JADAVPUR UNIVERSITY

Faculty of Engineering & Technology

Department of Mechanical Engineering
DATE.
EXPERIMENT NO..
EXERCISE NO

ABHIMANYU KAR
B.M.E. III SEC A21 ROLL NO 03036
TITLE :


OBJECT:
MAKING A SPUR GEAR


MAKING A CAST IRON GEAR OF 10 D.P.,
20 TEETH FROM 2.51 THICK
BLANK
Abhimanyu Kar Roll No. 03036
What is a mandrel ? What amount of taper is
usually given to it ?
Mandrel is a job holding device which is used to clamp jobs
having holes by the method of simple self-locking due to taper. It
is a cylindrical bar having taper along most of its length. The
remaining portion without taper is used for holding the mandrel
with any other job holding device like lathe dog, chuck etc. The
two portions are separated by a collar.
The mandrel has a ground surface of high surface finish. A
particular mandrel is used to hold a job of a particular diameter
the open end of the taper should have very loose fit to this
diameter and the other end of the taper should have interference
fit. A job is clamped into a mandrel in a mandrel press. Then the
mandrel is held for machining in other job holding devices. The
two ends of a mandrel have centre marks for holding between
centres in a lathe.
The taper given to a mandrel is usually 1 in 1000.
Collar
Abhimanyu Kar Roll No. 03036
Calculate the outer diameter of a gear having 45
teeth and 10 D.P. Develop the formula you have
used.

P
2 N
P P
N
P
D
a D D
D
P
1
a
D N
D
N
P
P
o
o
+
=
+ =
+ =
+ =
=
=




by given is gear the of diameter outer the So,

by given is gear the of a addedndum The
diameter.
circle pitch the is and teeth of number the is where So,
gear a of pitch diametral the be Let
2
2
2
Abhimanyu Kar Roll No. 03036
Draw a labeled sketch of the dividing head of a
milling machine for simple indexing.

Index plate
Driving plate
Worm (single thread)
Worm wheel (40T)
Spring-loaded
pin
Abhimanyu Kar Roll No. 03036
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Abhimanyu Kar Roll No. 03036
How would you index 45 divisions and 815
angles ?
Say we have to index n divisions. Then the number of turns
of the lead screw for each division will be 40/n. To index 45
divisions, for each division we have to rotate the crank and thus
the worm should be rotated 40/45 or 8/9 complete revolutions.
So the hole circle we will use on the index plate shall contain
number of holes which is a multiple of 9. The most commonly
used Brown and Sharpe index plates contain a set of three index
plates having the following hole circles
Plate 1: 15, 16, 17, 18, 19, 20
Plate 2: 21, 23, 27, 29, 31, 33
Plate 3: 37, 39, 41, 43, 47, 49
We can use the 18 hole circle, the 2
nd
circle from the
periphery in plate no.1 so we shall rotate the crank by 16 holes
every time or we can use the 27 hole circle, the 4
th
one from the
periphery in plate no.2 in this case we shall rotate the crank by
24 holes.
For angular indexing one rotation of the crank, which
corresponds to 1/40 of the periphery of the job corresponds to
360/40 = 9 of angular movement. To index 815 i.e. 8 or
33/4 the rotation of the crank shall be 33/(4x9)=33/36 or 11/12
revolution for each division. In Brown and Sharpe index plates
there is no hole circle having 12 or its multiple number of holes.
There are two solutions
To go for compound indexing
For compound indexing, two or more hole circles can be
used. This is done when the fraction of the periphery the
crank needs to be rotates can be expressed as the sum or
difference of two more fractions which, in their
denominator, has some number of which there is a hole
circle available. For rotating the crank by 11/12
revolutions, let us choose 18 and 12 hole circles. So
Abhimanyu Kar Roll No. 03036
We can find out which fraction to use by the following method







So we shall first use the 16 hole circle, move it 4 divisions,
then we shall loosen the crank from the worm (without disturbing
the job) and move it to 18 hole circle, there we shall move it
through 3 divisions and engage the pin. Compound indexing by
moving the crank in the same direction for all the circles has the
advantage of having no problem due to backlash.
To use Cincinati index plate
Cincinati index plate contain the following hole circles
In one side: 24, 25, 28, 30, 34, 37, 38, 39, 41, 42, 43
On reverse: 46, 47, 49, 51, 53, 54, 57, 58, 59, 62, 66
We can use the smallest circle on the forward side which
is the 24 hole circle, each time we shall turn it by 22
divisions.


( )
18
12
16
4
18
6
1
16
4
18
6
7
16
4
8
18
132
16
132
12
11
132
1
16 18 11
16 18 12
+ =
|
.
|

\
|
+ = =
|
.
|

\
|
=
=


=
So,
cirlces hole of Product
circles hole of Difference
Fraction
1
Abhimanyu Kar Roll No. 03036
Sketch a form milling cutter you have used.
What do you mean by the term cutter number ?


FRONT VIEW SIDE VIEW
3D VIEW GEAR CUTTER IN ACTION
Abhimanyu Kar Roll No. 03036
In gear milling cutters the cutter contains all of the cutter
profile from the dedendum to the addendum circle. For involute
gears the tooth profile does not differ for different sizes but the
tooth thickness (thus the difference between two teeth which is
proportional) and the amount of clearance (difference of base
circle and dedendum circle radii, inversely proportional to the
diametral pitch) differs though in small amounts. So the same
cutter can be used only for cutting a close range of sizes. So for
a particular profile, pressure angle and diametral pitch, there are
standard cutters available specified by their numbers each for a
range of number of teeth. For 10 D.P. gears they are

Cutter no. Number of teeth
1 135 to rack
2 55 to 134
3 35 to 54
4 26 to 34
5 21 to 25
6 17 to 20
7 14 to 16
8 12 to 13

We have used cutter no. 6 for cutting 20 teeth 10 D.P. gear.
Why cast iron is machined dry ?
Grey cast iron contains carbon in the form of graphite flakes.
Graphite acts as a good lubricant, so it does not need any
additional lubricant for machining.