1

LEARNING GUIDE

Week No.: __1__

TOPIC:

MULTIPLE THREAD CUTTING

I. EXPECTED COMPETENCIES

At the end of the topic, the student should be able to:

1. Familiarize the concept of multiple thread and different methods in cutting.

2. Perform multiple thread cutting by different methods.

II. CONTENT/TECHNICAL INFORMATION

Multiple Threads

A multiple thread consists of two or more intertwined threads running parallel to

one another. Intertwining threads allow the lead distance of a thread to be increased
without changing its pitch. This allows multi-start threads to maintain a
shallow thread depth relative to their longer lead distance.

Multiple threads are used to obtain an increase in lead without weakening the screw
itself. Multiple threads are much used in machine construction. Multiple screw
threads are refer to as double, triple and so on.

In a single thread, the lead is equal to the pitch. A double thread has two threads and
two grooves starting on opposites sides of the screw. The lead of the double thread is
twice that of a single thread having the same pitch. A triple thread has three threads
and three grooves. The lead of a triple thread is three times that of a single thread of
the same pitch.

Figure 1.1 Multiple Thread

(Source: https://forums.autodesk.com/t5/image/serverpage/image-id/239013iAB39618111AA3D7A?v=1.0)

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Methods of Cutting Multiple Threads

Cutting procedure of multi start threads is similar to that of cutting single start
threads. In multi start thread, circumference of the job should be divided in to as
many parts as the starts of the threads and thus every part of the divisions of the
circumference of job becomes the starting point for the new start.

The common methods are: By using drive plate having accurately spaced slots; by
indexing the spindle gear through the necessary fractional part of a revolution to
start the second thread; and by setting the compound parallel with the work axis and
advancing it a distance equal to the pitch of the screw.

1. Face Plate Method

To cut multiple threads by means of the face plate, it is necessary to have the slots
accurately spaced. To cut a double thread, cut the first thread completely as for
single thread cutting; then, without disturbing the cutting tool setting, and without
turning the lead screw, remove the work from between the centers and engage the
tail of the lathe dog in the slot opposite the one in which it was first engage; re-
engage the tailstock center and cut the next thread as though a single thread were
being cut.

Figure 1.2 Face plate Method

2. Gear Method

To cut multiple threads by indexing the spindle, it involves something of chance.

The procedure consists of cutting the first thread as though the screw had one start,
or a single thread, then determining the number of teeth in the spindle gear. If this
number of teeth is divisible by two, draw a narrow chalk or pencil line across the
face of this gear where it is tangent to the intermediate or stud gear; next count one-

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half the number of teeth in the spindle gear, starting at the chalk line, and draw
another line; then disengage the stud gear and turn the spindle until the second
chalk line on the spindle gear coincides with the line on the stud gear. This should
cause the work to make one-half a revolution and place it in position to cut the
second thread.

Figure 1.3 Gear Method

3. Compound Rest Method

In using the compound to cut multiple threads, it should be turned so that its lead
screw action is parallel with the axis of the work, then cut the first thread
completely as for single threads except that the final sizing of the thread is done
with the cross slide screw. To cut the next thread, move the compound by means of
its feed screw a distance equal to the pitch of the screw to be cut.

– The compound rest is set-up parallel to the workpiece. Compound rest

micrometer collar must set to zero. And also, cutting tool must be tangent to
the workpiece before starting a cut. NOTE: Gearbox setting for TPI and the
speed must be set up.

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– Start a cut about 0.002’’ deep. Proceed as cutting a single thread until the
thread is half of the depth.

– As finished cutting half of depth, proceed to the next part. Continue cutting
until the thread has been cut to its proper depth. You have now finished
cutting multiple thread using Compound Rest Method.

Figure 1.4 Compound rest Method

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III. PROGRESS CHECK

Choose any method to cut multiple thread and make a procedures/steps how to
produce multiple thread having a lead of 4 mm and pitch of 2mm.

Step No. Procedure

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IV. REFERENCE/S

Miller, Rex (2004). Audel Machine Shop Tools and Operations, Wiley Publishing Inc.

Burghardt, H.D. et. al., (1959). Machine Tool Operation 1.

EP DeGarmo et.al. (1988). Materials &Processes in Manufacturing 7th Edition,

Macmillan Publishing Company, New York

3G Elearning (2014). Machine Shop Operations, 3G Elearning

LEARNING GUIDE

Week No.: __2__

TOPIC/S:

SHAPER CONSTRUCTION & ATTACHMENTS/ACCESSORIES

I. EXPECTED COMPETENCIES

At the end of the topic, the student should be able to:

1. Define the operation of facing, chamfering, plain and shoulder turning.

2. State the methods of each operation.
3. Perform facing, chamfering, plain and shoulder turning in lathe.

II. CONTENT/TECHNICAL INFORMATION

Shaper

A shaper is a reciprocating type of machine tool intended primarily to produce flat

surfaces. These surfaces may be horizontal, vertical, or inclined. In general the shaper
can produce any surface compost of straight line element. Modern shaper can
generate contoured surface.

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Figure 2.1 Shaper Construction

(Source: https://static.learnmechanical.com/wp-content/uploads/2019/02/Shaper-Machine.jpg
Principal Parts of Shaper Machine

a. Base – The base is the necessary bed or support required for all machine tools. The
base may be rigidly bolted to the floor of the shop or on the bench according to the
size of the machine. It is also designed that it can take up the entire load of the
machine and the forces setup by the cutting tool over the work. It is made of cast iron
to resist vibration and take up high comprehensive load.
b. Column – The column is a box like casting mounted upon the base. It encloses the
ram driving mechanism. Two accurately machined guide ways are provided on the
top of the column on which serves as the guide ways for the cross rail is also
accurately machined. The lid on the left side of the column may be opened for
inspection and oiling of the internal mechanism with the column. The other side of
the column contains levers, handles, etc. for operating the machine.
c. Cross Rail – The cross rail is mounted on the front vertical guide ways of the
column. Its two parallel guide wayson its top in the vertical plane that are
perpendicular to the ram axis. The table may be raised or lowered to accommodate
different sizes of jobs by rotating an elevating screw which causes the cross rail to
slide up and down on the vertical face of the column. A horizontal cross feed screw
which is fitted within the cross rail and parallel to the top guide ways of the cross rail
actuates the table to move in a crosswise direction.
d. Saddle – The saddle is mounted on the cross rail which holds the table firmly on its
top. Crosswise movement of the saddle by rotating the cross feed screw by hand or
power causes the table to move sideways.
e. Table – The table which is bolted to the saddle receives crosswise and vertical
movements from the saddle and cross rail. It is a box like casting having T-slots both
on the top and sides for clamping the work. In a universal shaper it may be swivelled
on a horizontal axis and the upper part of the table may be tilted up or down. In
heavier type shaper, the front face of the table is clamped with a table support to
make it more rigid.

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f. Ram – The ram is the reciprocating member of the shaper. This is semi-cylindrical in
form and heavily ribbed inside to make it more rigid. It slides on the accurately
machined dovetail guide ways on the top of the column and is connected to the
reciprocating mechanism contained within the column. It houses a screwed shaft for
altering the position of the ram with respect to the work and hoods the tools head at
the extreme forward end.
g. Tool Head – The tool head of a shaper holds the tool rigidly, provides vertical and
angular feed movement of the tool and allows the tool to have an automatic relief
during its return stroke. The vertical slide of the swivel base which is held on a
circular seat on the ram. The swivel base is graduated in degrees, so that the vertical
slide may be set perpendicular to the work surface or at any desired angle. By rotating
the down feed screw handle, the vertical slide carrying the tool executes down feed or
angular feed movement while machining vertical or angular surface. The amount of
feed or depth of cut may be adjusted by a micrometer dial on the top of the down feed
screw, apron consisting of by a screw. By releasing the clamping screw, the apron
may be swivelled upon the apron swivel pin either towards right with respect to the
vertical slide. This arrangement is necessary to provide relief to the tool while making
vertical or angular cuts. The two vertical walls on the apron called clapper box houses
the clapper block which is connected to it by means of hinge pin. The tool post
dismounted upon the clapper block. On the forward cutting stroke the clapper block
fits secured to the clapper box to make a rigid tool on the work lifts the block-out of
the clapper box a sufficient amount preventing the tool cutting edge from dragging
and consequent wear. The work surface is also prevented from any damage due to
dragging.

Figure 2.2 Tool Head of Shaper

(Source: https://www.slideshare.net/RohithR22/shaper-machine-project-work-report-pdf)

Tool Head of Shaper

1. Down feed screw micrometer dial 6. Clapper block

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2. Down feed screw 7. Tool post

3. Vertical slide 8. Washer
4. Apron 9. Apron swivel pan
5. Apron clamping bolt 10. Swivel base

h. Clapper box – clapper box helps to avoid damage to machined surface during the
return stroke of tool

Attachments used in Shaping Machine

Some attachments are often used for extending the processing capabilities of shaping
machines and also for getting some unusual work in ordinary shaping machine.

Attachment for double cut

This simple attachment is rigidly mounted on the vertical face of the ram replacing
the clapper box. It is comprised of a fixed body with two working flat surfaces and a
swing type tool holder having two tools on either faces. The tool holder is tilted by a
spring loaded lever which is moved by a trip dog at the end of its strokes. Such
attachment simply enhances the productivity by utilising both the strokes in shaping
machines.

Figure 2.1 Double Cut attachment used in shaping machine

(Source: https://nptel.ac.in/content/storage2/courses/112105127/pdf/LM-22.pdf)

Thread rolling attachment

The thread of fasteners is done by mass production methods. Thread rolling is hardly
done nowadays in shaping machines. However the configuration, mounting and the

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
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working principle of the thread rolling (in shaping machine) attachment are visualised
in Fig. 4.6.10. In between the flat dies, one fixed and one reciprocating, the blanks are
pushed and thread – rolled one by one.

Figure 2.2 Thread rolling attachment used in shaping machine

(Source: https://nptel.ac.in/content/storage2/courses/112105127/pdf/LM-22.pdf)

Matterson’s attachment

Various machines and processes have been developed for producing gear teeth
with high productivity and job quality But, if required, it may be occasionally done by
shaping machine in some small tool room or small workshop specially for repair and
maintenance work. One or two, even all the teeth of a gear may be cut by forming tool in
shaper using an indexing head. But such forming, especially in shaper is not only very
slow process but also not at all accurate. But the Matterson’s attachment can produce
gear (spur) teeth even in shaping machine by generation process. For generation of the
tooth by rolling the blank is rotated and the bed is travelled simultaneously at same linear
speed by the synchronised kinematics as indicated in the diagram. After completing one
tooth gap both the tool and blank are returned to their initial positions and then after
indexing the blank for one tooth, the tool – work motions are repeated.

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Figure 2.3 Matterson’s Attachment for gear teeth generation in shaping machine.
(Source: https://nptel.ac.in/content/storage2/courses/112105127/pdf/LM-22.pdf)

III. PROGRESS CHECK

A. Choose the letter of the correct answer.

1. The front of the body provides guideways for _______
a) ram
b) crossrail
c) can’t say anything
d) none of the mentioned
2. The crossrail is mounted on the______ of the body frame
a) front
b) back
c) can’t say anything
d) none of the mentioned
3. Which movement of ram is called stroke?
a) only back
b) only forth
c) back and forth
d) none of the mentioned
4. Which of the following part of shaper supports all of the other parts of machines?
a) Base
b) Column
c) Cross rail
d) Table
5. Which of the following act as housing for an operating mechanism in shaper?
a) Base

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b) Column
c) Cross rail
d) Table
6. Which of the following part of shaper machine hold and supports the work piece?
a) Base
b) Column
c) Cross rail
d) Table
7. Which of the following part of shaper machine carries tool head?
a) Cross rail
b) Column
c) Ram
d) Table

8. Which of the following part of shape is used to hold the tool?

a) Cross rail
b) Tool head
c) Ram
d) Vice
9. Which of the following can be used as job holding device in shaping machine?
a) Cross rail
b) Column
c) Ram
d) Vice
10. Elevating screw causes the crossrail to slide up and down on the____ face of the
column.
a) horizontal
b) vertical
c) bottom
d) top

B. True or False:

______1. The ram can be moved up and down.

______2. The ram is driven back and forth in its slides by crank slider mechanism.

______3. In shaper, the cutting tool is made to reciprocate across the job.

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______4. The shaper is a reciprocating type of machine tool primarily intended for
producing flat surfaces.

______5. The crossrail has parallel guideways on its top in horizontal plane.

______6. The vertical cross feed screw actuates the table to move in a crosswise
direction.

______7. Crosswise movements of the saddle causes the table to move sideways.

______8. The table is bolted to the saddle.

______9. Toolhead of a shaper provides vertical and angular feed movements of the
tool..

______10. The ram is the reciprocating member of the shaper.

IV. REFERENCE/S

Miller, Rex (2004). Audel Machine Shop Tools and Operations, Wiley Publishing Inc.

Burghardt, H.D. et. al., (1959). Machine Tool Operation 1.

EP DeGarmo et.al. (1988). Materials &Processes in Manufacturing 7th Edition,

Macmillan Publishing Company, New York

3G Elearning (2014). Machine Shop Operations, 3G Elearning

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
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LEARNING GUIDE

Week No.: __3__

TOPIC:

SHAPER OPERATIONS

I. EXPECTED COMPETENCIES

At the end of the topic, the student should be able to:

1. Identify the different types of shaper and its features.

2. Determine the types of operations perform in shaper machine.
3. Familiarize/perform the setting of tool, length and position of stroke during
shaper operation.

II. CONTENT/TECHNICAL INFORMATION

Shapers are classified in number of ways depending upon the general features of
design or the purpose for which they are intended.

Shapers are classified under the following headings.

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1. According to the type of mechanism used for giving reciprocating motion to

the ram:
(a) Crank type (b) Geared type (c) Hydraulic type
2. According to the position and travel of ram:
(a) Horizontal type (b) Vertical type (c) Traveling head type
3. According to the type of design of the table:
(a) Standard shaper (b) Universal shaper

 Crank shaper: Shapers whose ram reciprocates with the help of a crank
mechanism.
 Geared shaper: The ram reciprocates with spur gear mechanism. This type of
shaper carries a rack under the ram for to and fro motion.
 Hydraulic shaper: The movement of the ram is provided by hydraulic pressure.
 Horizontal shaper: The ram reciprocates in horizontal direction.
 Vertical shaper: The ram reciprocates in vertical motion. It is also known as
slotter.
 Travelling head shaper: A shaper whose reciprocating tool head is mounted on
the bed in such a way that the head may be fed laterally on ways provided on the
bed prior to each cutting.

 Standard shaper - In this machine, the table has only two motion: crosswise in
the horizontal plane and vertical movement (up and down). The table is not
provided with a swiveling motion.
 Universal shaper- This machine is similar to plain shaper except that the table
can be tilted at a various angle, making it possible to inclined flat surfaces. The
table can be swiveled about 360 degrees about a central axis parallel to the cutting
stroke direction and also perpendicular to it, that is, around two horizontal axes.
The table also has a movement in the horizontal plane and vertical direction (up
and down ) as in plain shaper.

Shaper Operations

There are 4-types of operations performed in a shaper machine, and those are:

1. Horizontal Cutting – horizontal surfaces are machined by moving the work

mounted on the machine table at a cross direction with respect to the ram
movement. The clapper box can be set vertical or slightly inclined towards the
uncut surface. This arrangement enables the tool to lift automatically during the
return stroke. The tool will not drag on the machined surface.
2. Vertical Cutting – A vertical cut is made while machining the end of a
workpiece, squaring up a block or machining a shoulder. The feed is given to the
tool by rotating the down feed screw of the vertical slide. The table is not moved

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vertically for this purpose and the apron is swiveled away from the vertical
surface being machined.
3. Inclined Cutting – An angular cut is done at any angle other than a right angle to
the horizontal or to the vertical plane. The work is set on the table and the vertical
slide of the tooth head is swiveled to the required angle either towards the left or
towards right from the vertical position.
4. Irregular cutting – A round nose tool is used for this operation. For a shallow cut
the apron may be set vertical but if the curve is quite sharp, the apron swiveled
towards the right or left away from the surface to be cut.

Shaper Mechanism

In a shaper machine, the rotary-motion of the drive is converted into reciprocating

motion of a ram holding the tool, by means of mechanism inside the column of a
machine.

In a shaper, the metal id removed during forward cutting stroke, while in return
stroke no metal is removed. Therefore, in order to reduce total machining time, the
shaper mechanism should be designed.

The quick return mechanism of a machine can be obtained by the following

methods:

1. Crank and slotted link mechanism

2. Whitworth quick return mechanism
3. Hydraulic shaper mechanism

Crank and Slotted Link Mechanism:

A large bull gear mounted within a column and a radial slide bolted to the center
of the bull gear which carriers sliding block into which crank pin is fitted. The power
is transmitted from the motor through the driving opinion to the bull gear. The
rotation of the bull gear causes the crank pin to revolve at uniform speed. The rocker
are sliding block mounted on crank pin is fitted within the slotted link or rocker arm,
which is provided at its bottom end attached to the column frame. The upper arm of
the rocker arm is connected to the ram block in a rocker arm slides up and down,

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giving rocking movement to the arm, thus rotary motion to the bull gear is converted
into reciprocating motion of the ram.

Figure 3.1 Crank and Slotted Link Mechanism

(Source: https://4.bp.blogspot.com/-voKmQDjj-qQ/U8GM3pILsRI/AAAAAAAAN8Y/YqrRPjIBZfA/s1600/Crank-
and-Slotted-Link-Mechanism.png)

Whit Worth Quick Return Mechanism:

The bull gear is mounted on a fixed pin A which is free to rotate. The crank
plate is pivoted eccentrically on affixed pin at O A crank pin with sliding block fitted on
the face of the bull gear slides into the slot provided on a crank plate the other end of the
crank plate is connected to a connecting rod by means of pin and the other end of a
connecting rod is connect to a ram which reciprocates in a horizontal axis. When the bull
gear rotates at a constant speed, the sliding block slides in a slot of a crank plate causing
it to about point “ O “. The rotary motion of a crank plate is converted into reciprocating
motion of a ram by a connecting rod.

Figure 3.2 Whit Worth Quick return Mechanism

(Source: https://www.slideshare.net/RohithR22/shaper-machine-project-work-report-pdf)

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When the crank pin is at the position “C” the ram will be at the extreme backward
position and when the crank pin is at “B” the ram will be at extreme forward position.
When crank pin travels from C to B, the ram performs the forward cutting stroke and
when crank pin travels from B to C, the ram performs the backward return stroke. As the
crank pin rotates at constant speed, the time taken during forward cutting stroke through
an arc CEB is greater than the time taken during return stroke through an arc BDC. Thus
a quick return motion is obtained by this mechanism.

The length of stroke of a ram can be changed by changing position of a

connecting rod on crank plate from the fixed point ‘O’ . The position of stroke can be
altered by changing the position of pin on the ram.

Hydraulic Shaper Mechanism:

It consists of oil pump, valve chamber, a cylinder, piston, oil reservoir and reversing
lever. The piston rod is connected the ram body. The oil from the reservoir is pumped
under high pressure to the right side of the cylinder through valve chamber, which exerts
the pressure on piston causing the ram to perform forward stroke, and any oil on left side
of the cylinder is discharged to the reservoir through throttle valve at the end of forward
stroke, the shaper dog hits against reversing lever causing valves to change their position
in a valve chamber. Now the oil under high pressure is pumped to the left side of the
piston causing the ram to perform return stroke and discharging the oil present in right
side of the piston to the reservoir.

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Figure 3.3 Hydraulic Shaper Mechanism

(Source: https://i.ytimg.com/vi/hWijmERGToo/hqdefault.jpg)

At the end of return stroke another shaper dog hits the reversing lever changing
the direction of the piston and this cycle is repeated.

In this case, the quick return motion is affected by the difference in stroke,
volume of the cylinder at both ends. The left side being smaller due to the presence of
piston rod. As the pump has a constant discharge and same quantity of oil will be
supplied on both the ends, which increase the pressure on left side than right side and
increasing the speed during return stroke. The position and length of stroke is adjusted by
changing the position of reversing dogs. The cutting speed may be changed by
controlling the throttle valve, which regulates the flow of oil.

Quick Return Mechanism

In the forward stroke, the Slider moves fast and removing the material from the
workpiece. Whereas in the return stroke, the Slider moves faster than the forward stroke
that means Quick return, it takes less time to return, called a return stroke.

Figure 3.4 Quick return Mechanism

(Source: https://learnmechanical.com/shaper-machine/)

Setting The Tool, Stroke length & Position of stroke

 Setting the Tool

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- Tool overhang should be minimum

- Tool should be clamped properly with adequate support

Figure 3.5 Setting the Tool in Shaper

(Source: https://www.slideshare.net/RohithR22/shaper-machine-project-work-report-pdf)

 Setting the Stroke Length

- Maximum stroke length depends on the machine (18”, 24”, 36” etc.)
- Stroke length can be adjusted to a value less than maximum
- Stroke length depends on the length of job

To set the length of stroke on a shaper, move the ram to the extreme backward position
by means of the handwheel. Place the hand crank on the stroke setting shaft located on
the operator’s side of the shaper, and loosen the binding nut. Then turn the crank so that
the pointer on the ram indicates on the scale and the length of the work plus 5/8”, then
tighten the binding nut. The reason that 5/8’’ was added to the length of the stroke was to
provide clearance for the cutter.

Figure 3.6 Setting the Stroke length in Shaper

(Source: https://www.slideshare.net/RohithR22/shaper-machine-project-work-report-pdf)

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 Setting the Position of Stroke

- Position of stroke is the starting point & end point of stroke

To set the position of the stroke, move the ram to the extreme forward position by
means of the hand wheel. Place the hand crank on the stroke positioning shaft located on
the top front of the ram, and loosen the binder lever. Turn the crank so that the cutting
tool clears the front of the work by 1/8’’, then tighten the binder lever.

Figure 3.7 Setting the Position of Stroke in Shaper

(Source: https://www.slideshare.net/RohithR22/shaper-machine-project-work-report-pdf)
Specifications of Shaper Machine

 The maximum length of stroke of ram.

 Types of the drive ( Crank, Gear and Hydraulic type)
 Power input of the machine
 Floor space required to establish the machine
 Weight of the machine in tonne.
 Feed
 Cutting to return stroke ratio.
 Angular movement of the table.

III. PROGRESS CHECK

A. Choose the letter of the correct answer.

1. According to the type of mechanism used for giving reciprocating motion to the
ram, shaper can be classified as______
a) crank type
b) geared type
c) both crank type and geared type
d) none of the mentioned
2. According to the type of design of the table, lathe can be classified as_____
a) standard shaper

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b) universal shape
c) both standard shaper and universal shaper
d) none of the mentioned
3. Horizontal type shaper is type of shaper according to______
a) design of the table
b) position and travel of the ram
c) type of cutting stroke
d) none of the mentioned
4. Travelling head type shaper is type of shaper according to______
a) design of the table
b) position and travel of the ram
c) type of cutting stroke
d) none of the mentioned
5. In crank type shaper, for performing an operation a multi-point cutting tool is
employed.
a) true
b) false
6. Drive mechanism consists of ________
a) main drives
b) the gear box
c) quick return mechanism
d) all of the mentioned
7. Which of the following operation can be performed in shaper?
a) gear cutting
b) keyways cutting
c) curvilinear contours
d) all of the mentioned
8. At the end of one cycle, job is given a feed motion______ to the direction of tool
movement.
a) parallel
b) perpendicular
c) anti-parallel
d) none of the mentioned
9. Quick return mechanism is responsible for ram movement.
a) true
b) false
10. What should be adjusted first in the shaper machine?
a) position of stroke
b) length of stroke

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 23

B. Illustrate the following shaper operation and identify what types of operation
(Horizontal, vertical, inclined or irregular cutting).

Shaper Operations Type of Operation Illustration

Making V-block

Making external keyway

Making internal keyway

Machining a contour

Making a rack

Making a dovetail

Making T-slot

Making block (square &

parallel

Making a chuck key

Making hexagonal bolt

head

IV. REFERENCE/S

Miller, Rex (2004). Audel Machine Shop Tools and Operations, Wiley Publishing Inc.

Burghardt, H.D. et. al., (1959). Machine Tool Operation 1.

EP DeGarmo et.al. (1988). Materials &Processes in Manufacturing 7th Edition,

Macmillan Publishing Company, New York

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 24

3G Elearning (2014). Machine Shop Operations, 3G Elearning

LEARNING GUIDE

Week No.: __4__

TOPIC:

MILLING MACHINE OPERATIONS & CONSTRUCTION

I. EXPECTED COMPETENCIES

At the end of the topic, the student should be able to:

1. Familiarize the concept of multiple thread and different methods in cutting.

2. Perform multiple thread cutting by different methods.

II. CONTENT/TECHNICAL INFORMATION

Milling is the cutting operation that removes metal by feeding the work against a
rotating, cutter having single or multiple cutting edges. Flat or curved surfaces of
many shapes can be machined by milling with good finish and accuracy. A milling
machine may also be used for drilling, slotting, making a circular profile and gear
cutting by having suitable attachments.

Working Principle:

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 25

The workpiece is holding on the worktable of the machine. The table movement
controls the feed of workpiece against the rotating cutter. The cutter is mounted on a
spindle or arbor and revolves at high speed. Except for rotation the cutter has no other
motion. As the workpiece advances, the cutter teeth remove the metal from the
surface of workpiece and the desired shape is produced.

Figure 4.1 Principle of Milling

(Source:https://image.slidesharecdn.com/millingmachinehusain-151003135158-lva1-app6891/95/milling-
machinehusain-13-638.jpg?cb=1448736194)
Milling Machine Parts

A milling machine consists of the following parts:

 Base – it is the foundation part of a machine and all other parts are joined on it. It
carries the entire load so it should have high compressive strength and it is made
up of cast iron.
 Column – it is mounted vertically on the base. It supports the knee, table, etc. and
work as housing for all the other driving member. The column is a hollow
member which contains driving gears and sometimes motor for the spindle and
the table.
 Knee – it is a casting that supports the saddle and table. All gearing mechanism is
enclosed within the knee. It is fastened to the column by dovetail ways. The knee
is supported and adjusted by a vertical positioning screw (elevating screw). The
elevating screw is used to adjust the knee up and down by raising or lowering the
level either with the help of hand or power feed.
 Saddle – this is placed between the table and the knee, and work as an
intermediate part between them. This can moves transversally to the column face.
The slides over the guideways provided situated on the knee which is
perpendicular to the column face. The main function is to provide motion in a
horizontal direction to the workpiece. This is also made by cast iron.
 Table – this is a rectangular casting which is present on the top of the saddle. The
table is situated over the knee. It is the part of a machine that holds the workpiece
while machining. This is made by cast iron and has T-slot over it. This provides

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 26

vertical motion by moving the knee up and down. It provides horizontal motion
by the feed screw. This also provides a horizontal (transverse) motion by moving
the saddle.
 Overhanging arm – The overarm is used to fastened arbor support. It may
consist of one or two cylindrical bars that slide through the holes in the column. It
is made by cast iron.
 Spindle – the spindle is the main part of the machine which holds the tool in the
right place. The spindle provides the drive for arbors, cutters, and attachments
used on a machine.
 Arbor – this is a mechanical part, which is used as an extension part of the
spindle in a horizontal mill machine. It is fitted on the spindle whenever it’s
required. This holds the tool and moves it in the correct direction.
 Arbor Supports – there are generally two types of arbor supports used in the mill
machine. The first one has a small diameter bearing hole, 1-inch in maximum
diameter, and the other one has a large diameter bearing hole, usually up to 23/4
inches. The arbor support has an oil reservoir that lubricates the bearing surfaces.
It can be clamped anywhere on the overarm.
 Milling Head – it is the upper section of a vertical mill machine. It consists of a
spindle, driving motor and other controlling mechanisms.
 Ram – one end of the arm is attached to the column and other ends to the milling
head.

Types of Milling Machines

Column and knee type milling machine

- It is a very common machine type. In this machine, a vertical column is attached to

the bed which consists of all gear drives which rotate the knee and saddle. A knee is
situated on the base which provides vertical motion to the workpiece or which moves
up and down. A saddle is attached to the upper section of the knee which can move in
the transverse direction. The table is placed over the which can hold the workpiece by
use of climbing bolts.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 27

Figure 4.2 Column and Knee Milling Machine

(Source:
https://mechanical-engineering.s3.amazonaws.com/monthly_2015_05/knee_and_column.thumb.jpg.5e238412d4244
089365135738651a79f.jpg)

Vertical milling machine

- The spindle of this machine is in a vertical position. No arbor is required in this

machine. The cutter tool has the cylindrical shape and the cutting edges are situated at
the circumference of the cylindrical face.

Figure 4.3 Vertical Milling Machine

(Source: https://5.imimg.com/data5/EM/KU/MY-6502281/vertical-milling-machine-500x500.jpg)

Horizontal milling machine

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 28

- As the name implies, the spindle is situated horizontally. The spindle rotates
horizontally. An arbor is attached to the machine which holds the cylindrical disk
shape cutter which cuts the metal workpiece.

Figure 4.4 Horizontal Milling Machine

(Source: https://5.imimg.com/data5/QO/YP/MY-6697188/horizontal-milling-machine-500x500.jpg)
Universal milling machine

- It is the same as the horizontal mill machine, except there is an arrangement of swing
up the table to 45 degrees in either direction.

Figure 4.5 Universal Milling Machine

(Source: https://3.imimg.com/data3/GV/KB/MY-10906050/universal-milling-machine-500x500.jpg)

Fixed bed milling machine

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 29

- In this type of machine, the bed of the machine is fixed to the machine. There is no
arrangement of the knee and saddle which can move vertically and transversally. The
worktable is directly situated at the fixed bed. The spindle of this machine is mounted
on a movable spindle head. It can move in the vertical and horizontal direction and to
perform the cutting operation.

Figure 4.6 Fixed bed Milling machine

(Source: https://learnmechanical.com/milling-machine/)
Simplex milling machine

- In the simplex machine, spindle head or the spindle travel only in one direction.
Mostly it travels in the vertical direction.

Figure 4.7 Simplex Milling machine

(Source: https://learnmechanical.com/milling-machine/)

Duplex milling machine:

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- In this machine, the spindle travels both vertical and horizontal directions.

Figure 4.8 Duplex Milling machine

(Source: https://learnmechanical.com/milling-machine/)

Triplex milling machine

- In the triplex machine, the spindle can move in all three directions along X, Y, and Z-
axis.

Figure 4.9 Triplex Milling machine

(Source: https://learnmechanical.com/milling-machine/)

Planner milling machine:

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 31

- The planner milling machine is mostly used for facing operations in mass production.
These machines are similar to the bed type mill machine, except it can be mounted
with various cutters and spindle heads to the machine. These cutters in the machines
can perform the facing operations simultaneously which is a great function.

Figure 4.10 Planner Milling Machine

(Source: https://3.imimg.com/data3/FH/EK/MY-6126294/planer-type-milling-machine-500x500.jpg)

Special milling machine

- These machines are the modern milling machines that are developed to easy milling
operations according to the jobs.

Figure 4.11 Special Milling machine

(Source: https://learnmechanical.com/milling-machine/)

Tracer milling machine:

- This machine performs all difficult operations like, die making the job by
synchronizing the tracing unit. This can develop any difficult shape. This is mostly
used in the automobile and aerospace industries.

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 32

Figure 4.12 Tracer Milling machine

(Source: https://learnmechanical.com/milling-machine/)

CNC milling machine:

- CNC is the most versatile milling machine which is control by a computer. It is an

upgraded version of the bed type mill machine, in which the spindle can move in all
three directions and the table can rotate 360 degrees. These all movement is
hydraulically controlled which is commanded by a computer. In this, any difficult
geometry can make on it. A sketch of the workpiece is loaded to the computer which
is cut on the workpiece by the cutters automatically.

Figure 4.13 CNC Milling machine

(Source: https://learnmechanical.com/milling-machine/)

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 33

Milling Machine Operations

There are several types of operation that can be performed in a milling machine, and
those are:

Plain Milling Operation

- It is the operation on producing plain, flat, horizontal surface, parallel to the axis of
rotation.

- This operation is also known as slab milling.

- This operation is very common and done in almost all jobs.

- This can be carried out on every mill machine.

Figure 4.14 Plain Milling

(Source: https://learnmechanical.com/milling-machine/)
Face milling Operation

- This machining operation is done on the surfaces which are perpendicular to the axis
of the cutter.

- The operation is performed by the face milling cutter mounted on stub arbor of the
machine.

Figure 4.15 Face Milling

(Source: https://learnmechanical.com/milling-machine/)

End milling operation

- It is the process of producing flat surfaces which may be horizontal, vertical and at an
angle taking worktable as a reference.

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 34

Figure 4.16 End Milling

(Source: https://learnmechanical.com/milling-machine/)

Form milling Operation

- It is the process of machining special contour (outline) composed of curves, straight

lines, or entirely of curves, at a single cut.

- This operation is accomplished by using convex, concave and corner rounding

milling cutters.

Figure 4.17 Form Milling

(Source: https://learnmechanical.com/milling-machine/)
T-slot milling Operation

- It is the operation of producing the T-slots on the workpiece by using the T-slots
milling cutter.

Figure 4.18 T-slot Milling

(Source: https://learnmechanical.com/milling-machine/)

Side milling Operation

- It is the operation on producing the flat vertical surface on the sides of the workpiece
by using a side milling cutter.

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- The cutter is having teeth on its face as well as it's side.

Figure 4.19 Side Milling

(Source: https://i.imgur.com/VWDOQY2.png)

Gear cutting Operation

- It is the operation on producing gear tooth on the gear blank by using a form-relieved
cutter in a milling machine.

- The cutter profile is exactly matched with the tooth space of the gear.

Figure 4.20 Gear Cutting Milling

(Source: https://encrypted-tbn0.gstatic.com/images?q=tbn%3AANd9GcTU3-O6iAz0OQK5h9PQAhkZ-gd-
gsbAGhdXoA&usqp=CAU)
Straddle milling Operation

- It is the operation on producing the flat vertical surface on both sides of the
workpiece by using two side milling cutter mounted on the same arbor.

- The distance between the two cutters is adjusted by using a spacing collar.

- This is commonly used to produce a hexagonal or square surface.

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 36

Figure 4.21 Straddle Milling

(Source:
https://lh3.googleusercontent.com/proxy/RkeuJY4xiOkQ6qiD_dAL9PCA9dl34ZVDMw6W3aFg4u4LfZw9YBGBR_e
hAsGUf4CY0eNbN83ov-E_ASuu3QZ8blzw8M5ksRUy7CiS9szVOgli756GrK8FkyICFK7GsgK0o2YLEkHwE8UB)

Gang milling Operation

- It is the machining process in which two or more milling cutters are used together to
perform different milling operations simultaneously.

- In gang milling, the cutters are mounted on the arbor.

Figure 4.22 Gang Milling

(Source:
https://lh3.googleusercontent.com/proxy/Xf1zwqNvLAT2qFl9ZdOwFSpCDeSFpiIYaDf_OVjA31J5jcYqmNkMMzPA
Q5NS922jDnNYopL3YtX8oYI4Yx_EMOC
Jml577No5uotdMysCFtxSE7q_xCOqlETdFSFZ72o1cflEL_OhUK88)

Grooves milling Operation

- It is the operation on producing the groove on the surface of the workpiece by using a
saw-milling cutter or end milling cutter.

- The workpiece is fixed firmly on a milling machine and fixing the end milling cutter
on an arbor, by adjusting the depth of cut, the work is fed against the cutter to cut the
groove on the work surface.

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 37

Figure 4.23 Groove Milling

(Source: https://encrypted-t bn0.gstatic.com/images?q=tbn
%3AANd9GcSW4q5bBDLx5SgLon89Wfd9ncHi_UProzPxwg&usqp=CAU)

III. PROGRESS CHECK

A. Choose the letter of the correct answer.

1. Which of the following machine is superior to other machines as regards
accuracy and better surface finish?
a) lathe
b) drill
c) shaper
d) milling
2. Which of the following act as load bearing part of milling machine?
a) Base
b) Column

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 38

c) Knee
d) Table
3. Which of the following is the heavy support provided at the top of both plain and
universal milling machine?
a) Base
b) Over arm
c) Knee
d) Table

4. Which of the following milling operation can be used for machining a flat
surface, parallel to the axis of cutter?
a) Slab milling
b) Face milling
c) Angular milling
d) Form milling
5. Which of the following milling operation can be used for machining a flat
surface, parallel to the axis of cutter?
a) Slab milling
b) Face milling
c) Angular milling
d) Form milling
6. Which of the following milling operation can be used for machining of flat
surface which is at some angle to the axis of cutter?
a) Slab milling
b) Face milling
c) Angular milling
d) Form milling

7. Which of the following milling process is used for machining of irregular

shapes?
a) Slab milling
b) Face milling
c) Angular milling
d) Form milling
8. Which of the following milling process is used for machining of two parallel
vertical surface of a job simultaneously?
a) Key way milling
b) Groove milling

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 39

c) Gang milling
d) Straddle milling
9. Which of the following milling process is used for machining of a number of flat
horizontal and vertical surfaces simultaneously using more than two cutters at the
same time mounted on common arbor?
a) Key way milling
b) Groove milling
c) Gang milling
d) Straddle milling

10. Which of the following cutter can be used for finishing off previously milled slot?
a) Key way milling cutter
b) Dovetail milling cutter
c) Saw milling cutter
d) Slitting milling cutter

B. Fill in the blanks.

1. Table of milling machine is generally made up of ________.

2. Plain milling operation is also called __________.
3. The main function of _________is to provide motion in a horizontal direction to
the workpiece.
4. The __________is used to fastened arbor support. It may consist of one or two
cylindrical bars that slide through the holes in the column.
5. _________ is the same as the horizontal mill machine, except there is an
arrangement of swing up the table to 45 degrees in either direction.
6. No arbor is required in _________ machine.
7. ________is the cutting operation that removes metal by feeding the work against
a rotating, cutter having single or multiple cutting edges.
8. ________ is the most versatile milling machine which is control by a computer.
9. The ________ operation is commonly used to produce a hexagonal or square
surface.
10. _______ is a casting that supports the saddle and table.

IV. REFERENCE/S

Miller, Rex (2004). Audel Machine Shop Tools and Operations, Wiley Publishing Inc.

Burghardt, H.D. et. al., (1959). Machine Tool Operation 1.

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 40

EP DeGarmo et.al. (1988). Materials &Processes in Manufacturing 7th Edition,

Macmillan Publishing Company, New York

3G Elearning (2014). Machine Shop Operations, 3G Elearning

This module is a property of Technological University of the Philippines Visayas and intended
for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION