wide range of machine tools. The original class
of machine tools for milling was the milling machine (often called a mill). After the
advent of computer numerical control (CNC), milling machines evolved
into machining centers (milling machines with automatic tool changers, tool
magazines or carousels, CNC control, coolant systems, and enclosures), generally
classified as vertical machining centers (VMCs) and horizontal machining
centers (HMCs). The integration of milling into turning environments and of turning
into milling environments, begun with live tooling for lathes and the occasional use
of mills for turning operations, led to a new class of machine tools, multitasking
machines (MTMs), which are purpose-built to provide for a default machining
strategy of using any combination of milling and turning within the same work
envelope.

Milling can be carried out on a lathe, and it can do a good job, once a few small
modifications have been made. A resonably solid lathe can mill steel quite capably.

Accuracy within a thou of an inch is no problem.

Before the advent of relatively cheap Asian milling machines it was quite common
for this type of work to be carried out on a lathe.
Considering the limited amount of milling I do, I couldn't justify the space nor
expense of a large and heavy stand alone milling machine, and a close examination
of the lightweight hobby versions left me decidedly unimpressed.
MILLING PROCESS:

Face milling process (cutter rotation axis is vertical)

Milling is a cutting process that uses a milling cutter to remove material from the
surface of a workpiece. The milling cutter is a rotarycutting tool, often with multiple
cutting points. As opposed to drilling, where the tool is advanced along its rotation
axis, the cutter in milling is usually moved perpendicular to its axis so that cutting
occurs on the circumference of the cutter. As the milling cutter enters the workpiece,
the cutting edges (flutes or teeth) of the tool repeatedly cut into and exit from the
material, shaving off chips (swarf) from the workpiece with each pass. The cutting
action is shear deformation; material is pushed off the workpiece in tiny clumps that
hang together to a greater or lesser extent (depending on the material) to form chips.
This makes metal cutting somewhat different (in its mechanics) from slicing softer
materials with a blade.

The milling process removes material by performing many separate, small cuts. This
is accomplished by using a cutter with many teeth, spinning the cutter at high speed,
or advancing the material through the cutter slowly; most often it is some
combination of these three approaches.[2] The speeds and feeds used are varied to
suit a combination of variables. The speed at which the piece advances through the
cutter is called feed rate, or just feed; it is most often measured in length of material
per full revolution of the cutter.

THERE ARE TWO MAJOR CLASSES OF MILLING PROCESS:

In face milling, the cutting action occurs primarily at the end corners of the milling
cutter. Face milling is used to cut flat surfaces (faces) into the workpiece, or to cut
flat-bottomed cavities.

In peripheral milling, the cutting action occurs primarily along the circumference of
the cutter, so that the cross section of the milled surface ends up receiving the shape
of the cutter. In this case the blades of the cutter can be seen as scooping out material
from the work piece. Peripheral milling is well suited to the cutting of deep slots,
threads, and gear teeth.

MILLING CUTTERS

Many different types of cutting tools are used in the milling process.
Milling cutters such as end mills may have cutting surfaces across their entire end
surface, so that they can be drilled into the work piece (plunging). Milling cutters
may also have extended cutting surfaces on their sides to allow for peripheral
milling. Tools optimized for face milling tend to have only small cutters at their end
corners.

The cutting surfaces of a milling cutter are generally made of a hard and
temperature-resistant material, so that they wear slowly. A low cost cutter may have
surfaces made ofhigh speed steel. More expensive but slower-wearing materials
include cemented carbide. Thin film coatings may be applied to decrease friction or
further increase hardness.

They are cutting tools typically used in milling machines or machining

centres to perform milling operations (and occasionally in other machine tools).
They remove material by their movement within the machine (e.g., a ball nose mill)
or directly from the cutter's shape (e.g., a form tool such as a hobbing cutter).

GANG MILLING:

Heavy gang milling of milling machine tables

Gang milling refers to the use of two or more milling cutters mounted on the
same arbor (that is, ganged) in a horizontal-milling setup. All of the cutters may
perform the same type of operation, or each cutter may perform a different type of
operation. For example, if several workpieces need a slot, a flat surface, and an
angular groove, a good method to cut these (within a non-CNC context) would be
gang milling. All the completed workpieces would be the same, and milling time per
piece would be minimized
Gang milling was especially important before the CNC era, because for duplicate
part production, it was a substantial efficiency improvement over manual-milling
one feature at an operation, then changing machines (or changing setup of the same
machine) to cut the next op. Today, CNC mills with automatic tool change and 4- or
5-axis control obviate gang-milling practice to a large extent.

EQUIPMENT:

Milling is performed with milling cutters attached to a milling machine.

Types and nomenclature

Mill orientation is the primary classification for milling machines. The two
basic configurations are vertical and horizontal. However, there are alternate
classifications according to method of control, size, purpose and power source.

MILL ORIENTATION:

Vertical mill

Vertical milling machine. 1: milling cutter 2: spindle 3: top slide or overarm 4:

column 5: table 6: Y-axis slide 7: knee 8: base
In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in
the spindle and rotate on its axis. The spindle can generally be extended (or the table
can be raised/lowered, giving the same effect), allowing plunge cuts and drilling.
There are two subcategories of vertical mills: the bed mill and the turret mill.

A turret mill has a stationary spindle and the table is moved both perpendicular and
parallel to the spindle axis to accomplish cutting. The most common example of this
type is the Bridgeport, described below. Turret mills often have a quill which allows
the milling cutter to be raised and lowered in a manner similar to a drill press. This
type of machine provides two methods of cutting in the vertical (Z) direction: by
raising or lowering the quill, and by moving the knee.

In the bed mill, however, the table moves only perpendicular to the spindle's axis,
while the spindle itself moves parallel to its own axis.

Turret mills are generally considered by some to be more versatile of the two
designs. However, turret mills are only practical as long as the machine remains
relatively small. As machine size increases, moving the knee up and down requires
considerable effort and it also becomes difficult to reach the quill feed handle (if
equipped). Therefore, larger milling machines are usually of the bed type.

A third type also exists, a lighter machine, called a mill-drill, which is a close relative
of the vertical mill and quite popular with hobbyists. A mill-drill is similar in basic
configuration to a small drill press, but equipped with an X-Y table. They also
typically use more powerful motors than a comparably sized drill press, with
potentiometer-controlled speed and generally have more heavy-duty spindle
bearings than a drill press to deal with the lateral loading on the spindle that is created
by a milling operation. A mill drill also typically raises and lowers the entire head,
including motor, often on a dovetailed vertical, where a drill press motor remains
stationary, while the arbor raises and lowers within a driving collar. Other
differences that separate a mill-drill from a drill press may be a fine tuning
adjustment for the Z-axis, a more precise depth stop, the capability to lock the X, Y
or Z axis, and often a system of tilting the head or the entire vertical to allow angled
cutting. Aside from size and precision, the principal difference between these hobby-
type machines and larger true vertical mills is that the X-Y table is at a fixed
elevation; the Z-axis is controlled in basically the same fashion as drill press, where
a larger vertical or knee mill has a vertically fixed milling head, and changes the X-
Y table elevation. As well, a mill-drill often uses a standard drill press-type Jacob's
chuck, rather than an internally tapered arbor that accepts collets. These are
frequently of lower quality than other types of machines, but still fill the hobby role
well because they tend to be benchtop machines with small footprints and modest
price tags.

HORIZONTAL MILL:

Horizontal milling machine. 1: base 2: column 3: knee 4 & 5: table (x-axis slide is
integral) 6: overarm 7: arbor (attached to spindle)

A horizontal mill has the same sort but the cutters are mounted on a horizontal arbor
(see Arbor milling) across the table. Many horizontal mills also feature a built-in
rotary table that allows milling at various angles; this feature is called a universal
table. While endmills and the other types of tools available to a vertical mill may be
used in a horizontal mill, their real advantage lies in arbor-mounted cutters, called
side and face mills, which have a cross section rather like a circular saw, but are
generally wider and smaller in diameter. Because the cutters have good support from
the arbor and have a larger cross-sectional area than an end mill, quite heavy cuts
can be taken enabling rapid material removal rates. These are used to mill grooves
and slots. Plain mills are used to shape flat surfaces. Several cutters may be ganged
together on the arbor to mill a complex shape of slots and planes. Special cutters can
also cut grooves, bevels, radii, or indeed any section desired. These specialty cutters
tend to be expensive. Simplex mills have one spindle, and duplex mills have two. It
is also easier to cut gears on a horizontal mill. Some horizontal milling machines are
equipped with a power-take-off provision on the table. This allows the table feed to
be synchronized to a rotary fixture, enabling the milling of spiral features such
as hypoid gears.

COMPARATIVE MERITS:

The choice between vertical and horizontal spindle orientation in milling

machine design usually hinges on the shape and size of a workpiece and the number
of sides of the work piece that require machining. Work in which the spindle's axial
movement is normal to one plane, with an endmill as the cutter, lends itself to a
vertical mill, where the operator can stand before the machine and have easy access
to the cutting action by looking down upon it. Thus vertical mills are most favored
for diesinking work (machining a mould into a block of metal).[6] Heavier and
longer workpieces lend themselves to placement on the table of a horizontal mill.

Prior to numerical control, horizontal milling machines evolved first, because they
evolved by putting milling tables under lathe-like headstocks. Vertical mills
appeared in subsequent decades, and accessories in the form of add-on heads to
change horizontal mills to vertical mills (and later vice versa) have been commonly
used. Even in the CNCera, a heavy workpiece needing machining on multiple sides
lends itself to a horizontal machining center, while diesinking lends itself to a
vertical one.

INSTRUCTIONAL OBJECTIVES :
At the end of this lesson, the students will be able to;
(i) Comprehend and state the use of accessories and attachments in
machine tools
(ii) Realize and Identify why and when Attachments are necessarily used
(iii) Describe the basic construction and application principles of different
attachments used in;
 Centre lathes
 Drilling machines
 Shaping machines
 Planing machines
 Milling machines
(i) Use Of Various Accessories And Attachments In
General Purpose Machine Tools.
ACCESSORIES :
 A general purpose machine tool is basically comprised of power drive and
kinematic system for the essential formative and auxiliary tool – work motions and
a rigid body or structure to accommodate all of the above. But several additional
elements or devices called accessories are also essentially required for that
machines’ general functioning, mainly for properly holding and supporting the
workpiece and the cutting tool depending upon the type and size of the tool – work
and the machining requirements.
These accessories generally include for instance, in case of;
 Centre lathes : chucks, collets, face plate, steady and follower rests, centres,
tool holders etc.
 Drilling machines : vices, clamps, drill chuck and sockets etc.
 Shaping and planning machines : vices, clamps, tool holders etc.
Milling machines : vices, clamps, parallel blocks, collets, job – support like
tailstock etc.

ATTACHMENTS:
Each general purpose conventional machine tool is designed and used
for a set of specific machining work on jobs of limited range of shape and size. But
often some unusual work also need to be done in a specific machine tools, e.g.
milling in a lathe, tapping in a drilling machine, gear teeth cutting in shaping
machine and so on. Under such conditions, some special devices or systems are
additionally used being mounted in the ordinary machine tools. Such additional
special devices, which augment the processing capability of any ordinary machine
tool, are known as Attachments, Unlike accessories, Attachments are not that
inevitable and procured separately as and when required and obviously on extra
payment. Some attachments being used in the general purpose conventional machine
tools are :
In centre lathes :
 Taper turning attachment
 Copy turning attachments
 Milling and cylindrical grinding attachments
 Spherical turning attachments
 Relieving attachment
In drilling machines :
 Tapping attachment
In shaping machines :
 Double cut tool head
 Thread rolling attachment
 Matterson’s attachment (gear teeth cutting)
In planing machines :
 Contour forming attachment
 Helical grooving attachment
 Oil grooving attachments
 Milling and grinding attachments
In Milling machines :
 universal milling attachment
 indexing / dividing head
 rotary table
SLOTTING ATTACHMENT INSTRUCTIONAL OBJECTIVES
At the end of this lesson, the students will be able to;
(i) Comprehend and state the use of accessories and attachments in
machine tools
(ii) Realize and Identify why and when Attachments are necessarily used
(iii) Describe the basic construction and application principles of different
attachments used in;
 Centre lathes
 Drilling machines
 Shaping machines
 Planing machines
 Milling machines
(i) Use Of Various Accessories And Attachments In
General Purpose Machine Tools.
ACCESSORIES :
A general purpose machine tool is basically comprised of power drive and kinematic
system for the essential formative and auxiliary tool – work motions and a rigid body
or structure to accommodate all of the above. But several additional elements or
devices called accessories are also essentially required for that machines’ general
functioning, mainly for properly holding and supporting the workpiece and the
cutting tool depending upon the type and size of the tool – work and the machining
requirements.
These accessories generally include for instance, in case of;
􀁸 Centre lathes : chucks, collets, face plate, steady and follower rests, centres, tool
holders etc.
􀁸 Drilling machines : vices, clamps, drill chuck and sockets etc.
􀁸 Shaping and planning machines : vices, clamps, tool holders etc.
􀁸 Milling machines : vices, clamps, parallel blocks, collets, job – support like
tailstock etc.
ATTACHMENTS
Each general purpose conventional machine tool is designed and used for a
set of specific machining work on jobs of limited range of shape and size. But often
some unusual work also need to be done in a specific machine tools, e.g. milling in
a lathe, tapping in a drilling machine, gear teeth cutting in shaping machine and so
on. Under such conditions, some special devices or systems are additionally used
being mounted in the ordinary machine tools. Such additional special devices, which
augment the processing capability of any ordinary machine tool, are known as
Attachments, Unlike accessories, Attachments are not that inevitable and procured
separately as and when required and obviously on extra payment. Some attachments
being used in the general purpose conventional machine tools are :

In centre lathes :
 Taper turning attachment
 Copy turning attachments
 Milling and cylindrical grinding attachments
 Spherical turning attachments
 Relieving attachment
In drilling machines :
  Tapping attachment
In shaping machines :
 Double cut tool head
 Thread rolling attachment
In planing machines :
 Contour forming attachment
 Helical grooving attachment
 Oil grooving attachments
 Milling and grinding attachments

In Milling machines :
 Universal milling attachment
 indexing / dividing head
 rotary table
 slotting attachment

ATTACHMENTS USED IN MILLING MACHINES

Universal milling attachment
 Amongst the knee type conventional milling machines, horizontal arbour
type is very widely used, where various types and sizes of milling cutters viz. plain
or slab milling cutters and disc type cutters including single and double side(s) cutter,
slot cutter, form cutters, gear milling cutters, slitting cutter etc. having axial bore are
mounted on the horizontal arbour. For milling by solid end mill type and face milling
cutters, separate vertical axis type milling machines are available. But horizontal
arbour type milling machines can also be used for those operations to be done by
end milling and smaller size face milling cutters by using proper attachments. The
universal milling attachment is shown in Fig. 4.6.14. The rotation of the horizontal
spindle is transmitted into rotation about vertical and also in any inclined direction
by this attachment which thus extends the processing capabilities and application
range of the milling machine.

Universal milling attachment.

INDEXING OR DIVIDING HEAD
This device is essentially so frequently and widely needed and used that it is
also considered as an accessory. But it is taken as an attachment possibly for being
procured separately. This attachment is basically used for equi-angular rotation by
simple compound or differential indexing of the job while machining.

Universal type dividing head and its application.

ROTARY TABLE :
This device may also be considered both accessory or attachment and is generally
used in milling machines for both offline and online indexing / rotation of the job,
clamped on it, about vertical axis. Fig. 4.6.16 visualises such a rotary table which is
clamped or mounted on the machine bed / table.

SLOTTING ATTACHMENT

Such simple and low cost attachment is mounted on the horizontal spindle
for producing keyways and contoured surface requiring linear travel of single point
tool in milling machine where slotting machine and broaching machine are not
available. The configuration of such a slotting attachment and its mounting and
operation can be seen in
Vertical mill

In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in
the spindle and rotate on its axis. The spindle can generally be extended (or the table
can be raised/lowered, giving the same effect), allowing plunge cuts and drilling.
There are two subcategories of vertical mills: the bed mill and the turret mill.

 A turret mill has a stationary spindle and the table is moved both perpendicular
and parallel to the spindle axis to accomplish cutting. The most common example
of this type is the Bridgeport, described below. Turret mills often have a quill
which allows the milling cutter to be raised and lowered in a manner similar to a
drill press. This type of machine provides two methods of cutting in the vertical
(Z) direction: by raising or lowering the quill, and by moving the knee.
 In the bed mill, however, the table moves only perpendicular to the spindle's
axis, while the spindle itself moves parallel to its own axis.

Turret mills are generally considered by some to be more versatile of the two
designs. However, turret mills are only practical as long as the machine remains
relatively small. As machine size increases, moving the knee up and down requires
considerable effort and it also becomes difficult to reach the quill feed handle (if
equipped). Therefore, larger milling machines are usually of the bed type.
Vertical milling machine. 1: milling cutter 2: spindle 3: top slide or overarm 4:
column 5: table 6: Y-axis slide 7: knee 8: base

A third type also exists, a lighter machine, called a mill-drill, which is a close relative
of the vertical mill and quite popular with hobbyists. A mill-drill is similar in basic
configuration to a small drill press, but equipped with an X-Y table. They also
typically use more powerful motors than a comparably sized drill press, with
potentiometer-controlled speed and generally have more heavy-duty spindle
bearings than a drill press to deal with the lateral loading on the spindle that is created
by a milling operation. A mill drill also typically raises and lowers the entire head,
including motor, often on a dovetailed vertical, where a drill press motor remains
stationary, while the arbor raises and lowers within a driving collar. Other
differences that separate a mill-drill from a drill press may be a fine tuning
adjustment for the Z-axis, a more precise depth stop, the capability to lock the X, Y
or Z axis, and often a system of tilting the head or the entire vertical column and
powerhead assembly to allow angled cutting. Aside from size and precision, the
principal difference between these hobby-type machines and larger true vertical
mills is that the X-Y table is at a fixed elevation; the Z-axis is controlled in basically
the same fashion as drill press, where a larger vertical or knee mill has a vertically
fixed milling head, and changes the X-Y table elevation. As well, a mill-drill often
uses a standard drill press-type Jacob's chuck, rather than an internally tapered arbor
that accepts collets. These are frequently of lower quality than other types of
machines, but still fill the hobby role well because they tend to be benchtop machines
with small footprints and modest price tags

Horizontal milling machine

Horizontal milling machine. 1: base 2: column 3: knee 4 & 5: table (x-axis slide is
integral) 6: overarm 7: arbor (attached to spindle)

A horizontal mill has the same sort but the cutters are mounted on a horizontal
spindle (see Arbor milling) across the table. Many horizontal mills also feature a
built-in rotary table that allows milling at various angles; this feature is called
a universal table. While endmills and the other types of tools available to a vertical
mill may be used in a horizontal mill, their real advantage lies in arbor-mounted
cutters, called side and face mills, which have a cross section rather like a circular
saw, but are generally wider and smaller in diameter. Because the cutters have good
support from the arbor and have a larger cross-sectional area than an end mill, quite
heavy cuts can be taken enabling rapid material removal rates. These are used to mill
grooves and slots. Plain mills are used to shape flat surfaces. Several cutters may be
ganged together on the arbor to mill a complex shape of slots and planes. Special
cutters can also cut grooves, bevels, radii, or indeed any section desired. These
specialty cutters tend to be expensive. Simplex mills have one spindle, and duplex
mills have two. It is also easier to cut gears on a horizontal mill. Some horizontal
milling machines are equipped with a power-take-off provision on the table. This
allows the table feed to be synchronized to a rotary fixture, enabling the milling of
spiral features such as hypoid gears.

PROJECT PLANNING
 Chapter : 2

PROJECT PLANNING

2.1 CONCEPT OF THE PROJECT

Before starting every project its planning is to be done. Planning a

project is a very important task and should be taken up with great care as
the efficiency of the whole project largely depends upon its planning,
while planning a project each and every detail should be worked out in
anticipation should be carefully considered with all the relative provisions
aspects.

2.2PROJECT CAPACITY

The capacity of the project must be decided considering the amount

of money which can be invested. The availability of material and machines
and usefulness of the project.
2.3 DESIGN AND DRAWING

Having decided about the project to be

manufactured at must be designed. Design work should be done very
considering all the relevant factors. After design the p roject detailed
drawing are prepared. Detailed Specification for raw material and
finished products should be decided carefully along with the specification
of the machine required for the manufacture.

2.4 MATERIAL REQUIREMENTS

The list of material required for manufacture is prepared from the

drawing. The list is known as “Bill of materials”. Availability of these
materials is surveyed and purchased from the market.

2.5 OPERATION PLANNING

Next work of planning is to “select the best method” manufacture the

product, so that the wastage of materials, labor, machines and time can be
eliminated by considering various methods. The best method is to be
selected for fabrication and other works. The proper met hod and proper
person and the purposes of operation, necessity operation, proper machine
planning. The best method is the developmed and is applied to fabricate
the project.
2.6 MACHINE LOADING

While planning proper care should be taken to find the mach ining
time for the operation as correct as possible. So that arrangement of full
use of machines can be made and the machine loading program can be
decided.

2.7 PURCHASE CONSIDERATION

It is difficult to manufacture all the components needed for the

project in the machine shop. In each case, we should decide whether to
make or buy about a particular item. It is decided during the planning after
making a complete study of relative merits and demertis.

2.8 EQUIPMENT PROCEDURE

Results obtained from “Operation planning: and machine loading

help in calculating the equipment require Specification of the equipment
should be laid down by considering then drawings. Drawings will also
help in deciding the necessary requirement of tools and accessories.
 Chapter-3

FABRICATION DETAILS
 Chapter :3

FABRICATION DETAILS

3. FABRICATION OF PARTS DETAILS

3.1 BED

It is made up of mild steel material. The base of machine is holed

centrally and its attached with compound rest of lathe. The motor is
engaged with base plate. All the parts for milling attachment are mounted
on base plate or bed.

3.1.1. MACHINE VICE

The machine vice is used to hold the job. It is attached with the
swivel base. It is made up of cast iron.

3.1.2 SWIVEL BASE

The swivel base is fixed with L-angel. It is used to fix the machine
vice and used to change the angel for machining. It moves up-and down
wards direction feel is given.
3.2 TOOLS

3.2.1 MILLING CUTTER :

Milling cutters are cutting tools typically used in milling machines or

machining centers to perform milling operations (and occasionally in other machine
tools). They remove material by their movement within the machine

SLIDING BED :

A metal lathe or metalworking lathe is a large class of lathes designed for

precisely machining relatively hard materials. They were originally designed to
machine metals; however, with the advent of plastics and other materials, and with
their inherent versatility, they are used in a wide range of applications, and a broad
range of materials. In machining jargon, where the larger context is already
understood, they are usually simply called lathes, or else referred to by more-specific
subtype names (toolroom lathe, turret lathe, etc.). These rigid machine tools remove
material from a rotating workpiece via the (typically linear) movements of various
cutting tools, such as tool bits and drill bits.

The slotting/ milling attachment to lathe has two main sub-assemblies, viz. Cutter
arbor assembly and work holding device. For the purpose of explanation of the
components of the attachment, which is designed and fabricated, the isometric view
of the entire attachment is shown in Fig. 1.
A. Cutter Arbor Assembly Units
This sub-assembly consists of the following components, viz. Cutter arbor, Milling
cutter, Sleeve, Key and Hexagonal nut. The milling cutter is mounted on the cutter
arbor and its rotary motion is arrested by inserting a key, which partly occupies in
the collar portion of the cutter and in the keyway cut portion of the cutter arbor,
where the cutter is being located. Then, the sleeve is pushed to have contact with the
other side of the milling cutter. Then, the right side of the sleeve is tightened by a
hexagonal nut, which in turn will tighten the milling cutter. The milling cutter is
allowed to rotate in anti-clockwise direction. The entire cutter arbor assembly is
mounted between the headstock and the tailstock of the lathe as shown i

B. Work Holding Device

From, Fig.1, one can see the work holding device, which is mounted on the tool post
of the lathe. That is the original housing for fixing the single point cutting tool in the
lathe is removed and then the work holding device of the attachment proposed in
this project is mounted on the tool post of the lathe. This device enables the work
piece to be placed in front of the milling cutter. The sub-assemblies/ components of
the work holding device are Dovetail assembly, Base plate, Trapezium plates,
Square rod, Lead screw, Cross plate connecting square rod and lead screw, Ball
bearing housing plate, Ball bearing, Hand Wheel, Work holding vice plates, 4 sets
of bolt and nut assembly.

B.1. Dovetail Assembly

The dovetail assembly consists of two parts, namely male dovetail block and female
dovetail block. The male dovetail block will slide in the female dovetail block. In
this process, any object, which is kept on the male dovetail block will also move
along with it.
B.2. Base Plate
Base plate is the bottom plate of the work holding device, which will be mounted on
the tool post of the lathe. The female dovetail block is welded vertically at one end
of the base plate such that the movement of the male dovetail block can be even
below the base plate as shown in Fig.1.
B.3. Trapezium Plates
Two trapezium plates, one at each end (left end and right end) of the base plate are
welded vertically as shown

in Fig.1. Further the longer side of each plate is welded at the respective backside of
the female dovetail block to provide support at the time of experiencing force while
removing material from the work piece by the milling cutter.
B.4. Square Rod
The square rod is welded vertically at the top of the base plate and further it is welded
at the backside of the female dovetail block. The purpose of this square rod is to
incorporate a screw jack like arrangement with the help of lead screw, cross-
connecting plate, bearing and bearing housing plate. This arrangement will move the
male dovetail block up and down, which in turn will move the work piece up and
down in front of the milling cutter.
B.5. Cross Plate Connecting Square Rod and Lead Screw
The cross plate connects the square rod and the lead screw. A square hole is made at
one end of the cross plate through which the square rod passes through. Then, at the
top of the square rod, the cross plate is tightened with a hexagonal nut. This makes
the square rod acts as the fixed portion of the screw jack like arrangement.
B.6. Lead Screw
The lead screw is used to move the male dovetail block up and down. Its one end
passes through the cross plate connecting the square rod and this leads screw. At the
top end of this lead screw, a hand wheel is fixed. The bottom end of the lead screw
is fitted tightly in a ball bearing, which in turn is mounted in a bearing housing plate.
The lead screw has left-hand square thread (reverse square thread) mainly to move
the male dovetail block against heavy cutting force induced in it by the milling cutter
while it removes material from the work piece. When the hand wheel is rotated in
clockwise direction, the male dovetail block will move up and vise versa.
B.7. Hand Wheel
A hand wheel is mounted at the top end of the lead screw. The square hole at the
center of the hand wheel passes through the square portion of the lead screw. This
square portion avoids the slipping of the hand wheel on the lead screw, while turning
it. Then the hand wheel is tightened with a hexagonal nut (M12)
B.8. Ball Bearing
A ball bearing is used to support the bottom end of the lead screw. The bearing is
mounted tightly within a bearing housing plate, which in turn is fixed at the top of
the male dovetail block using screws. When the lead screw is rotated using the hand
wheel, the ball bearing enables it to move the male dovetail block up and down
depending on the direction of rotation of the lead screw.
B.9. Bearing Housing Plate
As mentioned earlier, the ball bearing is mounted tightly within the bearing housing
plate. The plate in turn is mounted on the top of the male dovetail block.
B.10. Work Holding Jaws
Two rectangular plates are used to firmly hold the work piece in front of the milling
cutter. Hence, these plates are called as work holding jaws. One plate is welded at
the left side of the male dovetail block facing the milling cutter and the other one is
a movable jaw. There are three holes
3.3DESIGN PROCEDURE

The forces on the cutter and in the direction of the machine saddle movement are
shown in Fig. 2. The various components of the attachment are designed as follows
to withstand the forces acting on them during the operation. The tangential force Pt
creates a movement of resistance Mb = Pt. d/2 and also tends to bend the cutter. This
movement of resistance should be overcome by the torque of the lathe-motor. Thus,
the H.P. of the motor is calculated considering the tangential force Pt.

The forces of the cutter are listed below.

Pt – Tangential force.

Pr – Radial force.

R – Resultant force of Pt and Pr.

The forces in the direction of machine movement are as listed below.

Ph – Force in a direction opposite to the feed.

Pv – Force in the direction of vertical

MECHANISM Of MILLING
A. Forces in Milling
 Ph’ and Pv’ are the horizontal and vertical forces in milling. The radial force Pr
exerts pressure on the cutter, bearings and also tends to bend the cutter. Thus the
cutter arbor is subjected to bending by the action of the two forces Pt and Pr or their
resultant R. Also, the arbor is subjected to torsion by the action of the movement of
resistance. So, the arbor is designed for both bending and torsion.

The horizontal force Ph tends to push the work from the cutter. This is prevented
by providing an appropriate clamping device on the male dovetail block. The
horizontal force Ph and the vertical force Pv are used to design the work holding unit
including the block. The vertical force Pv tends to lift the base from the saddle and
this is prevented by clamping the base rigidly on to the saddle/ tool post.

While milling, the forces Ph’ and Pv’ tend to separate the cutter from the work
piece.

B. Chip Cross Section

The cross section of the chip produced by a single point tooth will be the one which
is confined within two arcs of a radius equal to one half of the cutter diameter (d) as
shown in Fig.3 ( Sundaramoorthy and Shunmugam, 2000).
 Fig. 3. Chip Cross Section

OC = (d/2 – a); OB = d/2

Therefore, BC = {d2/4 – (d/2 – a2)} 1/2 = {a(d-a)}1/2

SINQS = BC/OB = {a (d-a)}1/2/(d/2)

When the cutter tooth has entered the work piece material by an angle Q,

Chip thickness X = St. SIN Q, where, St is the feed per tooth. If the cutter rotates
at n rpm, the feed per minute is equal to S = n.nt.St, where nt is the number of teeth
in the cutter and X = {S/(n.nt)}Sin Q

The maximum chip thickness is then equal to:

 Xmax = {S.SinQS/(n.nt)} That is Xmax = S. 2{a(d-
a)}1/2/(n.nt.d)

A. Power Required for Cutting

Even during cutting operation with straight teeth, and therefore, constant width of
cut, the cutting force and the power required are not proportional to the depth of cut,
because the specific cutting resistance is not constant and it varies with the changing
chip thickness.

The mean power required at the milling cutter is calculated by means of specific
cutting resistance Km. The cross sectional area of the chip at any instant is given by
the following formula (Vijayaraghavan 2006

Chi Specific cutting

Max. p pressure kg/mm2

thickness
(mm) Cast iron

Mediu
Soft m Hard

0.02 210 305 420

0.04 163 235 426

 0,06 142 205 285

0.08 129 186 259

0.10 122 175 244

A. Power Required in Milling

Ncut = P.v/4500 H.P, where v is cutting speed in m/min.

Calculation:

Work material = Cast iron

Cutting speed (v) = 20m/ min

Cutter diameter (d) = 70 mm No. of teeth (nt) = 12

Feed for cast iron (S) = 100mm/min

Cutter thickness (t) = 10 mm

Taking the module (m) = 4

Depth of cut (a) = 2.157m = 2.1.57x4 = 8.628 mm Cutter speed (n) = 1000.v/(π.d)
= 1000.20/(3.141x70

= 91 rpm.
Max. chip thickness is:

Xmax = 2S{a(d-a)}1/2/(n.nt.d) =2x100{8.628(70-8.628)}1/2/(91x12x70) =

0.062 mm

The specific cutting pressure from the table is :

Km = 285 kg/mm2 for hard martial.

Mean area of cross section is computed as shown below. Am = S.t(a/d)1/2/(n.nt)

=100x10(8.628/70)1/2/(91x12) = 0.322 mm2 Pheripheral force/ tangential

force (Pt) = Km.Am
= 285 x 0.322
= 91.77 kg

Therefore power required, Ncut = P.v/4500 H.P

= 91.77x20/4500
 = 0.408 H.P.

Power required for the motor Nm = Ncut/η, where η is the efficiency

(0.75)

Therefore, Nm = 0.408/0.75 = 0.544 H.P.

Design power N=1.15 Nm =1.15 X 0.544 = 0.0.6256 H.P. The power of the lathe
motor is 7 H.P., it is sufficient to meet the power required for cutting.

E. Other Forces During Cutting

Horizontal = (1 to 1.2) x
component Ph Pt

= 1.2x 91.77 =
110.124 kg

Vertical = (0.2 to 0.3) x

component Pv Pt

= 0.3 x 91.77 =
27.53 kg

R = Resultant
force = (ph2 + pv2)1/2
 = (91.772 + 27.532)1/2 = 95.6
kg

Radial force Pr =(R2 – Pt2)1/2

= (95.62 – 91.772)1/2 = 26.78

kg

Tangential force 91.77

Pt = kgf

Horizontal force 110.124

Ph = kgf

27.53
Vertical force Pv = kgf

79.975
Radial force Pr = kgf

Resultant force R = 95.6 kgf

The design of cutting arbor is explained in this subsection (Kurumi and Gupta
2001). H.P. of the lathe = 7

Diameter of cutter d = 70mm

HP = 2πNT/4500, where T is the torque in kg.-m and N is the speed of the cutter
which is 91 rpm.
Therefore, T= HPx4500/(2Nπ) = 7x4500/(2x91x3.141) = 55.09 kg-m = 5509 kg-
cm

Assuming the cutter distance from the chuck as 20 cm, the bending moment Mb is
computed as shown below.

Mb= Rx20 = 95.6x20 = 1912 kg-cm

The diameter of the cutter arbor is calculated using the following formula.

16

{(Kb.Mb)2 +
do3 = (Kt.Mt)2 }1/2

where τ is the design shear stress which is 900 kg/cm2 for mild steel.

Bending moment Mb = 1912 kg-cm

Torque Mt = 5509 kg-cm

 Kb is the combined shock and fatigue factor applied to Mb, which is equal to 1.5
and Kt is the combined shock and fatigue factor applied to Mt, which is equal to 1.2.

16

do3 = { (1.5x1912)2 + (1.2x5509)2}1/2

900

do = 5 cm

So, the diameter of the cutter (d0) is taken as 5 cm.

G. Design of Dovetail Blocks

Since, the cutting force acts on the outer surface of the male dovetail block, the
stress induces in the dovetail blocks (male as well as female blocks) is very minimal.
However, the weakest section of each dovetail block is kept as 10 mm and the
thickness of each of them is assumed as 20mm. The top view, side view and the
front view of the whole assembly are shown from Fig.4 to Fig.6. The front view of
the whole attachment in working condition is shown in Fig.7 and its rear view is
shown in Fig.8.
MECHANISM OF MILLING ATTACHMENT:

whole construction of machine is placed on the base plate. The base plate
is drilled centrally, is attached with the compound rest of lathe. The tool is fixed in
the chuck. The chuck will be rotated at the front side the swivel base is fixed over
the tool post. In the swivel base the machine vice is fixed on the front. The job is
fixed on the machine vice. The feed is given by carriage at the same time the depth
time the depth of cut is given by swivel base by moving up-wards .The milling
attachment in the used for key way cutting in the shaft.

WORKING PRINCIPLE

The sliding bed is rotated with the help of a screw rod. In that sliding bed the
vice is fixed. The vice is used to hold the work piece. The milling cutter is fixed to
the lathe drill chuck. The exciting tool post is replaced so that to fix the attachment
here by suitable arrangement. By changing the milling cutter, the required shape is
obtained in the work piece.

CUTTING IN ACTION/ MILLING PROCEDURE

The steps of milling the work piece using this attachment are presented below.

Step 1: Fix the work piece on the male dovetail block, facing the milling cutter.

Step 2: Mark the area to be machined on the work piece.

 Step 3: Push the male dovetail block down such that the milling cutter exterior
tooth coincides with the top mark of the cutting region of the work piece.

Step 4: Move the Carriage of the lathe such that the milling cutter exterior tooth
coincides with the left vertical side of the cutting region on the work piece.

Step 5: Move the cross slide towards the milling cutter till the work piece surface
gets in contact with the tip of the exterior tooth of the milling cutter.

Step 6: Switch on the lathe and allow the headstock to rotate in anti-clockwise
direction.

Step 7: Give the necessary depth of cut for rough cut (for example 2.5 mm for mild
steel)

Step 8: Turn the hand wheel clockwise slowly until the cutter reaches the bottom
line of the cutting region on the work piece.

Step 9: Move the cross slide back to release the work piece from the cutter.
 Step 10: Turn the hand wheel anti-clockwise such that the tip of the milling cutter
touches the top line of the cutting region of the work piece.

Step 11: Move the carriage of the lathe for the next cut.

line of the cutting region of the work piece is reached.

Step 13: Switch off the lathe.

Step 14: Repeat Step 4 to Step 13 until the required depth of cut is attained

HOLDING WORK PIECES IN THE VISE

AS previously mentioned, five types of vises are manufactured in various

sizes for holding milling machine workplaces. These vises have locating keys or
tongues on the underside of their bases so they may be located correctly in relation
to the T-slots on the milling machine table.

The plain vise similar to the machine table vise is fastened to the milling
machine table. Alignment with the milling machine table is provided by two slots at
right angles to each other on the underside of the vise. These slots are fitted with
removable keys that align the vise with the table T-slots either parallel to the machine
arbor or perpendicular to the arbor.

The swivel vise can be rotated and contains a scale graduated in degrees at
its base which is fastened to the milling machine table and located by means of keys
placed in the T-slots. By loosening the bolts which clamp the vise to its graduated
base, the vise may be moved to hold the work piece at any angle in a horizontal
plane. To set a swivel vise accurately with the machine spindle, a test indicator
should be clamped to the machine arbor and a check made to determine the setting
by moving either the transverse or the longitudinal feeds, depending upon the
position of the vise jaws.

Any deviation as shown by the test indicator should be corrected by swiveling

the vise on its base. The universal vise is used for work involving compound angles,
either horizontally or vertically. The base of the vise contains a scale graduated in
degrees and can rotate 360° in the horizontal plane and 90° in the vertical plane. Due
to the flexibility of this vise, it is not adaptable for heavy milling.

ADVANTAGES:

The unit is compact in size.

Less maintenance is essential

The unit gives long life with proper alignment of gears.

Jobs can be easily handled in this unit.

APPLICATIONS:

Desired milling cutting can be easily turned.

CHAPTER:5

LIST

OF

MATERIALS

5.LIST OF MATERIALS

S.NO COMPONENT MATERIAL QUANTITY NO.

1 L.ANGLE CAST IRON 1
2 PLUMBER BLOCK CAST IRON 4
3 PULLEY CAST IRON 2
4 SPINDLE(SHAFT) CAST IRON 1
5 END GRINDING ABRASIVE 2
STONE

Table 5.1
 Chapter:6

COST ESTIMATION

6.COST ESTIMATION

S.NO COMPONENT MATERIAL QUANTITY COST

1 L-ANGLE CAST 1 50
IRON
2 MOTOR - 1 1000
3 GRINDING ABRASIVE 1 50
STONE
4 V-BELT ABRASIVE 1 50
5 PLUMBER CAST 2 400
BLOCK IRON
6 SPINDLE CAST 1 300
(SHAFT) IRON
7 BOLDS&NUTS CAST - 50
IRON
 8 PULLEYS HSS 2 100
9 PAINT - ILT 150
10 GURD(SIDE) HSS 1 250
TOTAL 2400

CONCLUSION :

The lathe with milling attachment is to eliminate the need for an operator
owning both a milling machine and a lathe. It is designed to be mounted to the side
of the milling machine and to be used without disturbing a setup in the associated
vise. The details of manufacturing a Miniature Lathe are given in a clear manner.
Different types of components are essential for various purposes. These components
include several operations, initially the component to be machined as irregular
shapes. This shape is into regular form and to our required wish by performing
various operations on it. Therefore a machine is required to convert this irregular
shape material into a finished product. We have selected a Miniature Lathe for doing
several small components which is used for various purposes in various fields.
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Lakshmi Publications, Sirkali, 2006.
[3] M. Sagar, 2016, “Design and Fabrication of Gear Cutting Attachment to Lathe
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Technology, Special Issue NCRTEEF OSS 2016, pp.217-285.
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