ADVERTISEMENTS.

USEFUL BOOKS
THE CALCULATION OF CHANGE-WHEELS FOR SCREW-
CUTTING ON LATHES. A Practical Manual for Manufacturers,
Students, and Lathemen. By H. DE VRIES. With 46 illustrations,
83 pages, 8vo, cloth. (1908.) y. net.
THE LATHE — CALCULATION OF CHANGE- WHEELS — Systems— What Change-
Wheels are to be found on a Lathe— The Cutting of Metric Threads on a Lathe with
Metric Leadscrew— Cutting English Threads on a loathe with an English Leadscrew —
Cutting English Threads on a Lathe with a Metric Lea Iscrew— Cutting Metric Threads
on a Lathe with an English Leadscrew — The Wheel with 127 Teeth— Method for
Calculating Approximate Fractions — Proof of the Sum— Fixing Up the Wheels— Thread-
Cutting with Double Compound Train— Cutting Left-Hand Threads— THREADS AND
THEIR CONSTRUCTION— Forms of Threads— Types of Threads— Screw-Cutting Tools-
Catting the Thread— Cutting Double and Multiple Threaded Screw's— Cutting a Very
Coarse Thread — The Hendey-Norton System.

MODERN MACHINE SHOP CONSTRUCTION, Equipment, and Man-

agement By OSCAR E. PERRIGO, M.E., Member of the American
Society of Mechanical Engineers, Expert in Machine Shop and
Factory Organisation, Modern Shop Methods, etc. With 208 illus-
trations, 343 pages, crown 410, cloth. (Nav York, 1906.) 2is. net.
MACHINE SHOP CONSTRUCTION. Introduction — General Plans — General Con-
struction ofthe Building — Slow Burning Construction— Slow Burning Construction of
Brick and Wood — Slow Burning Construction of Wood only — One-story Machine Shop
of Brick and Wood — Design and Construction of Chimney — Construction of Foundations
— Construction of Floors — The System of Heating and Ventilation — The System of
Lighting — Power and Transmission — Some Concluding Remarks.
MACHINE SHOP EQUIPMENT. Planning the Different Departments— Equipment of
Tool-Room and Tool Store Room— The Drawing Room — The Pattern Shop and
Pattern Storage Room — The Iron Foundry — The Forge Shop — Shop Transportation
Equipment — Miscellaneous Equipment of the Manufacturing Plant.
MACHINE SHOP MANAGEMENT. The Superintendent's Office — The Problem of
Apportioning the Fixed Charges— The Drafting Room— The Tool and Stock Room —
Pattern Shop System— General Efficiency in Manufacturing Operations — Machine Shop
Mutual Aid Associations— Index.

AMERICAN TOOL MAKING AND INTERCHANGEABLE MANU-

FACTURING. ByJOSEPH W. WOODWORTH, Author of ' Dies, their
Construction and Use,' etc. With 600 illustrations, 544 pages, large
8vo, cloth. (Nav York, 1905.) 171. net.
Modern System of Interchangeable Manufacturing — Machine Tools, Designing,
Tool-making and Tool Rooms — Fundamental Principles, Processes, Practical Points for
Jig Design and Construction — Types of simple and inexpensive Drilling Jigs — Intricate
and positive Drilling Jigs — Drilling Jigs for heavy machine parts — Drilling Jigs of novel
design— Use of Milling Machines — Simple Milling Fixtures— Milling Fixtures for
accurate work — Miscellaneous Milling Fixtures — Devices for Machining repetition parts
in the Turret Ijtthe and Screw Machine— Construction and Use of Boring Fixtures —
Design, Manufacture and Use of Milling Cutters — Drills and Drilling — Broaches and
Broaching— Shop use of Micrometer, Callipers and Height Gauge— Mould Construction
— Special Tools, etc., in Metal Working — Special Machines for accurate work on Dies —
Art of Sheet .Metal Working in Dies— Making and Use of Punches and Dies for Sheet
Metal Working — Processes for the rapid and economical Working of Sheet Metal —
Manufacture ofaccurate Sheet Metal Parts in the Sub- Press— Dies for Medals, Jewellery,
etc. — Modern Art of Swaging — Methods and Processes for Working Aluminium — Hints,
Kinks Ways and Methods of use to Tool Makers and Die Makers— Value of Up-to-date
Fixtures and Machine Tools.
" The book U Kxnewhat of • miftccllany. but it i» the production of a Master Mechanic, and the
intelligent workman in search of pUin direction* and really useful information will not look through these
pai«« M vain.' - Americmm M*cki*i»t.

E. & F. N. SPON, Ltd, 57 Haymarket, London, S.W.

 NTS.

ADYER"

GENUINE CU; CORUNDUM

DON'T WASTE A GOOD WORKMAN'S TIME with a poor
GRINDING WHEEL. The man's time costs you money, and you
have got to give him the best tools you can find to get full value
for the wages you pay.
CARBORUNDUM
GRINDING WHEELS
BEST,
are the World's
and in actual value
THE CHEAPEST.
Cut faster. Last longer.
You cannot afford to be
without them.

TRADE, TV! ARK

CARBORUNDUM
SHARPENING STONES
are invaluable for sharpening
milling cutters and tools, often
saving the necessity of grinding.
We stock every convenient shape
and size; special sizes can be
made to order.

GIVE US A TRIAL
ALL OUR GOODS GUARANTEED.

THE CARBORUNDUM GO,

29 CLIFTON STREET,
FIN8BURY SQUARE, LONDON, E.G.
 ADVERTISEMENTS.

GENUINE CARBORUNDUM
DON'T WASTE A GOOD WORKMAN'S TIME with a poor
GRINDING WHEEL, The man's time costs you money, and you
have got to give him the best tools you can find to get full value
for the wages you pay,
CARBORUNDUM
GRINDING WHEELS
BEST,
are the World's
and in actual value
THE CHEAPEST.

Cut faster. Last longer.

You cannot afford to be
without them.

TRADE, TVTARK

CARBORUNDUM
SHARPENING STONES
are invaluable for sharpening
milling cutters and tools, often
saving the necessity of grinding,
We stock every convenient shape
and size ; special sizes can be
made to order.

GIVE US A TRIAL.

ALL OUR GOODS GUARANTEED.

THE CARBORUNDUM GO,

29 CLIFTON STREET,
FINSBURY SQUARE, LONDON, E.G.
ADVERTISEMENTS.
 D. DE VRIES
MILLING MACHINES AND MILLING PRACTICE
MILLING MACHINES
— AND —

MILLING PRACTICE
A PRACTICAL MANUAL
FOR THE USE OF

MANUFACTURERS, ENGINEERING STUDENTS

AND PRACTICAL MEN
BY

D.JXE VRIES
AUTHOR OF "THE CALCULATION OF CHANGE WHEELS"

WITH 536 ILLUSTRATIONS

I
OL o n & o n
E. & F. N.-SPON, LIMITED, 57 HAYMARKET
ti3ew lorfc
SPON & CHAMBERLAIN, 123 LIBERTY STREET
1910
 PREFACE.

It is an indisputable fact that with the beginning of the

present century the manufacture of machinery has already
attained a high state of development and taking into con-
sideration the progress which it has made in the last
decade and is still making, it must be admitted by everyone,
who is in anyway acquainted with any branch of the metal-
working industry, that the final stage of this development
is very far from being reached, but, at the present time,
it may be considered as being in a very flourishing condition
whilst its forces are still developing.
In speaking of metal- working, we do not refer to the
working of the precious metals, the usefulness of which,
except as a medium of barter, is far inferior to that of the
common metals.
It is just the baser metals that become valuable by being
fashioned into useful objects by the hand of the workman
assisted by machines of more or less modern construction.
We say this intentionally, as nowadays the complaint is
so often heard that owing to the general application of
machinery, the skill of the workman is gradually becoming
a thing of the past; and it cannot be gainsaid that half a
century ago greater skill was often required of the workman's
hand even in the metal-working industry, than is the case
in the days in which we are now living.
But we would ask: Has the metal-worker's trade deteri-
orated on this account? Certainly not. The development
which has arisen of late years in this special branch of
industry has simply made other demands on the workman
vi Preface.
than was the case half a century ago, and we should not
be true children of our age, if we did not strive to live up
to these new requirements, and do all in our power to adapt
our technical knowledge to these newer methods.
To achieve this, it is absolutely imperative that the
machines required for manufacturing purposes should be
known and their rational application thoroughly understood.
The purpose of the present work is to make the milling
machine in its various forms more generally known, together
with the tools used in connection therewith, to familiarize
the reader with the manner of working on the milling
machine and so make the milling machine better known
and appreciated.
It is equally important that not only the owner but also
the workman should be thoroughly familiar with the milling
machine, should have a clear insight into this type of machine
with the use of which one may at any time be entrusted ;
that one should be able to do with the machine everything
that can be done on it, and bring to the highest point not
only the productiveness, but also the quality of the work
to be performed.
It is my earnest desire that this work may be of some
assistance in the promotion of industry.
In conclusion, I desire to express my sincere thanks to
the many home and foreign manufacturers who have so
kindly provided me with the necessary information, drawings
and illustrations.
D. DE VRIES.
 CHAPTER I.

GENERAL REVIEW.

The Milling machine in comparison with the Lathe,

the Planing and the Shaping machine.

As a result of the rapid development which the manu-

facture of machinery has undergone during the last decade
the question of the most advantageous manner of working
has come to the front as a factor of the first importance.
This is only natural seeing that those who are able to
manufacture under more advantageous conditions than others,
owing to a cheaper xrate of production, are not only enabled
to greatly extend their business, but, as a result of their
increased profits, are also able to replace their old machines
by those of the most up-to-date construction, thus assuring
a still cheaper rate of cost.
The question as to the most advantageous manner of
working, - - metalworking being, of course, understood
both here and subsequently, — is one which is, however,
not so easy to answer.
Each particular machine, each tool, each manner of working
has its own peculiar advantages and disadvantages which
come into prominence alternately in connection with the
different pieces to be worked.
Moreover, exceptional circumstances are always occuring
which it is impossible to avoid and which tend to render a
correct decision still more difficult. To take a single instance —
the power absorbed by a machine, the cost of tools, their
8 Milling Machines
durability as also that of the machine itself, besides a large
number of other, smaller factors have to be taken into account
when answering the question of economical manufacture.
Even the question of conservatism is one which may by
no means be lightly treated.
Old shoes are so much more comfortable than new ones.
Thus, each individual, each group of persons in the sphere
of human activity to which they belong - - in short, each
nation has conservative tendencies.
We do not here refer to that conservatism which consi-
ders everything bad as a matter of course which is done
in a different manner to that to which it has so far been
accustomed.
Such conservatives cannot be converted, they must simply
become extinct, their places being taken by a younger
generation, amongst whom, doubtless, will be found the con-
servatives oftheir own time.
We are thinking here more especially of that conservatism
from which the most properous man can never free himself.
Does not this explain to a great extent the cause of the
enormous development of technical knowledge in the United
States?
England, which has so far been to the front in technical
matters, is now behind America with machine tools because
she has had to struggle to free herself from the trammels
of older methods, whilst America, on the other hand, which
had scarcely any technical knowledge, was free to expand
in this territory, untrammelled by conservative instincts.
The question as to which are the most advantageous
methods of machine manufacture is thus one of primary
importance for all who are in any way connected with this
industry.
The answer thereto depends upon :
The chucking of the work on a particular machine.
The operations which can be performed without the neces-
sity of rechucking.
The time needed for the operations.
The power required.
 and Milling Practice. 9

The quality of the work.

The cost of the cutting-tools, (lathe-tools, planing-tools,
slotting-tools, drills, milling-cutters, etc.).
If, until comparatively recently, a comparison between
the planing- and shaping-machine on the one side and the
milling-machine on the other, resulted to the disadvantage
of the latter, at the present time the milling-machine is
even proving a keen rival to the lathe.
In ordinary machine tools, the cutting tools invariably J
work with a small cutting-edge, whereas with the movement
of the cutting tool or the workpiece in a straight line —
as is always the case with planers and shapers, — a certain
part of the time required for the operation is invariably lost
in useless return.
If we fix the speed for the forward movement per unit
of time at 100 and that for the return at 150, the latter will
cause a loss of time of 40 percent.
Seeing that the machine is working all this time, the loss
of energy will consequently amount to the same percentage.
The return movement of the machine is, it is true, non-
effective, but the increased speed will at least absorb the
power required for cutting the material during the forward
movement.
By changing the straight motion into a rotary one as^
is the case, with the milling machine this loss of power and /
time has been entirely done away with.

The only part of the milling machine with which the cutter is
connected is the spindle and it is not very difficult to arrange
this at any desired position as regards the work-piece,
or, vice versa, to set the work-piece at any desired position
as regards the cutter, so that different surfaces can be
machined without rechucking. Furthermore, whilst the forms
which can be machined on a planer or shaper are extremely
limited, with the milling machine, on the other hand, the
work which can be done, especially in conjunction with the
application of copying and profiling work is practically limitless.
 10 Milling Machines

As regards the^durability of the milling cutter no other

tool can compare with this tool.
The fundamental principle of the milling cutter as a rotary
cutter places it at a far greater advantage in comparison
to any other cutting tool.
Whilst all other cutting tools are at work without inter-
/~~mission
affected all
by the
the time
heat they are cutting
generated, and are
the milling consequently
cutter under the
I same circumstances, experiences a constant change of cutting
/ edge, so that the heat generated is dissipated, whilst there
) is this further advantage, that owing to the larger number
/ of working cutting edges, each tooth of a milling cutter
I has only a portion of the work to do.
In almost inseparable connection herewith is the quality
of the finished work, so that when handled skilfully the
milling machine will dispense with a great deal of manual
labour.
For a considerable time the milling cutter was looked
upon, as indeed it was, a very expensive tool.
The reason of this was that the construction of the milling
cutter was imperfect. For a long time milling cutters were
pitched too finely, mostly filed by hand, or if milled, required
subsequent finishing.
It must further not be forgotten that at that time milling
cutters were sharpened before being hardened, owing to
the lack of the grinding wheel and that there were very
few who were capable of hardening a milling cutter.
A milling cutter that had become dull had to be softened
and treated all over again, whilst there was always the risk
of its spoiling. For this reason milling cutters were used
as long as there was any possibility of cutting, used even
when they had become very dull, a circumstance which
did not fail to leave its effects on the quality of the work.
This state of things has been rendered wholly different
by the present-day construction of the milling cutter.
The finely pitched milling cutters have given place to
the coarse pitched cutter, the milling cutter itself now being
entirely produced by machinery.
 and Milling Practice. 11
Only after being hardened is the milling cutter sharpened
on the grinding machine which has been invented for the
purpose, whilst repeated regrinding is also possible.
As a natural result the character of the milling machined
has also changed from being a special machine tool to one /
of general use, - - to a " universal tool " , and the way has >
been prepared for a general expansion and a continuous \
improvement and perfecting of the milling machine.
Before bringing this brief resume to a close, just a few
words which are applicable to so many workmen.
It is a well known fact that a large number of working
men regard the milling machine with anything but a friendly
eye, treat it very suspiciously and by no means exert their
best endeavours to cause the milling machine to assume its
rightful place, simply and solely because it works so pro-
fitably that it will supersede the manual work of their fellow-
workmen. Just as if cheaper production will not lead to
an increased output !
Do you not realize that the newer methods of working
must and will make headway ; that if you will not do it,
others, more progressive than you, will, for the purpose of
eventually handicapping you who have remained behind ?
By you, we mean not only you personally, but the works
in which you are employed, your country and your nation :
for the expansion and progress of all branches of industry
are most intimately bound up and associated with the pros-
perity of the whole nation at large.
 PART I.

THE MILLING CUTTER.

CHAPTER II.

The development of the Milling Cutter.

The relative position of the milling cutter to the milling

machine may be expressed by the inverse proportion which
other machine tools bear to the cutting tools belonging to
them.
Machine tools, such as the lathe, planer, shaper, drill,
etc. have undergone a process of development entirely
independent to that of their cutting tools, and only after
they had been made equal to the higher demands imposed
upon them, were the same demands made upon the
requisite tools.
With the milling machine, on the other hand, just the
opposite has been the case.
In proportion as the milling cutter proved to be a cutting
tool of such supreme excellence for metal working, the milling
machine adapted itself to this higher degree of development,
so that the milling machine of recent years is the result,
and not the cause of the development of the milling cutter.
Although it cannot yet be said that the milling machine
has been generally adopted in this country and its general
use leaves very much to be desired, it is, however, some 70
years ago since the milling cutter was first brought into use ;
according to report, the instrument-maker Joseph Bramah,
 Milling Machines and Milling Practice. .13

of St. Giles, London, had, even prior to the beginning of

the 19th century, employed milling cutters in his workshop.
Notwithstanding the fact that about 1830 and for several
decades subsequently , the milling cutter began to be employed,
it still occupied a very modest place in the metalworking
industry, being only made use of under quite exceptional
circumstances, whilst the work which it turned out was
regarded as decidedly expensive.
The cause of this was to be found in the erroneous principles
on which the first makers of the milling cutters had set to
work, as a consequence of which the milling cutter had been
constructed with a large number of extremely fine teeth.
The reason which led to
the construction of such
milling cutters was the idea
that the greater the number
of teeth on a milling cutter,
the less the strain imposed
upon each tooth during that
portion of the revolution
in which that tooth was

actually at work. Fie- L

^ , . Early milling cutter with
Considered alone, this openings for chips.
would appear to have been
quite correct, but owing to their number, the pitch was very
fine and the teeth very shallow, with the consequent result
that crowding and choking soon occured, so that a number
of teeth were rendered useless and the work produced of
inferior quality.
Fig. 1, in which there are openings between every 10 or 12
teeth to allow of the chips escaping, clearly shows that
this defect was not passed over unnoticed. The possibility of
cracking with the hardening was, however, greatly increased
by these openings.
Moreover, the depth of the cut was dependent on the depth
of the tooth, and although theoretically the depth of the tooth
may be taken as the maximum depth to be cut, in practice not
more than 0.7 of the depth of the tooth can be reckoned.
14 Milling Machines
The cutting depth was consequently very limited.
There was furthermore a reason for not making the teeth,
especially of profiling cutters, too deep and also of not too
coarse a pitch since the teeth mostly had to be resharpened
with the file.
Furthermore, the grinding machine had not yet been
introduced so that the milling cutter had to be sharpened
before being hardened, so that a hardened cutter with really
sharp teeth was practically an impossibility, the sharp edges
suffering considerably in the fire. Now, a fine pitched cutter
will still cut when a coarse pitched cutter has already ceased
cutting, so that, viewed from this point, the preference was
still somewhat in favour of a cutter with a fine pitch.
Owing to thp fact that a milling cutter, which had become
dull required to be treated all over again whilst these was
also a great risk of its cracking during the hardening
process, the cutter was used as long as possible, so long in
fact, that it began to turn out bad work, and consequently,
as far as the quality of the work was concerned, it could
no longer be accounted one of the best of cutting tools
and was simply employed where manual labour was very
expensive.
For these reasons the milling cutter made practically
no advancement for a number of years, but notwithstanding
the serious defects with which the milling cutter was
hampered, it came slowly but surely into more general use.
It was chiefly in the manufacture of rifles, sewing machines
and similar articles produced in large quantities, that the
milling cutter, although expensive, was employed for the
purpose of turning out cheaper work.
In these factories certain workmen were continuously
occupied with the making and hardening of milling cutters
and were thus in a position so to improve the milling
cutter (and in direct connection therewith, the quality of
the work which it turned out), so that the milling machine was
able to take the place of a considerable amount of manual
labour and it thus became a really indispensable factor in
such manufacture. From that time onward, the milling cutter
 and Milling Practice. 15
came more and more into general use in these and similar
factories and was constructed in every possible shape and form.
It is curious to note that the formed cutter in its most complex
form was the precursor of the plain milling cutter, and as soon
as the latter was constructed in the right manner under these
new methods, the formed cutter found general application.
It was in the United States that Messrs- Brown & Sharpe
first manufactured milling cutters of a new type, the coarse
pitched cutter, and as a natural result with much deeper
teeth, thus making it possible to take a deeper cut, so that
these cutters could be used for work-pieces of considerably
larger dimensions.
Almost at the same time this firm first introduced the
emery wheel for sharpening cutters after hardening.
This new type of cutter had important advantages:
1st So as has already been said, more metal could be
removed.
2nd The cutter could not only be sharpened after hardening,
but a cutter which had become dull could be reground
in its hardened state, thus prolonging its usefulness
tenfold. It was now no longer necessary to let the
cutter get absolutely dull in order to use it as long as
possible; it could now be kept sharp at comparatively
little cost and, consequently:
3rd The quality of the work turned out was considerably
improved.
This revolution in the science of milling cutters took
place in the States about the year 1870, and became generally
known in Europe during the Exhibition in Vienna in 1873.
However strange it may seem now that this type of cutter
has been universally adopted and its undeniable superiority
to the old European type is no longer doubted, it was
regarded very distrustfully and European experts were very
reserved in expressing their judgment. Even we ourselves
can remember that after the coarse pitched cutter had
been introduced, certain very clever and otherwise shrewd
experts and engineers regarded the new cutting tool with
many a shake of the head.
16 Milling Machines and Milling Practice.
When however, the Worlds Exhibition at Philadelphia in
1876, exhibited to European experts a universal and many-
sided application of the coarse pitched milling cutter which
exceeded even the most sanguine expectations, the most
far-seeing engineers were then convinced of the immense
advantages which the application of the new type opened
up for the metalworking industry, and from that time onwards
the American type advanced, slowly at first, but later on
with rapid strides, so that, at the present time, it is quite
an exception to come across a fine pitched cutter.
The teeth were formerly ground on the back-side of the
milling cutter. Now, it was practically impossible to regrind
a formed cutter on the back-side in such a way that the
cutter would not lose more or less of its original form after
regrinding, a fault, which for profile work at any rate could
not be overlooked.
All sorts of ingenious devices for grinding were experi-
mented with in order to avoid this defect, but without
success, so that for curvilineal surfaces the fine pitched cutter
still remained for some time in general use, until, the „ backing
off" of the cutters was introduced, again by Messrs Brown
& Sharpe, and the frontside of the cutter could be reground,
thus ensuring a perfect similarity of the milling work both
before and after grinding.
At the same time another excellent improvement was
obtained, viz : that the teeth of plain cutters were no longer
milled straight but in such a way that each tooth formed
a spiral line, whilst some years later the „ backed off" cutter
underwent a still further improvement in certain forms of
cutters, by its being backed off sideways.
 CHAPTER III.

Denomination of Cutters.

a. CLASSIFICATION.

Under the title of " Cutter " are included all those cutting
tools possessing several cutting edges all working in the
same circumference or on one and the same surface. In the
following description one single exception will shortly be
met with in the separate types referred to under group I.
The outside lines of a cutter are straight, broken or curved ;
if straight, the outside lines form together a cylinder or
cone ; if broken, then the lines lie altogether in a common
rotating body.
A further general characteristic is that all the teeth have
the same form and are placed equidistant from each other
in a circle. In this connection, there are, however, a few
exceptions.
For what is understood by the word " cutter " , it is not
at all necessary that the teeth should form one whole with
the body, they can equally well consist of separate parts,
not only that they are then united with the body so as to
form an undivided whole, or are exchangeable, but also from
the point of view that they can differ as to the material
from which they are made.
The cutting parts are accordingly distinguished as teeth
and blades. Teeth form one whole with the body of the
cutter but blades do not.
Practically without exception a rotary movement is imparted
to the cutting edges of a cutter round a common centre,
which in connection with an uninterrupted straight, curved
2
18 Milling Machines

or relative motion from cutter or work-piece, enables the

cutter to perform its work uninterruptedly.
The cutting edges thus traverse a certain course which
takes the shape of a closed, curved or straight line.
Each cutting edge of the cutter does not work continuously
but at intervals, at the most during half the time taken up
by one revolution ; in this respect it is similar to the
shaping and planing tool but differs from the lathe tool and
the drill.
As the cutter can be used for a variety of operations in
the broadest sense of the word, it is accordingly constructed
in a variety of forms, cylindrical as well as conical, as a
rotating body with curved lines, composed of two or more
of the first-named principal forms, whilst the different lines
of its cutting edges are also very divergent.
For the purpose of classifying the different types it is
scarcely possible to take the form of the cutter or of its
teeth as a basis, a much simpler grouping being obtained
by separating them according to the manner in which the
cutter works.
Taking this as the basis, the different types can be arranged
in groups as follows :
Group I. Cutters composed of blades which are either ex-
or interchangeable.
Group II. End-mills. To this group belong all cutters
used for working surfaces, the teeth or blades
of which run in a radial form.
Group III. Shell-mills. This group includes all cutters,
the teeth of which lie on the circumference of
a rotatory body, the cutting edges together form-
ing such a body circumscribed by straight lines.
Group IV. Shell-end-mills. A combination of the types
referred to in groups II and III.
Group V. Formed cutters. In this group the backing-off
of the cutter is principally employed.
Group VI. Composite cutters. In this group are usually
reckoned cutters composed of two or more of the
foregoing types.
 and Milling Practice. 1.9

b. GROUP I. CUTTERS COMPOSED OF BLADES.

This group may be subdivided into :

1st Cutters, the blades of which are interchangeable.
2nd Cutters, the blades of which form one complete whole
with the body.
a. Fig. 2 represents the simplest form
of type 1 , which, as it works with only one
cutting edge and can remain uninterruptedly
at work, may be considered as a deviation
from what is ordinarily understood by a

Fig. 2.
Cutter with single - Fig. 3. Fig.
edged tool. Cutter with single -edged tool.

* cutter" and displays a great resemblance to the lathe tool.

It is mostly used for large borings and in holes which
are not a closed circle.
b. Figs. 3 and 4 also show a
cutter with one blade which
is however distinctly different

Fig. 5. Fig. 6.
Cutter with two tools. Mill for cutting out sheaves.
20 Milling Machines

to that shown in fig. 2, in that it cannot continue uninter-

ruptedly at work. It is but seldom used and then only in
the manufacture
of bronze or
wooden gear
wheels.
c. Fig. 5.
Shows a face mill
with two inserted
teeth which can
be used either for
face milling or
for milling holes
or segments.
Figs. 7—9.
Cutters with two, three and five inserted teeth.
When used as
face cutter its
work is not uninterrupted, but when used for milling a
complete circumference it can work continuously, in which
case it has an advantage over that referred to under a. in

! tooth (utter.

that by giving both tools a difference in height of '//' a cut

"f double depth can be taken.
d. Fig. 6. Represents a mill with two teeth. It is prin-
 and Milling Practice. 21

cipally used for cutting holes and

manholes in boiler shells, etc.
e. Figs. 7 — 9. Cutters with
two, three and five inserted teeth
which are used for milling key-
ways, for milling oblong holes
and for border surfacing the width
of which does not exceed the
diameter of the mill.
f. Figs. 10 and 11. These are
termed inserted tooth cutters, and
are employed for milling large,
rough surfaces, such as the joints
of split flywheels or rope pulleys,
joints of large machine parts, etc.
g. Fig. 12. Represents an in-
serted tooth mill which is employ-
ed for grooves and surface milling.
h. Fig. 13. This mill differs
from what is generally under-
Fig. 11.
stood by a " cutter " in so far Inserted tooth cutter.
that the form of each of the
teeth varies alternately. A large quantity of material can be
removed with this mill. The
working method is similar to
that of fi g. 1 2 . The cutter shown
in fig. 12 will be chiefly used
when a groove has already
been milled in the material ; the
cutter illustrated in fig. 13, being
employed when a deep, broad
groove has to be milled from
the solid material.

The mills classified under

Fig. 12.
Inserted tooth cutter. 2 are employed only for milling
rough surfaces.
Fig. 14 illustrates such a miller.
22 Milling Machines
In the foregoing, blade and tooth millers have been dealt
with as an independent group,
without taking into considera-
tion their manner of working;
Considered with reference to
this,
they would have to
be divided up with the
various other groups.
Taken however toge-
ther as an independent
group, a much better
idea is gained of this
sort of millers.

c. GROUP II.
END MILLS.

This is a type that,

owing to its limited
use, is seldom em-
Fig. 13.
a. Fig. 15. Shows
ployed.
Inserted tooth cutter with cutters
of different form. this type in its original
but bad construction,
which has been rather more used of late in this particular[form.

14. Plain mill.-r.

b. A cutter of similar form is illustrated in figs. 16 and 17,

 23
and Milling Practice.

The proportion of the

width of the teeth to the
diameter of this mill is
greater than in that illus-
trated in fig. 15, so that
its use is different. Fig. 17
shows the manner in which
it works.
c. An end mill as illus-
trated in fig. 18, which is
used for milling pinions, can,
under certain conditions, be
employed to good account ;
for example, in milling
pinion s, theis outsid e diameter — ~
of which either equal to
or smaller than that of the
shaft of which such pinion
forms a part; ;it is also
employed on milling ma- Fig. 15. End mill.

Fig. 16. End mill.

chines with vertical spindle only as also for milling spiral

gear wheels.
 Milling Machines

UpJ

Fig. 19-20. Fig. 18. Fig. 21.

Hollow mill. End mill for milling pinions. Double edged cutter.

d. Figs. 19 and 20 represent a mill for the milling of

round pins.
e. Fig. 21 is a miller extensively used for milling narrow
faces, key ways, oblong holes etc.
d. GROUP III. SHELL MILLS.
This group may be directly divided into two constructions
which are very easily distinguished the one from the other.

Fig. 22. Shell mill. Fig. 23.

 and Milling Practice. 25

1st Millers, in which the cutting edge of the teeth runs-

parallel to the centerline of the miller.
2nd Millers, in which a certain number of teeth bisect a

Fig. 24.
Slitting cutter.

line drawn through the external diameter parallel with

the core of the mill, i. e., where the cutting edge of
one tooth is a spiral.
a. The simplest type of the millers referred to under 1
is shown in figs. 22, 23 and 24.
The cutter with coarse pitch
was first introduced in this
form.
The mill shown in figs. 22
and 23 is principally used for sur-
face milling, that, illustrated in
fig. 24 for milling keyways etc.
b. The screw slotting cutter
fig. 25 is very similar to the
foregoing, only being conside-
rably thinner. The thickness
depends upon the diameter of the Fig. 25.
Screw slotting cutter.
screw head or the width of the
slot which it must slit. It is even made up to a thickness
of '.
26 Milling Machines

c. Conical millers as represented in figs. 26 — 28 are

chiefly used for milling sloping faces.

Fig. 26. Fig. 27. Fig. 28.

Conical mill.

d. Fig. 29 shows the type of mill referred to under 2

most commonly in use. It is used for the same purposes
as the miller depicted
in fig. 22—23.
Owing to the spiral
form of the teeth, a
greater number are
engaged on the work
at the same time on
each line of the surface
being milled parallel
Fig. 29.
Shell mill with spiral teeth.
to the core of the mill.
The irregular working
of the mill over rough surfaces is consequently diminished
as before one tooth has left
.^^H^^^^HH \*' '• '-^^^^Bfcfc ^^g^^/"^1 ^ ^.
the cutting surface, other r^^^^^w. ^^W * .?
teeth have begun to cut, thus
ensuring smooth cutting.
Another advantage in
favour of the spiral mill is
that it very seldom happens
that - the
,, .
cutting over
tooth is _, Fis- 30-
Shell mill with backed-off spiral t«-«-th.
its full length. The cutting
charge is generally divided over a certain number of teeth,
 27
and Milling Practice.

whilst a further advantage is that the tooth, instead of taking

up the cut suddenly over the entire length of the cutting
surface, gradually advances to its maximum cutting length,
thus greatly reducing the danger of teethbreaking.
e. Fig. 30 illustrates the same miller as fig. 29 with the
difference that the teeth are much stronger to admit of
milling tougher material.

e. GROUP IV. SHELL END MILLS.

This group may be divided into the following principal

types :
1st Side or straddle milling cutters with straight teeth on
both sides and edges.
2nd Side or straddle milling cutters with spiral teeth.
3rd Angular cutters.
a. .Fig. 31 is the simplest type
of the cutters referred to under 1.
It is used for milling right-angled
surfaces.
b. Fig. 32 is used for cutting T
slots.
c. Figs. 33 and 34 serve for milling
triangal grooves and are much used
for milling the teeth of small cutters.
d. Angle cutters are illustrated in
figs. 35 — 37. These cutters are made
with different angles according to the
nature of the work to be performed.
e. Fig. 38. Shows a cutter of the
type referred to under 2. It is very
much used in different diameters and Fig. 31.
Shell-end-mill.
lengths.

Fig. 32. T slot cutter.

28 Milling Machines

Figs. 33 and 34.

Small angular cutters.

Fig. 35. Fig. 36. Fig. 3'

Angular cutter. Angular cutters.

Fig. 38. End mill with spiral teeth.

f. Side milling cutter (fig. 39), are used for widening

slots, milling keyways and
used in pairs for sizing nuts,
bolt heads, etc. and are then
called "straddle mills". They
have teeth upon both sides and
edges, (fig. 40).

39. 40.
Sid.- inilliti" < utter. Straddle mill.
 29
and Milling Practice.

g. Figs. 41 — 42. These cutters are made in two parts and

can be adjusted easely for maintaining a standard width of slot.

Fig. 41. Interlocking side milling cutter. Fig. 42.

/ GROUP V. FORMED CUTTERS.

As has already been stated in Chapter II, formed milling
cutters were the first to be used. Latterly the old European
type has been almost entirely superceded by the backed-
off milling cutter, which latter consists of such a variety of

Fig. 43. Fig. 44.

Formed cutter for Gear cutter. Fig. 45.
Convex cutter.
milling ledges.
30
Milling Machines
forms and size that it is wellnigh impossible to illustrate
even the principal forms.
A few of the different forms of the backed- off formed
milling cutter are depicted in figs. 43 — 48.

Fig. 46.
Concave cutter. Fig. 47.
Backed-off formed < uttrr.

Fig. 48.
Backed-off formed cutter with spiral grooves.

g. GROUP VI. COMPOSED FORMED CUTTERS.

There is at least a limit to the width of the backed-off

milling cutter. The tool with which the teeth of the cutter
are backed-off, must, if the latter have an irregular form,
have the same shape.
If the form of the cutter is composed of ?<raight lines
 and Milling Practice.
31
which can be traversed by the tool in a transverse direction
composing will not be necessary and the cutter can be
backed-off with a common lathe tool.
In this case the tool can be constantly
set in in a slightly transverse direction
whilst the
cutter or a
portion
can beof it
backed-off

by a mon lathe
com-
tool. Should
the form
however,
Fig. 49.
A few composed formed cutters. The be such as
foremost has been taken apart.
to render
this impossible, the tool will then have to be set in square
on the centre line
of the cutter and
the whole width
of the cutter '\

worked in one
cut.
When, how-
ever, the formed
milling cutter Fig.' 50. d backed-off cutter for milling
Compose
came more and flanged pulleys.

more into general

use and even the
beds of lathes and w&
the tables of _t
horizontal and
vertical milling
machines were
milled over their Fig. 52. Fig. 53.
Composed backed-off cutter for milling
entire width by rope pulleys.

one mill in a single cut, milling cutters were required for

32 Milling Machines
this purpose, which in addition to their composit form,
attained a length of 20 inches or more, so that such cutters
could no longer be manufactured from one piece.
A number of sheaves of varying thickness are therefore made

Fig. 54. Fig. 55.

Composed backed -off cutter with Composed backed-off cutter with
irregular cutting edges. irregular cutting edges, ready
for grinding.

which are either first held together with suitable pins or

simply kept in position by a true keyway, after which the
desired form is given to the whole on the lathe, when the
cutter has been turned in this form, it is dismounted and
each separate sheave finished off
as an ordinary backed-off cutter.
Naturally, in fixing the thickness
of the sheaves, the form of the
cutter has to be taken into con-
sideration.
The milling of spiral grooves
is scarcely possible with a cutter
such as that illustrated in fig. 54.
Fig. 66.
The cutting edge is then inter-
Composed formed cutter backed- rupted, as can be seen in fig. 54.
off at sides and cir-
cumference. The cutters are provided with
two sets of key ways. The key
runs in one set when the cutter is being used for milling
and in the other when the cutter is ready for grinding.
The more the plane parallel to the centre line of the
cutter inclines to the line rectangular to the centre line,
 and Milling Practice. 33

the cutting angle at that point is consequently reduced. If

the cutting edge is a line squared on the centre line, the
cutting angle is then 90°. and scrapes along the workpiece.
For small raised edges this is less important as the teeth
on the circumference remove practically the whole of the
material.
If, however, the raised edges are higher or lines of semi-
circular form as shown in fig. 56, the teeth must also be
backed-off on the sides. The cutter in fig. 56 consists of
4 parts; the two outside parts being backed-off on the
circumference and at the sides, and the two middle parts,
the connecting surfaces of which form a spiral.
A number of sheaves of varying width are therefore
made which are either first held together with suitable pins
or simply kept in position by a true key way, after which
the desired form is given to the whole on the lathe; when
the cutter has been turned in this form, it is dismounted
and each separate sheave finished off as an ordinary backed-
off cutter. Naturally, in fixing the thickness of the sheaves,
the form of 'the cutter has to be taken into consideration.
The milling of spiral grooves is scarcely possible with such
a cutter as that illustrated in fig. 56.
 CHAPTER IV.

The working methods of the cutter.

a. THE RELATIVE POSITION OF CUTTER AND WORKPIECE.
The manner in which workpieces are treated by the cutter,
the shape which
can be given to
a particular piece
of work, do not
solely depend on
the form of the
cutter, but also on
the movement
imparted either
Shell-mm ^facing. tO the CUtt6r Or tO
the workpiece or
to both together at the same time, during the rotary motion
of the cutter. It is quite possible, provided the construction
of the machine on
which the cutter
is being used per-
mits of it, to turn
out many different
kinds of work, to
obtain the most
divergent forms
and to finish off a
Fig. 58.
piece of work Slu-ll-mill slitting.
either wholly or
partially with the same cutter.
Leaving the formed cutter on one side for a while, it is
 35

Milling Machines and Milling Practice.

quite possible to carry out an illimitable number of operations

with the plain milling cutter of which the principal kinds
will now be dealt with successively.
In figs. 57 and 58, whilst the cutter is completing the
rotary movement indicated by the arrow, a movement in a
contrary direction, either to the workpiece or to the cutter,
is imparted
to the rotary
cutting move-
ment of the
cutter. In
cases as indi-
cated in figs.
57 and 58,
Fig. 59.
this horizon- Shell-mill milling portion of a flat surface.
tal movement
in a straight line is almost invariably imparted to the
workpiece that is fastened with bolts to the milling table
or chucked. The cutter thus remains stationary, whilst the
workpiece moves.
In figs. 57 and 58, the lenght of the cutter exceeds the
width of the plane which is to be machined, and seeing that
the direction of movement of the workpiece is parellel
to its undersurface,
either one plane or two
new planes will formed
parallel to either one
or both planes of the
workpiece. Whilst the
cutter in fig. 57 is
milling the upper sur-
Fig- 60; face, from which a cer-
Milling a groove with a shell-mill.
tain depth h is being
removed, thus reducing the thickness of the piece, the cutter
in fig. 58 is working at a certain distance from the two'
planes, so that a slit h equal in width to the diameter of
the cutter, is milled, or, if going through the whole piece,
the two parts become separated.
36 Milling Machines
The same operation is to be seen in figs. 59 and 60 as
in figs. 57 and 58, with this single difference that in this
case the length of the cutter, or to be more correct, that
portion of its engaged in working, no longer exceeds the
width of the plane, so that, as a consequence only a portion
of the plane is machined and removed.
However trifling this difference in the working may be,
the results are very divergent.
These four examples show in their simplest form a few
of the principel operations.
Fig. 57 shows the most favourable manner of working
as far as the cutter is concerned, the material being all cut
away parallel to the core of the cutter, whilst the direction
in which the teeth
move during the
time they are
cutting is just the
opposite rection
to in the di-
which
the work piece is
moved. All the
Fi 61 material which is
Milling a slot with a slitting cutter. CUt away IS di-
rectly free, so that
it is impossible for the teeth to become clogged.
In fig. 58, the contrary movement of the teeth to the
direction in which the workpiece is being moved is changed
above the line drawn over the centre of the cutter parallel
to the under surface into a movement in the same direction,
so that the cutting of the upper half is less favourable.
In fig. 59 the cutter is milling a right angle in the
workpiece, the material being cut away in the same manner
as shown in fig. 57, though with this difference, that the
plane b. c. is formed not by the cutting away but by the
breaking off of the chips. Provided care is taken that the
front of the cutter is concave, a fairly accurate plane can
be formed in this manner. It must, however, be borne in
mind, in order to get a right idea of the working of the
 37
and Milling Practice.

cutter, that the plane b. c. is not milled, but formed by the

breaking off of the chips.
Finally, in fig. 60 the working of the cutter is a combi-
nation of that shown in figs. 58 and 59, and in this way
a groove is milled
throughout the dotted
lines, the rear plane,
which is really the
bottom of the groove,
being formed not by
milling, but by the
chips continously
breaking off. It must
be borne in mind
that we have in view
here a shell mill also Fig. 62.
Milling a groove with a slitting cutter.
without teeth at the
front, so that figs. 61 and 62 show this more clearly.
If the results obtained with the cutter in the workpieces
in figs. 61 and 62 be compared with those in figs. 58 and
60, it will be found that they are precisely similar, though
the manner in which the material is cut away in the former
cases is totally different t©
that in figs. 58 and 60. At
the same time it will be
noticed that the centre line
of the cutter is no longer
perpendicular to the ground
plane of the groove but runs
parallel to it. If in fig. 58
Fig. 63.
Milling a groove with a shell mill. a portion of the teeth of the
cutter happens to work
under unfavourable conditions owing to the direction of
movement of the upper portion of the teeth being no longer
contrary to the direction of movement of the workpiece,
this is not the case in fig. 61 in which the direction of
movement of all the teeth engaged on the work is contrary
to the direction in which the workpiece is moved; only a
38
Milling Machines
small portion of the total number of teeth on the cutter are
engaged on the work, thus causing but a trifling heating
of the cutter.
In the case of a cutter working as shown in fig. 62, this
noticeable difference noticed in addition to what was pointed
out above will be that whereas in fig. 60 the material is
cut away on the sides along the lines ab and cd, the chips
breaking off at the bottom, in fig. 62 the order of things
is reversed, the material being cut away along the bottom
and the chips breaking off at the sides. It practically goes
without saying that as this
breaking oif occurs at the
extremity of the teeth
where the chips are
formed, no point on the
sides of the cutter can
come beyond the width of
the teeth without causing
considerable friction and
as a natural result heating
of the cutter with other
attendant results.
The unfavourable re-
Fig. 64.
sults of a cutter working
Horizontal rotating cutter with vertical
feed movement. as shown in fig. 58 are
still more clearly evident
in fig. 63. In this instance the groove has already been
cast in the piece. Now, the surfaces of castings are very
hard, steel pieces also having a hard surface owing to the
oxydation of the hot iron or steel.
If the cutter begins to work on a rough surface, as is the
case in fig. 57, it will first come in contact with this hard
surface which it will have to cut away, although a careful
workman who is saving with his tools will prefer to remove
this crust first with a file or chisel. When once the cutter
has gone through the rough crust, the teeth cut the
soft material from the beginning of the cut and only
touch the crust at the end. This finally breaks off and the
 and Milling Practice. 39

cutting edge of the teeth is saved from coming in contact

with the hard surface of the workpiece.
This is the case along the line ab in fig. 63, but along

Fig. 65.
Horizontal rotating cutter with horizontal and
vertical feed movement.

the line cd the teeth of the cutter first come in contact with
the hard surface, and only when they have gone through
it, do they cut into the soft material.
If a large number of grooves of the same width have to

Fig. 66.
Vertical rotating miller with horizontal feed movement.

be milled, the manner of working illustrated in fig. 62 is

the most commendable. To give an example of workshop-
practice : A certain factory has a number of keys in stock
of different width and for each width there is a suitable
cutter, then, after having been but a short time in use, the
40
Alilling Machines

cutter, according- to fig. 63, will mill a narrower groove

than when first used.
On the other hand, by working as shown in fig. 62, the
grooves milled will always be of precisely the same width.
There is always wear; in
the cases illustrated in figs.
60 and 63 the wear will
have an appreciable effect
on the width of the groove
cut, but not in the case of
figs. 61 and 62.
Moreover, narrow
Fig. 67.
Vertical rotating miller with horizontal, grooves can be milled much
longitudinal and traverse movement.
quicker by the manner
shown in figs. 61 and 62
than by that shown in figs. 58 and 60.
In the foregoing cases it has been presumed that the
workpiece has only been moved in a horizontal direction
parallel to the centre line of the cutter, so that only a
horizontal plane can be
formed by the teeth on
the circumference of the
cutter whilst the front of
the cutter can only form
a vertical plane ; as soon
however as a vertical
feed is given to the work-
piece, the teeth on the
circumference will form
vertical planes, (fig. 64), Fig. 68.
whilst by feeding in both Vertical rotating ruttor with rotai
movement.
directions, it is possible
to cut two planes at right angles to one another (fig. 65).
If vertical planes have to be milled with horizontal feed
of the workpiece, then the cutter will have to work in a
vertical direction as in fig. 66, and thus with two perpendicular
movements one after the other, it will be possible to form
two rectangular planes (fig. 67).
 and Milling Practice,
41
A vertical rotating cutter is almost invariably adopted
whenever circular or profiled lines have to be formed, and
for this reason, that not only does this permit of a better
view of the workpiece, but the table or the workpiece
can move much better along a horizontal than a vertical
formed line.
A profiled line can be obtained in two different ways,
first when the line forms a circle, the segment of a circle
or a union of arches of a circle. In this case, an imaginary
centre can be fixed upon for the circle or the arch which
is to be cut, equivalent to the centre round which the
milling table rotates. Figs. 68 and 69 give two examples

Fig. 69.
Vertical rotating cutter with rotary feed movement.

of this. In fig. 68 the centre of the circle to be worked

lies within the workpiece itself.
In fig. 69 on the contrary, it lies far outside.
The profile line can, however, consist of lines which form
no parts of a circle, or of a large number of small arches,
in which latter case it is quite possible that the .trueness of
the profile will be reduced, owing the various arches joining
less accurately. In such cases the profile lines can be formed
by a combination of two rectangular movements, the slide
moving along a cam (fig. 70).
If, in addition to a longitudinal feed, a slowly rotating move:
ment is imparted to the workpiece, this will cause spiral
groves which can be formed equally as well by a cutter
moving in a vertical as in a horizontal course (fig. 71).
42 Milling Machines

The working of a flat faced slitting cutter rotating hori-

zontally however hides a fault which, in the case of shallow
grooves is not
of such great
importance, viz:
that the sides
of the cutter
form right
angles with the
teeth and con-
sequently have
to force a way
through a
groove which is
formed by two
Fig' 70- 'IT th
Vertical rotating cutter profiling work. Spiral lines ; tne
groove is cut
according to the width of the cutter, so that if two straight
lines are drawn along the spiral lines, their width will not
be as great as
the width of the
cutter, which will
consequently
work through the
groove with con-
siderable friction .

If the centre
line of the cutter
forms any other
than a right angle
with the milling
table on which Fig. 71.
the workpiece is Working method of a slitting cutter and an end-mill
milling a spiral groove.
placed, sloping
planes will be formed (fig. 72).
If, moreover, the feed of the table is circular, conical
planes will be formed (fig. 73).
 and Milling Practice. 43
Conical planes can also be obtained with a conical cutter

72. Fig. 73.

Slope plane cut with a cylin- Conical plane cut with a cylindrical
drical cutter. cutter.

the centre-line of which runs rectangular with the milling

table (fig. 74).
. ->* If, however,
the spindle
cannot be
moved from a

perpendicular
or horizontal
Fig. 74.
Conical plane cut with a conical cutter the axis of which
position, only
is rectangular on the milling table.
one conical
plane can be formed by one particular cutter. If, on the
contrary, the spindle is adjustable, the use of a conical cutter,
which is much more dif-
ficult to make and keep in
order, becomes unnecess-
ary and, therefore, un-
desirable.
In the same way,
oblique planes can also
be cut with a fixed hori-
zontal spindle, (figs. 75 Fi 75
and 76), Whilst dove-tail Slope plane cut by conical cutter.
44
Milling Machines
grooves can also be milled with a conical cutter (fig. 77).
Although in fig. 77, the cutter is working in the full
material, it is never-
theless advisable to
mill as large a
groove as possible
beforehand, not
only on account of
the time taken up
by milling but also
to spare the cutter.
All the opera-
tions which have
been considered so
Fig. 76.
far, have been car-
Sloping plane cut by conical cutter. ried out by means
of a milling cutter,
the general type of which was shown in fig. 29.
Fig. 78 represents the working method with an end mill
as illustrated in fig. 15. In this case, the diameter of the
cutter considerably exceeds the width of the plane to be
milled; in fig. 79,
the end mill is
shown milling a
keyway, but as
only the front is
toothed so that it
is impossible to
take a deeper cut
than the depth of
the teeth, it is
necessary to go
through the same
groove more than Dove-tail groove milled with conical cutter.
once.
From this it is clear that this is not the right manner
of working and that it therefore cannot be recommend' <1
Fig. 80 represents a similar case in which a T slot has to
 45
and Milling Practice.
be cut, the sides of which must each be cut seperately with
due regard to the size.

b. THE MANNER IN WHICH THE CUTTER WORKS IN

RESPECT TO THE PLANE OF MOTION.

In general, the formed cutter works horizontally to

Fig. 78.
Face milling with an end mill.

the plane of motion. Its use is practically limited to the

manufacture of articles in quantities; in machine shops the
percentage of
milling work
performed
with the
formed cutter
is rather small.
One of the
most common
forms of
formed cutters
is certainly the
gear cutter,
fig. 81. In gen-
eral machine
Construction Milling a keyway with an end mill.
as well as for
machine tools, the composed formed cutter is extensively used.
46 Milling Machines
The formed cutter, which at the present day is almost
universally known . as the backed-off cutter, has a manner of
working which makes it difficult to say when it is cutting
as a shell mill, when as an end mill or
when as a combination of both. Fig. 81
serves as an example of what is meant.
-» The two sides work as an end miller, cutting
away the material at the sides. The greatest
diameter, the circumference, on the other
hand, acts as a shell mill, but it is difficult
Milling a T slot with
, to point out the exact spot where it begins
an end mill. to work as a shell mill or as an end mill ;
it is nevertheless a fact that the ends of the
sides act more as a shell mill than an end .mill; further
consideration shows that on the greatest and smallest
diameters the teeth mosty act in
the same manner as an shell mill,
whilst a cutting action can only be
expected from the sides, seeing that
they do not yet form a rectangular
plane in regard to the centre line
of the spindle. Where this is the
case, as in fig. 82 for example,
where the teeth at the side cannot cut
but are only rubbing, the cutting of
the ordinary backed-off cutter is
practically not worth taking into
consideration.
This defect of the backed-off
cutter is not very serious when the
movement of table and workpiece
is rectangular to the centre line of
the cutter, but it is more so when
the relative positions are oblique, so
that the workpiece is fed in some- Fis- 81-
what to one side and still more so,
when in addition to a movement in
a straight line, a rotating motion is also imparted to the
 and Milling Practice. 47

workplace. In figs. 83 — 89, three positions are shown in

which it is possible for the cutter to come, in respect to
the feed movement of the table, viz: - - figs. 83 — 85 give
the most favourable position, i, e. the feed is rectangular to
the centre line of the cutter. In figs. 86 — 87, the workpiece
is fed in in an inclined plane in respect to the course of the
spindle and moreover completes a rotating movement which
causes the milling of a spiral. In figs. 88 — 89, the move-
ment is parallel to the centre line of the spindle so that the
material is cut away almost
exclusively by the sides of the
cutter.
In these and similar cases,
recourse has had to be taken
to another method of construc-
ting the backed-oif cutter and
as a result Reinecker's oblique
backed-off cutter, (fig. 90) has
come into existence, whilst for
larger dimensions of the side Fig. 82.
flanks, the cutter is formed of
two parts, the one with left hand and the other with right
hand backed-off teeth (figs. 91 and 92). Fig. 92 shows the
cutter disconnected ; the guide, which can be seen separately,
serving for the exact centering of the two parts: fig. 91
shows the cutter ready for use.

C. THE MANNER IN WHICH THE CUTTER WORKS

IN RESPECT TO THE CUTTING PLANE.

It is always advisable when deciding on the form of the

cutter, to take into consideration the manner in which it
will cut.
It is quite possible to obtain the same result with two
cutters of wholly different form ; the one will quickly wear
out while the other will remain in good condition a much
longer time.
48 Milling Machines

1 ig. 83. Fig. 84. Fig. 85.

Formed cutter milling a groove rectangu'ar on the spindle.

r ± x

..:. 86-87.
': < iitt«-r milling .1 -j.iral Formed cutter Fig. 88 -S9.
milling a groove parallel
with the spindle.
groove.
 and Milling Practice. 49

This, as also the rotating direction of the workpiece with

regard to the form of the teeth, will have to be taken into
consideration, especially in the case of spiral teeth. With
cutters such as those shown in figs. 94 and 95, precisely
similar results can be obtained; the only thing that is
necessary being to adjust the position of the workpiece with
regard to the cutter, taking care that the line a b always
passes through the centre o.
It is clear that the teeth b c on the contour of the cutter
in fig. 94 have to do all the cutting, the side teeth being
relieved from doing any work, whilst in the case of the
cutter in fig. 95, the teeth on both sides cut away the
material, so that the strain imposed on those teeth is much
less. The angle of the
teeth in regard to the
centre line of the cutter
may practically be deter-
mined at will; an angle
of 75° from one of the
side flanks in regard to
this centre line may be
regarded as sufficient ;
both angles may, how-
ever, be made equal, as
shown in fig. 96 and the
same groove be milled. Fig. 90.
Backed-off cutter.
With the cutter as
shown in fig. 96 the right or lefthand rotation of the
workpiece exercises ho influence on the working of the
cutter, but with varying angles, (see fig. 96), the work-
piece must rotate against the angle which is least acute.
Figs. 97 — 100 give the exact movements of two cutters
rotating in opposite directions.
The plain milling cutter is by far the most frequent
and the range of work' for which it can be employed is
illimitable. For this reason, the milling cutter in its sim-
plest form is a tool that cannot be valued too highly for
general machine construction. It can do the work of the
4
50 Milling Machines
planing and slotting tools in a thousand cases and not

Fig. 91. Fig. 92. Fig. 93.

Oblique backed-off cutter with left and right hand halves.

only' that, but it does the work quicker, better and cheaper,

94. 95.
Cutter with one square side. Double angle cutter.

whilst if it is properly handled, the plain miller is,

 and Milling Practice. 51
by no means the dearest but
rather the cheapest tool, as this
same plain miller can be used
in hundreds of different cases
for which tools of other forms
and dimensions would have
to be provided if the work
had to be performed with
the planing or slotting tool.
The milling cutter is, there-
fore, worthy of our best atten-
tion, but only when the way of
handling the cutter is tho-
roughly understood can this tool
be estimated at its true value. Fig. 96.
Double angle cutter with equal angels.

Fig. 97—100.
Movements of cutter and workpiece in milling spiral grooves.
 CHAPTER V.

The construction of the Milling Cutter.

a. DIAMETER AND NUMBER OF TEETH.

Whenever an object has to be made or constructed, the

most important point to be considered is its size. This is
also the case as regards the construction of a milling cutter,
(if the determining of the dimensions, the number of teeth,
the angle of the teeth, etc. may be regarded as the con-
struction of the cutter), the primary question being as to
what diameter must be chosen.
In connection herewith no hard and fast rules can be laid
down which have as their basis a common starting point,
and it is for this reason that practical experience is of such
supreme importance in deciding this question. The foreman
or workman gauges, with his eye the diameter required for
the cutter for certain work, so that it can thus be said that
the diameter may practically be determined at will.
» The greatest experience in the manufacture of milling
cutters will be found in those factories which make a spe-
ciality of supplying cutters to the trade, but, however much
one may rely upon their ability to give reasons for cases
which regularly occur as to why they would, in a particular
case, give a cutter a certain diameter, the nature and cir-
cumstances ofthe work which the cutter must perform are,
as has been clearly explained in the preceding chapter, of
so unlimited and divergent a character, that it is wholly
impossible for them to inform the purchaser precisely within
what limits a cutter of certain diameter can be used or
 Milling Machines and Milling Practice. 53
within what limits a cutter of larger or smaller diameter
should be employed.
Although the choice of the diameter cannot thus be con-
fined within certain defined limits, still there are a few
circumstances which can give some indication with respect
thereto and especially when these circumstances are just the
opposite, there will be a point where the advantages of the
one will not counterbalance the disadvantages of the other
and on this account the diameter can to a certain extent
be determined. One must always be carefull not to let the
diameter be too small for the following reasons, viz : cutters
which are mounted on a spindle, have a bore, and the
cutter with a diameter approximating too closely to that of
the bore, will be weak and difficult to handle.
Cutters which are not mounted on a spindle but form
one piece with the cone, i. e. end mills become weak,
vibrate and are liable to breaking off. Moreover with a
large cutter, a much smaller number of teeth are engaged
on the work at the same time under otherwise similar
circumstances, consequently, the heating of a cutter of
larger diameter will not be as great as that of a smaller
one, where as many as half the number of teeth may be
engaged on the work at the same time. For these reasons,
as stated above, one will generally be inclined not to choose
a cutter with too small a diameter.
On the other hand, a cutter with too large a diameter is
still less desirable than one with too small a diameter.
In the first place, the cost is much greater in the case
of a cutter with a larger diameter than for one of smaller
dimensions, whilst the possibility of cracking in the hardening
is much greater with the former than with the latter.
At the same time the diameter of the cutter can cause
a considerable difference in the time required for cutting
away a certain thickness of material just because in reaching
to and receding from the work the diameter exercises
a great influence on the time required for milling certain
pieces. Suppose for instance, that in fig. 101, a certain
depth a. b. c. d. has to be removed from the workpiece P.
54 Milling Machines
and that a cutter D. is employed for that purpose. Then,
either this cutter or the workpiece will have to traverse a
distance AB from point b where the teeth first come in
contact with the workpiece to point d where the last material
is cut away.
If, however, a cutter Dj is employed the distance which
the cutter or the workpiece must traverse in order to remove
the same quantity of material will be represented by the
line A, B, which is shorter and consequently requires less

.-—I—- -.

p
Fig. 101.
Traverse of tw<> cutters of different diameter.

time than the distance A B. Accordingly, the greater the

J^'
difference in diameter between D and D, or R and r, the
greater will be the difference between A B and A, B,.
With respect to the diameter of the cutter this difference
can be expressed in a stated formula, since
AB = A,B,-f/ — q
p = R sin 0
q= r sin 0,
further A B = A, B, + R sin 0 — r sin 1}
so that A B — A, B, = R sin 0 — r sin 0,.
 and Milling Practice. 55
If therefore, the feed is the same for both cutters and
this feed per second is denoted by S, the removal of the

depth a. b. c. d. by the cutter D will require *——-

seconds longer than that with cutter Dj.
The distance, i. e. the feed, traversed by the workpiece
per second is, however, very small, so that the value of the
fraction „ will quickly increase very considerably.
Suppose for instance, that fig. 101 is drawn to a scale
of 1 : 2 and that 1000 of the workpieces P have to be
milled, and that futher the feed amounts to Vs2 mcn Per
second, the difference in time required by the cutters D or D,
will amount to : —

1000^- o "-i = 1000 ~-=

VM 1600 sees, or about 4 V2 hours,
The time, therefore, that would be required for milling
1000 pieces with the cutter Dj would be : —
1000 ^5io= 10oo ^ Y32 seconds = 46 hours,
Similarly with the cutter D the time would be: 46 hours
-f- 4 hours 30 min. = 50 hours 30 min., thus entailling a
loss of time of about 10 °/o and consequently making the
cost of production 10 °/o higher the time taken up for fixing
and taking off need not be taken into consideration as this
will be precisely the same in both cases. This will, however,
naturally affect the percentage to a certain extent.
Viewed from this point, it is certainly worth while to
devote sufficient attention to the diameter of the cutter.
In the foregoing there is evidently still something contra-
dictory, seeing that with the same feed, the cutter D removes
a plane of metal equal to x± d X b, if b is the width of
the workpiece P ; with the cutter Dt on the contrary, this
will be x d X ^ and x\ d being longer than x d, more
material will be cut away per unit of time by the larger
cutter than by the smaller, whilst the time required for the
whole work will still be longer for the larger cutter. The
reason of this is that the cutter D! is already fully engaged
56 Milling Machines
after it has traversed a distance c x from the first contact
with the material whilst the cutter D has to traverse a
distance c x} for the same purpose.
As long as the cutter D has a full cut on the work, it
gains on the cutter Db but loses so much time at the
beginning and the end that this results in a total disadvantage
for the cutter D.
For this reason, the cutter should always be chosen with
a diameter as small as is consistent with practical utility.
In this respect two possibilities have to be taken into
consideration, viz : — the cutter which is mounted on an
arbor : (see fig. 39), and the end mill with taper shank (gee
fig. 38).
The first type of cutter must from its very nature have
a minimum diameter owing to the bore, the latter, on the
contrary can have a very small diameter which, however,
owing to other considerations, must still remain within
certain limits.
In the first place the proportion of the length of the
•cutter must be considered with respect to the diameter,
which proportion can generally be determined as 4 : 1, i. e.
the diameter will be J/* °f the length of the teeth. Excep-
tional cases deviate from this, but there is a limit where
the diameter of the cutter will be too small in proportion
to the length, and the cutter will be either very difficult
to harden, get out of true in this operation, or it will
not be strong enough, will vibrate and run the chance of
breaking.
Further the number of teeth diminishes in proportion to
the reduction of the diameter, or, if the number remains
the same, the thickness of the teeth will be reduced and a
reduction of the thickness entails a diminution of the strength
of the teeth. A reduction of the number of teeth, however,
increases the work proportionally which each tooth has to
perform, which by the same depth of cut may be regarded as
a diminution of the strength of the tooth. Taking this into
consideration, an excessive reduction of the diameter of the
cutter may thus be very disadvantageous.
 and Milling Practice. 57
In order to secure a smooth, even working of the cutter,
at least 2, if possible 3 or more teeth should be at work
at the same time, the highest speed at which the cutter
may rotate being further taken into consideration and in
connection therewith the diameter of the cutter must be
of such dimensions, as to obtain a sufficient circumference
speed.
With the old European type of cutter the pitch was
generally taken 0,1 D, so that if P = the pitch and / =
the number of teeth,
5rD 3.14 D
-p- =-oTD =
At that time there was no uniform idea as to construction,
as the strength of the teeth diminished with a reduction of
the diameter or increased with an increase of diameter
without any apparent reason.
Formerly, the diameter of the millers did not differ much
so that this did not cause any great difficulty; though
with the diversity of diameter met with at the present day,
it would be quite impossible to fix upon an exact number
of teeth.
The general formula however remains that if P = Pitch
and t = the number of teeth

P = — and *=

It goes without saying that there must be a certain

relation between the diameter of the cutter and the thickness
of the teeth, as also with the number of teeth with a fixed
limit for the thickness of the teeth. A formula which has
always served us excellently and has proved good in practice
is, according to Knabbe, P = 1,2 1/D. D being expressed
in m.M.
The following table of the diameters of cutters most
frequently met with has been compiled according to this
formula.
58 Milling Machines

Table I.

Table for determining the pitch and number of teeth

for cutters of a given diameter.

D p D p
Diam. of Diam. of
Pitch No. of No. of
cutter. cutter. Pitch.
mM. mM. teeth. mM. mM. teeth.

20 5.23 12
100 12.07 26
27
30 6.73 14 110 12.77
40 28
29
7.85 16 120 13.46
8.72 125 13.53
50 18
9.42 140
60 20 14.18
9.99 22 150 14.72 31
32
70
10.92 23 175 16.14 34
80
90 11.30 25 200 16.19 37

Only a few of the diameters of cutters which are met

with in the trade have been given in table I, whilst
with the formula referred to, the number of teeth for any
other diameter can be found. The pitch is first calculated
according to the formula so that after the number of
teeth has been fixed upon, the exact pitch can be definitely
settled.
For instance, a cutter of 250 mm.
then P= 1.21X250= 18.96 m.m.

IF
,_*D_ 785.4
Isle
In this case 41 teeth will be chosen.

If 41 teeth, then the actual pitch will be ' = 19.15 m.m.

b. THE TOOTH AND ITS INCLINATION.

In order to ensure a really good construction of the

cutter the inclination of the teeth is of quite as much importance
 and Milling Practice.
59
as the pitch or the number of teeth, as its angle is closely
associated with the pitch and the number of teeth.

Fig. 103.

In connection with the teeth of the cutter, the following

angles have to be considered, (see fig. 102), viz:—

Fig. 104. Fig. 105. Fig. 106.

Angle cutter. Double angle cutter.

q = that portion of the circumference of the circle occupied

by one tooth.
60 Milling Machines

d = the angle formed by rake and the plane of the

workpiece.
b = the angle of the tooth.
c = the cutting angle.
If the teeth be taken separatly, the angles b, c, and d, are
also to be found by lathe and planing tools, (fig. 103).
Angle q is
quickly deter-
mined as depend-
ing upon the
number of teeth;
360
thus q = — — .
The teeth of a
cutter are milled
by another cutter
and for this pur-
pose either a
cutter similar to
that shown in
fig. 104 or one
like that illustra-
ted in figs. 105
and 106 can be
used.
The angle of
the types of cut-in
ter shown
Fig. 107.
Angle of cutters. fig. 104 varies
from 60° to 75°,
in figs. 105 and 106, the sharpest angle varies from 12°
to 20° so that the angle which is milled by this cutter varies
from 52° to 60°.
As to the use of one of these types of cutters, see what
was said in connection with figs. 95 and 96.
52° to 75° can thus be accepted as the greatest deflection
of the angle which should be cut.
In fig. 107, if the angle q is known, as likewise the angle
 and Milling Practice. 61

x from the number of teeth, the angle / can consequently

be determined, since
/ = 180° — (z + x]
and as z = 180° — q
p = q — z
The following table gives the different angles of x and /
for the pitch given in table I.
Table II.
< P
Table of angles of x and / for a given diameter and pitch.
D t
diam. of cutter.
mM. No. of teeth No. <of degrees
x No. of degrees

20 12
30. 22.
30 14 25.43 26.17
40 16 22.30 29.30
50 18 20. 32.
60 20 18. 34.
70 22 16.22 35.38
80 23 15.38 36.22
90 25 14.24 37.22
100 26 13.51
27 38.9
110 13.20 38.40
120 28 12.51 39.9
125 29 12.25 39.35
140 31 11.37 40.23
150 32 11.15 40.45
175 10.35 41.25
34
37
200 9.44 42.16

Angle O the angle originally milled, which is equal to

90° — /is very large ; much too large in fact, to obtain
good results when cutting. It is however, necessary for it
to be so large in order to get a cutter which allows of
sufficient clearance for the chips as well as to allow of
regrinding when the cutter has become dull. For this reason
the sharp edge is ground after hardening so that angle p
62 Milling Machines
which is much too small and angle O which is much too
large are replaced by angles /, and O{ fig. 108 which can
now be given the most advantageous angle for cutting. To
obtain this the portion a. b. c. is ground off from the upper
edge of the tooth.
For the purpose of distinctness, the portion to be ground
off has been purposely enlarged in the drawing fig. 108 ; in
practice, the rake a c of a new cutter may not exceed Ve*"-
The grinding of rake a c is a matter of the greatest
importance for the good working of the cutter, not only with
reference to the quality of the work, but also with reference

Fig. 108.
Cutting angles.

to the power required ; by far too little attention is paid to

this particular. Most factories buy their cutters ; such cutters
will be properly constructed and will come from the factory
ground to the correct angle, but the regrinding, which will
be done at the works where the cutter is in use, will not
be carried out properly, and one of the first conditions for
a good cutter, viz : the exactness of the angle O, will be
neglected.
It is impossible to emphasize this point too strongly seeing
that the rake a c is too small to permit of the cutter being
altered after grinding ; the greatest attention must be directed
to the correct position of the cutter with regard to the emery
wheel with which it is ground.
 and Milling Practice.
63
Angle O[ may vary from 3° for hard to 12° for soft
material, the intermediate angles can be determined for
different kinds of material. However, to avoid the necessity
of having an excessive number of cutters, 3° to 6° is gene-
rally adopted for hard and 7° to 12° for soft material.

Fig. 109. Fig. 110. Fig. 111. Fig. 112.

Cutting angles of millers.
Fig. 109 ft = 75°, «j = 15° (too sharp).
Fig. 110 ft = 80°, «! = 10° (angle of teeth for soft material).
Fig. Ill ft = 86°, «a = 4° (angle of teeth for hard material).
Fig. 112 ft = 90°, «j = 0 (ground too obtuse or teeth have become dull.

The limit up to which material can still be cut away is q^ = 90°,

as soon as gl exceeds 90° further cutting becomes impossible.
The necessity of keeping the teeth of the. cutter sharp
cannot be too strongly insisted upon,
since when once the sharp edge is off,
and a large portion of the plane a c,
(fig. 108), still remains, a new plane is
really formed, viz i • • q\\ which is an
angle of 90°. Some makers of cutters
stamp on their goods the warning " grind
frequently " so that this -weighty factor Fig. 113.
Cutting angle.
may be continually borne in mind.
The depth h of the teeth can now
further be calculated from fig. 107, provided the sin angles
p x
and / are known as also the diameter of the cutter.

2 2 2 sin 2 sin (180-^J

from which follows that:

2 sin q
64 Milling Machines
If the angles known from table II are substituted in this
formula for D, x and p, the exact depth h of the teeth
can be calculated for each cutter which is mentioned in
table III according to the diameters given in table II, whilst,
at the same time, the ratio of the depth to the pitch

p- and of the depth to the diameter -=r are also included.

It will be seen from table III that the depth of the teeth
for diameters from 3//'— 8" varies from pitch to 0,87 pitch
which for sizes so divergent is decidedly but a slight diffe-
rence. The average depth of the teeth with regard to the
pitch can thus be generally fixed as

Table III.
Table of depth of teeth and ratio h : D and h : P
for a given diameter of cutter.
D h h h
Diam. of cutter. depth in mM.
Inch. mM.
17, 20 5.3 0.26 —
7,
17.. 30 6.6 0.22 1.
40 7.6 0.19 0. 99
97
2 7s 50 8.3 *0.16
0.12 95
96
60 0.15 0.
27, 70 2.1 0.13 0.91
3V, 80 0.
3V,
90 10.3 0.11 0. 91
- 91
41/,. 100 10.-9. 0.11 90
91
110 11.5 0.10 0.
120 11.- 0.10 89
55V*lit 125 12.5 0.10 0. 92
411
/ 140 12.-
12.6 0.09 88
6 150 0.08 0.
12.7 . 87
7 175 0.08
8 200 0.07 0.
0. 87
0.88
14.-
15.—
 and Milling Practice. 65

Table IV.

D t p h h h
diam. No. of Pitch depth D
of cutter teeth in mM. in mM. < X

Inch. mM.
3A

20 12 5.23 5.3 0.26 30.

1% 14 6.73 6.6 0.22 0.99 25.43
in °
22.
26.17 °
30 in
r/16 40 16 7.85 7.6 0.19 0.97 |
0.95
22.30 29.30
2 50 18 8.72 8.3 0.16 20.
2% 32.
60 20 9.42 0.15 0.96 1.-
18. 34.
35.38
23/4 70 22 9.99 9.1 0.13 0.91 I 16.22
3V, 80 23 10.92 0.91 15.38 36.22
0.12
31/, 90 25 11.30 10.3 9.- 0.11 0.91 14.24 37.22
4 100 26 12.07 10.- 0:11 0.91 13.51 38.9
45/,6 110 27 12.77 11.5 0.10 0.90 13.20 38.40
11.- 0.10 0.89 12.51
4 /16 120 28 13.46 39.9
5 125 29 13.53 12.5 0.10 12.25 39.35
0.92
51/, 12.- 0.09
140 31 14.18 12.6 0.88 ;: 11.37
0.87 40.23
6 150 32 14.72 12.7 0.08 11.15 40.45
7 175 34 16.14 0.08 0.87 10.35 41.25
8 200 37 16.19 0.88 0.07
9.44 42.16
14.-
15.—
The ratio of the depth of the tooth with regard to the
diameter is too diverse, (from 0,26 to 0,07), to permit of
a ratio being fixed upon.
A smaller depth of tooth equal to from '/a to */4 of the depth of
the tooth of a milling cutter is usually taken for end cutters.
Finally, table IV is a combination of tables I, II and III
and by its use a well constructed, good working cutter can
always be obtained for general purposes.
C. THE SPIRAL LINE OF THE TEETH.

Table III and what was previously said apply equally as

.well to cutters with straight as to those with spiral teeth;
as however, the latter type of cutter lasts very much longer,
5
66 Milling Machines

turns out much better quality work and the spiral teeth
increase to no small degree the cutting capacity of the
cutter, whilst the milling machine itself suffers less by the
use of spiral cutters, it is generally advisable to make as
much use of the cutter with spiral teeth as possible. We
say with reason as much as possible, because to make
formed cutter with spiral teeth has even up to the present
day presented certain insurmountable difficulties. Figs. 54
and 55 show how even if not actually a spiral, still an
irregular line of teeth can be formed for some types of
cutters ; for plain and slitting cutters as also for conical
cutters, the spiral form of teeth is much to be prefered.
The question as to the length of the spiral line partly depends
on the diameter of the cutter, and partly on the width of the
plane to be milled, with which is also included the fact that the
length of the cutter should be chosen in accordance therewith.
The length of the spiral line can also be expressed by
the inclination of the spiral line ; moreover the determining
of this inclination is necessary for the construction of the
cutter. This is discussed in detail in Chapter VI in con-
nection with the construction of the cutter.
The inclination of the teeth of spiral cutters varies in
general from 20° to 30° which is equivalent to a pitch of
from 7 to 9 times the diameter of the cutter. Although the
leading manufacturers of cutters show a decided tendency
to cut spirals to the smallest angle and still smaller, our
own personal experience is somewhat opposed to this and
cutters which we have made and which always approached
the largest angle, have served us much better, whilst once,
as an experiment, we cut a miller with a pitch equal
to four times the diameter and that for an end mill of only
1 inch diameter ; the cutting capacity was really surprising ;
but in such a case other difficulties are encountered, grinding
especially becomes much more difficult, whilst with spiral end
mills, an angle which is too large causes the front teeth to
assume a very unfavorable angle. With spiral teeth the front
rake of the front teeth is part of a spiral on the mill ; it is thus
only in the case of straight teeth that the front rake of the front
 67
and Milling Practice.

teeth comes squarely on the plane of the work. With spiral

teeth, the cutting angle of the front teeth is less than 90°
and the smaller the pitch of the axial teeth, the smaller the
angle, till at length, the cutting capacity is entirely lost owing
to the unfavorable angle. (Fig. 114).
Table V gives the different pitches with
angles of from 15° to 30° for cutters of from
3/4 to 8 inch diameter. For the calculation
of the change wheels the pitch is given in
round numbers and not the exact fraction.
The question as to whether a cutter shall
cut to the right or left hand is also of interest.
On this depends also whether the spiral
line has to be right or left handed. If the
cutter on account of the rotating direction Fig. 114.
End mill with large
must rotate to the right, the cutter must inclined teeth.
have left hand spiral teeth, should it, on
the contrary, rotate to the left, it must have right hand
spiral teeth. (Figs. 115 and 116).
As they both rotate in opposite directions, the feed motion
of the table must naturally be contrary to both.
If the milling machine can rotate at will and the feed
motion be in two directions then for plain shell mils, the

Fig. 115. Fig. 116.

Left hand cutter. Right hand cutter.

question as to the choice of a right or left hand cutter

remains an open one.
The question here arises as to what kind of work the
cutter has to perform.
The cutter has always to be selected so as to allow the
chips to be released as easily as possible in order to
prevent their clogging between the teeth and the surface
of the work and so destroying the cutter.
 68 Milling Machines

Table V.

Table of pitch of the teeth of cutters for a given

angle and diameter.

Diam. of
Pitch of the Pitch of the Pitch of the Pitch of 4 %5%
the
teeth at an angle teeth at an angle teeth at an 5angle
% teeth at an angle
6%
cutter.
6%
inches. »'/«
of 15°
inches. of 20°
inches. 6V,9
inches.
of 25°
inches.
7 %
8%
9% '/2
of 30'
8V, 9%
% n'A
ii3/,, 11%
1% 14
I8V,
i8ov,
18%
i9/,, 16'/4
15% 13% 1101%%
1% 20%

1214V,
2 23
2% 17
2% 27%
24'/3 17%
18
201/, 16
23% 13
2%,
2% 32% 181/, 16%,
30 14
34% 22 1521
251/, %
3 20
3V«
81/, 37 27
801/, 21 1723%
4«V.
41'/2 261/.
24 19
4 50% 3440% 34%
4%
4%, 36 29
5V,
55'/3 32 2632%
5% 60
47
44 V, 28
5% 641/, 37 30
6% 691/, 49 40 42%
54 34
74
77%
9% 83
110%
6181%
68
48
42
53
38

64 52
 and Milling Practice. 69
In ordinary surface work as shown in fig. 57, no trouble
is experienced with the chips, but on the other hand the
lateral pressure has to be taken into account. As the teeth
of the cutter form a spiral, the cutter will experience a
pressure either on one side or the other.
If the arbor on which the cutter is mounted runs free
and fits in the spindle by means of a taper shank a right
hand cutter with left' hand spiral will then receive a pressure
in a direction to the shank which will consequently be
pressed more firmly into the taper. A left hand cutter will,
on the contrary, be pulled out of the taper.
If the end of the arbor is supported by a centre, the spindle
bearing will take up the pressure in the case of a right
hand cutter; with a left hand cutter, this will have to be
done by the centre which has only a small surface for the
absorption of pressure. In all cases the preference is thus
to be given to the right hand cutter.
For this reason, makers of cutters almost invariably supply
right hand cutters unless otherwise stipulated in the order.
It is, however, always advisable when ordering cutters to
state that right hand cutters are required, but this is impe-
rative, ifleft hand cutters are desired.

d. THE BACKED-OFF CUTTER.

The construction of a good backed- off cutter rests on an

entirely different basis to that of the cutter with ordinary
milled teeth ; in fact, the whole construction of the backed-
off cutter is different to that of the ordinary cutter. Without
going directly into the question of grinding, it may here
be pointed out that the method of grinding is entirely
different for the two kinds of cutters. In the case of
the ordinary cutter which has become dull, the teeth are
ground on the back, along the line a b in fig. 117,
which line makes a certain angle with the radius O a, of
which the front of the tooth generally forms one line as
well as with the tangent a P.
70
Milling Machines
It is evident that as easy as it is to grind an ordinary
straight tooth as represented in fig. 39, the grinding of
the teeth of a formed cutter as shown in fig. 47 is just as
difficult, nay, almost impossible and however ingeniously
one may set to work, it is impossible to grind a cutter on
the back of the teeth
in the case of the more

.I*, composite forms of the

•^~> . _ cutter.
The invention of the
'vx^ backed-off cutter has
therefore proved of the
utmost importance in
the development of
milling and it has
thereby become possi-
Fig. 117. ble not only to render
the grinding so very
simple that, if necessary, it can be performed by an unskilled
workman, but to guarantee the absolute similarity of the
teeth both before and after grinding, so that the form,
even after many times regrinding will not have undergone
the slightest altera-
tion.
A striking
example of this is
shown in the case
of the cutter Hlustra-
ted in fig. 118,
which is preserved
in Reinecker's mu-
seum. 200.000
triggers of Mann- Fig. 118.
licher rifles were Fig. 119.
Worn out backed-off New cutter.
backed-off
milled with this cotter.

cutter, which
reckoning a thickness of '/i inch each represent a total milling
length of 4166 ft. Fig. 119 shows this cutter in- its original
 and Milling Practice.
71
state whilst it can be seen from fig. 118 that, as a result
of repeated regrinding, not more than !/5 °f the original
thickness of the teeth remained, but, notwithstanding this,
the form of the last trigger was identical with that of
the first.
The principle of the backed-off cutter is that the back
of the tooth is formed
according to the loga-
rithmic spiral, which
line has the property
that at every point it
forms with the radius
one and the same
angle. With the
backed-off cutter,
therefore, care has only
to be taken that the
rake forms a part of Fig. 120.
Teeth of backed-off cutter.
the radius in order to
ensure perfect uniformity of its form.
Thus, if in fig. 120, the tooth is ground to b, the angle
O b e will still be precisely similar to the original angle
O a e, whilst the angles b a c and bed are also equal.
The number of teeth on the backed-off cutter is totally
different to that of the ordinary cutter; various consider-
ations which are of considerable importance with regard
to the ordinary cutter, can be completely ignored in the
case of the backed-off cutter. One of the chief conditions of
the backed-off cutter is that the root of the tooth may
not be weakened too much. With a straight groove, and
this is almost universally adopted whilst in many cases
where a deep groove is necessary on account of the form
of the tooth, a straight groove is unavoidable, the root of
the tooth will always be weaker than the end and therefore
with millers of small diameter, a pitch varying from \" — l1^"
is sometimes necessary.
72 Milling Machines

Table VI.
Table for backed-off cutters.

Diameter of cutter
Depth of tooth
No. of teeth.
in inches. in inches.

I'/l
8
%
0,208
1 9
1% 0,23
IV. 9
10 0,275
21/, 11 0,29
0,3
2 12
23A 0,343
14
15
61 0,36
6V, /, 17
0,38
18 0,39
19 0,41
4 6'/i
0,434
5 22 0,45
25
27 0,46
6 0,458
7 30
0,48
8 34
0,49
No universally adopted construction exists for backed-off
cutters. Every expert who has used backed-off cutters to
any extent, employs the results of his own experience in
the manner in which he considers the best results are
obtainable. Table VI, (although it must be distinctly under-
stood that it cannot be accepted as universally applicable),
yields excellent results in the majority of cases.
The depth of the tooth, which is also the depth of the
groove, has been taken as equal to 2 /3 of the pitch. With a larger
pitch, '/a pitch will possibly suffice but a depth of tooth which
 and Milling Practice. 73

exceeds 2/3 of the pitch

cannot be recommended,
the more so that, as the
depth of the groove in-
creases, the strength of
the tooth diminishes.

e. THE BORE OF THE

CUTTER.

A very large number

of cutters are provided
with a bore and mounted
on an arbor. Every
milling-machine is the-
refore supplied with a
certain number of arbors
of various diameter and
length, whilst to avoid
the necessity of having
too many arbors for cut-
ters of different length
the thickness of which
does not coincide with
the length of that part
of the arbor intended for
mounting cutters, the re-
maining part is filled up
with sleeves, (see fig. 121).
The arbors are provided
with a cone, the end of
which fits in the spindle
of the milling machine,
whilst the other end is
hardened and provided
with a centre supported by
the overhanging arm of
the machine. The conical bore in the spindle frequently
74 Milling Machines
corresponds to one of the numbers of the morse-cone, in
which case, twist drills can also be used on the milling machine.
The shell end mills which are also provided with taper
shanks corresponding to the dimensions of the cone fit direct
in the spindle.
The dimensions of the cone which are bored in the spindle
of the milling machine depend upon the size of the machine ;
the diameter of the arbor, on the contrary, is dependent on
the bore of the cutter, which, in its turn depends on the
diameter of the cutter and varies from \ — If inch. Reinecker
takes the following as the normal bore of cutters of varying
diameter: -
for gear cutters:
D = to 2f 2f 2£— 3£ 5— 6 inches.
It H — 4 H
cutters for
1 — taps,
1} twist drills, etc. : H inches.
D — to 2£-3f
d= ^ — 4 inches.
I 4 3f— 1-J- inches.
for side milling cutters:
D== 2-2| 2|— 3| — 7 — 1 inches;
2
H H !•£ inches.
for plain milling, cutters:
D = 2-lf 2-2| 4—5 inches.
H 1-J- inches.
for backed-oif cutters: - 2}-4
D= 2-2J 2|— 3| 5-6 6 — 8 inches.
d = 4 I H 1 inches.
D =. diameter of cutter, d = bore of cutter.

One of the first requirements for the good working of the

cutter is that the bore fits exactly to the arbor without any play.
In order to ensure a perfect fit without the cutter bciii-
actually tight fitted to the arbor, the cutter is provided
with a recess, (Fig. 122), and the bore a and b is only
ground after hardening.

The arbor is further provided with a key way, the cutter

having a corresponding keyway. The key in this keyway
 and Milling Practice. 75

may not serve any other purpose than acting as a security.

Under no circumstances may the key lit tight in the keyway
of the cutter. The cutter must fit
exclusively on the bore as other-
wise it might possibly swing.

Fig. 122. Fig. 123. 3/6

Cutter with recessed bore. 4
Square keyway with rounded corners.

Table VII.
3/3
2
Dimensions for square key ways with rounded S2corners.
Bore of cutter
in inches.

D
With of keyway
Si
in inches.
•/r Depth of keyway
in inches.
3/l
3/1

6
6

% - 7.6

,>- y»
i ',C— 17!
7,'I-2 4
7/8

2i'Y,6-2'/3
ju

7,6
2 '/* -3
7s
7,6
%2
76 Milling Machines
Table VII and fig. 123 give the dimensions of the key ways
for the various bores according to Reinecker.
Loewe, Pratt and Whitney and others make a semi-
circular keyway, (fig. 124), to prevent cracking because of
the keyway, which keyway is drilled in cutters of not too
great a width in the full material before the central bore of
the cutter is made.
In any case, the corners of the keyway should not be sharp.
The leading manufacturers are gradually fixing upon
normals as given in table VIII for this purpose which are
n»w generally followed.

Fig. 124.
Semi-circular keyway.

See table VIII. '

Table VIII.
Dimensions of semi-circular keyways. '/..
Diameter of semi-circular
Bore of cutter.
keyway W. Depth D.

inches inches inches

V,
3/ 6/

"/,,-"/„
/a— /8
'/,-l3/,, V..
IV,- 17/,.
lVi-2 V, V,
2V,,-2'/,r,

V.
 CHAPTER VI.

The manufacture of cutters.

a. XrENERAL CONSIDERATIONS.

The manufacture of cutters has in the last ten years

reached such a degree of perfection, not only with regard
to the quality and durability of the tool itself but also of
its capacity, that one might almost speak of it as the acme
of perfection.
It cannot be too strongly insisted upon to purchase the
cutters which one may require from firms making a spe-
ciality of this manufacture and have thus obtained the neces-
sary experience to turn out a cutter that really cannot be
improved and that no one should endeavour to make their
own cutters unless with sufficient means at their disposal
in the way of machinery, tools, material and skilled
workmen.
At the present time there are firms such as Pratt and
Whitney, Brown and Sharpe and others to whom milling
technic. owe a deep debt of gratitude, who have set about
the manufacture of cutters on such an extensive scale,
that an inspection of their establishments is bound to con-
vince one that such firms are in a position to supply the
very best which the technical world in this branch has to
offer. These firms manufacture cutters of every conceivable
form, size and construction, and in addition, keep such an
enormous stock such as surface, shell and angle cutters and
end mills, etc. that it can be truly said that their manu-
facture has become a wholesale industry and one would
require an exceptionally well-equipped toolmakers-shop to
78 Milling Machines
be able to turn out cutters at the prices for which they can
be purchased at one or other of these factories.
Although, notwithstanding what has just been said, the
manufacture of cutters is discussed in the following pages,
this has been done since even if one purchases the cutters
required, an acquaintance with the process of manufacture
is a sine qua non to a good judgment of the tool to be
used, as, owing to a variety of circumstances it is quite
possible that one may be called upon to manufacture cutters
oneself.

The cutter must be made of the very best quality steel.

The cost of the steel required for the manufacture of a
cutter is so small in proportion to the cost of manufacture,
that the loss occasioned by the cutter not reaching such a
high pitch of efficiency owing to its inferior quality, as one
manufactured from first quality steel, cannot be very con-
siderable. All economy in the choice of the steel to be
used for the manufacture of cutters should, therefore, be
set on one side.
The steel best adapted to the manufacture of cutters is
that which is entirely free from all injurious elements such
as sulphur, copper, phosphorus, etc. but contains a per-
centage of carbon varying from 0.9 to 1.45 %.
The old type of fine pitched cutter which can only cut
away a very thin chip may, in contradistinction to those of
the new type, the coarser teeth of which penetrate the
material to be worked to a considerable depth and which
are consequently exposed to a much higher pressure than
the first-named, contain a higher percentage of carbon than
the coarse pitched cutters, whilst the quality of the latter
is considerably improved by adding Wolfram, Chroom or
Mangaan to the steel from which they are made. Cutters
made of Wolfram steel, in particular, excell on account of
their excellent quality and take the leading place as regards
cutting capa<
Of late, since the introduction of high speed steel, cutters
made from high speed steel have also been put on the market
 and Milling Practise. 79

and have quickly won a place on account of their con-

siderably greater capacity.
At the exhibition of machine tools held at Olympia, London
in October 1906, we ourselves witnessed a milling cutter
cutting a depth of 3/8/x from a casting of 16" long and 6"
wide in 1 min. 15 sees. Only a short time ago such tests
would have been quite impossible.
Meanwhile the reason of the exceptional capacity of these
cutters is attributable not simply to the addition of Wolfram,
Chroom or Mangaan, but to a great extent to the peculiar
method of heating and hardening. This process, together
with the above-mentioned additions, gives the steel such
resistance that even when heated to 400° C. it does not
lose its cutting capacity.
The forging of the cutter is confined almost exclusively
to cutting off a sufficient length from the bar and planishing
surfaces. But seldom the cutter is forged in a special form
whilst, as a rule, a cutter of a certain diameter is not made
from a bar of smaller diameter as this would affect the
quality of the steel.
Even at the first operation the quality and cutting capacity
of the blank can be considerably injured by an unskillful
treatment of the steel. The steel must be quickly raised
throughout to a temperature just sufficiently high for forging.
Every part of the steel is permeated by a fine tissue of
carbon ; if, therefore, during the heating process, much
oxygen comes in contact with the steel, the carbon unites
with the oxygen and evaporates, so that, as a consequence,
the cutting capacity of the surfaces and more particularly
of the edges is considerably diministed. Especially when
the heating is done in an open fire in which, moreover,
ordinary sulphurous coal is burned the quality of the steel
is injured. Only as a last resource should ordinary coals
be used and even then the coals should be well burned
dead: it is, however, far preferable to use charcoal.
The very best results are obtained when the cutters are
heated in a furnace which excludes all possibility of cold
air .coming in contact with the heated steel, (fig. 125).
80 Milling Machines
During the process of forging it is unavoidable that the
steel becomes strained owing to the various parts not
receiving precisely the same treatment or to their being
more or less unequally heated and these strains will have
to be removed by reheating and tempering. The further
handling of the steel is at the same time, considerably
facilitated by a proper tempering. After forging, when
the steel has been heated throughout to an almost white
heat, the fire is drawn from the furnace which, together with

Fig. 125.
Heating furnace.

the cutter, is allowed to slowly temper. This will take

from 24 to 72 hours.
If one has not had sufficient practical experience in the
handling of cutter steel, as it is so seldom that this has to
be done in a workshop, it is advisable not to attempt it
at all.
The leading tool steel works supply cutter sheaves all
ready for mechanical treatment in various diameters, thick-
ness and length as well as in different qualities so that one
is certain of receiving a cutter forged without any mistake.
1 he bore. After tempering the rough cutter is turned
 and Milling Practice. 81

and bored. In order to facilitate the grinding of the bore

later on and to ensure the cutter fitting more accurately on
its arbor, a recess is turned in the centre, (fig. 122), so that
only two edges,
about J/4 inch
wide, remain of
the actual bore at
either side of the
cutter. These
edges are turned
0.01 inch smaller
than the exact Fig. 126. Fig. 127.
Threaded bore. Recessed bore with nut-chamber.
diameter for
subsequent grinding.
Cutters having a threaded bore as also the chambers in
cutters for nuts for fastening, (figs. 126 and 127), are not
subsequently ground but are
turned at once to size.
After this the cutter blank
Fig. 128. End mill. is mounted on an arbor and
turned in the desired form.
End mills with cylindrical or conical shank, (fig. 128), are
turned from the bar on the lathe. However, before proceeding
to turn the cutter blank to the desired form, the two end surfaces
must be straightened, after the
piece of steel has been tempora-
rily centered, the old centres
being removed; it must then be
re-centered and provided with
centre holes (figs. 129 to 131).
In this case also the conical or
cylindrical shank must have an
Fig. 129—131.
allowence of 0.02 inch for subse- Centering of cutterblanks.
quent grinding, whilst the actual
diameter is allowed to remain 0.02 inch for grinding.
Cutting the teeth. Thus far there has been nothing
special to mention in connection with the machining process,
since giving the cutter blank its exact form on the lathe
6
82 Milling Machines
does not differ in the least from ordinary lathe-work; the
cutting of the teeth, by which the cutter blank, whether
sheave or bar, is now really given the form of a cutter, is
a matter of far greater importance.

Fig. 132—133.
Cutters with fine pitched teeth.

The type of cutter is determined by the cutting of

the teeth, the manner of working, the direction of move-
ment, etc.
The teeth are cut on a milling machine by means of
other cutters. The form and size of the cutters used for
cutting the teeth depend on the form and very often on
the dimensions of the
cutter to be made.
If cutters are con-
sidered only with ref-
erence to the form of
their teeth, they may
be distinguished by
the folio wing types :—
I. Cutters of the old
type with fine
pitched teeth,
Fig. 134. (figs.l32and!33).
Cutter with coarse pitched straight teeth.
II. Cutters of th«-
new type with coarse pitched straight teeth, (fig. 134).
III. Cutters of the new type with coarse pitched spiral teeth,
(fig. 135).
IV. Backed-off cutters with straight teeth, (fig. 136).
;V. Backed-off cutters with spiral teeth, (fig. 137).
Small cutters, as illustrated in figs. 138 and 139, are used
 and Milling Practice. 83

for cutting the teeth of fine pitched cutters as per type 'I.

Fig. 135.
Cutters with coarse pitched spiral teeth.

Cutting the straight teeth of a coarse pitched cutter as

Fig. 136. Fig. 137.

Backed-off cutter with straight teeth. Backed-off cutter with spiral teeth.

per type II is one of the simplest operations with regard to

Fig. 138—139.
Small cutters for cutting fine pitched teeth.

the cutting of teeth. They are cut with a cutter as shown

in figs. 140 and 141, and can be turned out on a plain
milling machine with plain index centres.
84 Milling Machines
This cutter is also used for cutting teeth on front faces
(fig. 142).
The cutter shown in fig. 140 with one
cutting edge square
on the axis of the
cutter is unsuited for
cutting spiral teeth
mentioned under type
III, as, owing to the
rotating movement of
the cutter blank, the
Fig. 140—141.
Cutters for milling straight coarse teeth. cutting edge would
not have free play over
the cutter so that the cutting rake would be sloped. For
this reason a cutter similar to that
shown in fig. 143 is employed with
both cutting edges at an angle
to the axis. As has already
been stated on pages 59 and 60,
the larger angle is generally fixed
at 40°, the smaller
one varying from
12° to 20°. The
axis of the cutter-
blank must also Fig. 142.
Cutting the end teeth.
be placed at an
angle to the milling table and that for
the following reason, viz: — to prevent
the teeth acquiring another form to that
given by the operating cutter. This
becomes much more involved :
1°. The cutter to be milled must be
placed at an angle, (fig. 144).
Fig. 148.
•• •:..
2°. line.
It must be fed on in a straight
Cutter for milling spiral

3°. It has to revolve on its own axis

during the feed.
The operating cutter must be placed in such a position
 and Milling Practice. 85

to the blank that the cutting

plane of the smallest angle passes
exactly through the centre of the
cutter to be milled, (fig. 143), or,
as it occasionally happens when
a sharper cutting edge than 90°
is desired, the tangent of the Fig. 144.
Position of the cutter and blank
cutting plane of the sharpest when cutting spiral teeth.
angle is allowed to fall slightly
at the side of the centre, (fig. 145).
According as the larger angle of the
cutter is to the right or left, and
the rotating movement of the blank
a right or left hand cutter is ob-
tained.
Of the backed-ofF cutters those refer-
red to under type IV with straight
teeth are the most general. If the
cutters mentioned under types I — III
obtain their definite form after the
teeth have been cut, this is not so in
Fig. 145. the case of backed-ofF cutters. As a
Position of operating cutter
to the blank. matter of fact, it cannot in this case
be correctly said that the teeth are
cut; a number of grooves
are cut with a cutter as
illustrated in figs. 146 and
1-47 which serve not only
to allow the chips to es-
cape but also as an outlet
for the tool which will
form the teeth ; the cut-
p.g
ter and the backing- off
tool together form the
teeth in this case, since
the CUtter Which milled Cutter for backed-off mills with
the grooves, forms the straisht teeth-
front plane of the backed-ofF teeth.
86
Milling Machines
The backed-off cutter with spiral teeth, type V, undergoes
precisely the same treatment as that with
straight teeth. The difference in treatment
between the backed-off
cutter with straight teeth
and that with spiral teeth
is just the same as exists
between ordinary coarse
pitched cutters with
straight or spiral teeth.
As is the case with the
last named cutters, an-
Fig. 148. Fig. 149. other cutter is also neces-
Cutter for backed -off mills with spiral teeth.
sary for milling the front
planes, (figs. 148 and 149).
In principle the two pairs
of cutters display the same
difference; the treatment of
the backed-off cutter with
spiral teeth is considerably
more complicated than is
the case with the cutter
with straight teeth.
Figs. 150 and 151 repre-
sent a type of cutter which, Fig. 150.
Plain milling cutter.
considering the form of the
teeth, could be reckoned among the backed-off cutters men-
tioned in types IV and V,
but which, considering the
manufacture, belongs to
those referred to in types
II and III, the teeth being
milled entirely by the cutter
on the milling machine.
Fig. 151.
Fig. 150 represents, a
Plain milling cutter. cutter with a flat tooth
back, fig. 151 one with a
tooth back similar to that obtained on the backing-off lathe.
 87
and Milling Praclice.
The cutters shown in figs. 146 to 149 are also employed
for milling the spiral and straight
grooves in this type of cutter.
However, with this kind of cutter
spiral teeth are almost exclusively
used, being intended for heavy
work, whilst, at the
same time, it is ex-
clusively made as a
plain milling cutter,
(figs. 150 and 151).
Figs. 152 and 153
shows a cutter and
the manner in which
it is employed for
milling flat teeth Fig. 152. Fig. 153.
Cutter for milling flat teeth.
figs. 154 and 155
that for milling teeth having the form of backed-oif teeth.
The question as to whether backed- off cutters or those
with ordinary teeth shall be
used depends on the kind
of work to be done. It is
impossible to lay down any
fast rule. We shall, how-
ever, try to indicate certain
points which will
show which sort
is most advan-
tageous in cer-
tain cases.
The backed-oif
cutter is the gen-
erally employed
type for profile
Fig. 154. Fig. 155.
milling in its
Cutter for milling round teeth.
most varied form :
it has almost entirely superseded the old type formed cutter
with a fine pitch of teeth, though this latter is still
88 Milling Machines
occasionally met with. Formed cutters with ordinary coarse
pitched teeth are not made, unless the profile is composed
of a combination of straight lines or is very simple.
The backed-off cutter preserves its tooth form unaltered until
it is entirely worn out, an advantage of great importance
in the case of articles manufactured in large quantities.
The teeth of backed-off cutters are much stronger and
possess greater resistance than those of the ordinary milled
type.
Owing to the stronger form of the teeth, the backed-off
formed cutter may be given a considerably higher degree
hardness without fear of the teeth breaking off, consequently
they need less sharpening.
Backed-off cutters last very much longer than those with
ordinary milled teeth as there is much more material on the
teeth so that more re-sharpening is possible. When re-
sharpening the backed-off cutter, the space for the chips is
increased, whereas in the other type it becomes smaller.
The re-sharpening of backed-off cutters, which is only
done on the cutting plane, and not on the back of the
teeth, is quickly and easily carried out, with the other type
this is more difficult.
Plain cutters for milling straight surfaces such as face
cutters, end mills and angle cutters, the cutter with coarse
pitched teeth have held their own against the backed-off
cutter and have, of late, been much more used than was
the case some years ago, especially for work requiring
great accuracy.
More and better work can be obtained on the smaller
and lighter-built milling machines by using a cutter with a
pitch of teeth which is not too coarse than with a backed-
off cutter, as, with the same cutting speed and feed,
more teeth are cutting at the same time, because the
backed-off cutter works with far fewer teeth and must,
with the same feed, cut away a much thicker chip.
The ordinary cutter is almost exclusively employed for
working bronze and brass on account of the softness of
the metal.
 89
and Milling Practice.
What has here been said with reference to backed-off
cutters does not apply altogether to milled- off cutters.
After we have successively considered with which cutters
the various types of cutters are milled, we shall proceed to
consider the process of teeth milling.

b. MILLING THE
TEETH.

I. The fine pitch-

ed cutter.

a. With straight
lines or composed
of straight and cir-
cular lines.

Fig. 156 repre-

sents one of the first
milling machines
for the manufacture
of cutters.
The cutter that
is filed by hand is
of very small dia-
meter, and mounted
on a small arbor
which forms part
of the spindle itself.
A pinion at the Fig. 156.
rear of the cone Machine formerly in use for milling the teeth of fine
pitched cutters.
pulley meshes in an
idle wheel which imparts movement to the wheel mounted
on the main spindle which rotates in the left hand side
arm of the fork which is provided with a hub for carrying
the spindle. The end of this spindle is provided with a
conical bore for fixing the arbor. One end of the little
cutter arbor is tapered with a slot, at the other end it is
90
Milling Machines

provided with a centre. The tapered end of the arbor is

fixed in the spindle bore (fig. 157), whilst the other end
has an end thrust bearing. The cutter blank is placed on
the top of the spindle rotating in the sleeve indicated in
fig. 156 with a. This sleeve, and with it the spindle,
can swivel round the pin / at an angle of 90° from ver-
tical to horizontal ; for cutting teeth on the circumference,
the sleeve a is set vertically. A worm and worm wheel
are to be seen at the end of the spindle, with which the
division is accomplished as follows: —
The wormwheel has for instance 180 teeth. The worm
is single.
Each turn of the handle which is fastened on the
wormshaft causes the spindle
to move Vi8oth of a revolu-

Thetion orhandle,
2°. and with it the
worm, is locked in the notch
of the disc which is provided
Fig. 157. with 4 notches at 90°, and as
Fixing the arbor in the spindle. the handle can be turned
exactly 1/2 or V* revolution,
the wormshaft consequently also makes a half or a quarter
revolution, equal to 1° = ^aeo or 30' = V?2o revolution. In
this way a different number of teeth can be cut, though
always a multiple or fraction of the number of teeth of the
wormwheel (this should be a wormwheel but was formerly
simply a spur wheel).
The number of divisions obtainable was amply sufficient
for the earlier fine pitched cutters.
The approximate number of teeth of the cutter is
first decided upon according to the diameter of the
cutter and the thickness of the teeth, after which the
number obtainable which approaches most closely to that
is taken and from this the exact thickness of the teeth
can be fixed.
1st example.
A cutter with a diameter of 4 inches is to be provided
 and Milling Practice. 91

with teeth of about J/s " ', consequently - -j^ — = about

104 teeth must be cut.
The numbers most closely approximating hereto are either
90 or 120; if 90 be chosen, the thickness of the teeth will

be - ^—
yu = 0.14 inch. No: of turns of the handle
180 =2
.
90 •

2nd example.
A cutter having a diameter of 1 */a inch is to be provided
with teeth of about 3/32 inch; consequently — — ^ — — =
about 50 teeth must be cut.
The numbers most closely approximating hereto are either
45 or 50 ; if 45 teeth be taken, the thickness of the teeth
4 71
will be - 45 - = 0.1 inch. No: of turns of the handle,
/32
180 = 4.
45
3rd example.
A cutter having a diameter of 1 inch is to be provided

with teeth of about V12" inch, consequently - '— -^ =

about 36 teeth must be cut.
It being possible to cut exactly 36 teeth, the thickness
O 1 ,1

oO
of the teeth will accordingly be -^r— = 0.09 inches. No :
180
of turns of the handle, — DO
— - = 5.
4th example.
A cutter having a diameter of 53/s inch is to be provided
with teeth of about V8 men J consequently, - — -$- — =
about 143 teeth must be cut.
The nearest number is 144. The thickness of the teeth
will accordingly be */« incn- No: of turns of the handle,
180
92 Milling Machines

The foregoing examples hold good provided the worm-

wheel has 180 teeth. It is self-evident that the calculation
depends upon and must be in conformity with the number
of teeth of the wheel in question.
The slide which carries the fork with the little arbor
can be adjusted in accordance to the diameter of the
cutter blank.
We have now explained how the cutter is driven, how
the cutter blank is mounted and how the division is ob-
tained.
When the slide has set the working cutter at the
exact depth and the machine has been set in motion, the
handle of the fork visible in the illustration, is taken
in the hand. The fork swivels on the same centre as
the cone pulley. If then, the stud which supports the
fork as seen in the illustration is removed, the latter
falls by its own weight. The fork has however, in the
meantime been taken in the hand, the working cutter is
allowed to descend on the cutterblank and the milling
of the teeth is commenced. According as the metal is
cut away, the weight of the fork causes the working
cutter to go farther. The workman must now feel with
his hand to what extent he must bear the weight of the
f<>rk or can allow it to continue uninterruptedly or must
even increase the pressure, according as it is necessary
to cut more or less coarse teeth.
Up to about 15 years ago cutters were still manufactured
on the Continent in the manner described, later on one
of the arms of the fork on this machine was lengthened
and provided with an adjustable counterweight so as
to obtain the desired pressure and the feed may now be
said to be more or less automatic. In any case, the pressure
with which the working cutter was forced through the
metal could now be regulated and was not entirely dependent
on the hand of the workman which was very uncertain
owing to the hand becoming tired so quickly so that the
fork was held first with the right hand, then with the
left and vice versa. Moreover, the workman's hands were
 and Milling Practice.
93
now free to brush away the fine chips from the teeth of the
working cutter which otherwise clogged it up and destroyed it.
Seeing that the working
arch,
cutter describes an
the teeth cut will also
be arched, being deeper
in the middle of the cutter
Fig. 158.
than at the edges, (figs. Course of milling cutter.
158 and 159), so that the
tooth will have to be filed straight after being milled by hand.
These machines were also employed for milling gear
wheel cutters
similar to those
shown in figs.

^g._. 132The 133,

and teeth
were first mill-
Fig. 159.
ed onr the cir-
CUmfer etlCe
Course of milling cutte, and as this line
is very short, the arch was not very much out of the
straight and the back was finished off subsequently without
much trouble.
The flanks are given a circular
form, the spindle being placed hori-
zontally, sometimes a little slanting
and a cutter is used, the diameter
of which is equal to double the
radius which is desired for the flank
of the cutter.
The stop is set in a desired posi-
tion so that the cutter always works Fig. 160 and 161.
Rounding- of the teeth.
to the same point, the sharp edges
being afterwards rounded-off with the file. (figs. 160 and 161).
The development of the milling machines has first and
foremost led to the correct cutting of gear wheels, though
formerly people were satisfied with gear wheels milled with
such imperfect cutters.
94 Milling Machines
The machine described above
was built at the time by
Oerlikon.

The foregoing may safely be Fig. 162.

regarded as history, though Milling a formed cutter with fine
striking testimony is afforded to pitched teeth.
the progress made by milling machines when this machine is
compared with the universal milling machine of the present day,
about which we have so far purposely kept silent, but which is
certainly known to every reader, and it is known that the
machine described above was in use on the continent even as
late as 1890 in large establishments and that in 1893 Knabbe
described it as " a compact and neatly constructed machine."
b. Formed cutters
with fine pitch of teeth.
The machine shown in
fig. 156 is unsuitable for
the manufacture of formed
cutters.
It is necessary as far
as the working cutter
is concerned that the
diameter should always
be smaller than twice
the smallest radius of
the profile. (See fig. 162).
The desired form is
obtained by a combi-
nation of a horizontal
and vertical motion.
Fig. 163 represents
profile milling a ma-
chine manufactured by
Fig. 163.
Hure. The cutter blank is
• milling machine by Hure. mounted on the arbor
 and Milling Practice. 95

whilst the working cutter has to complete three motions,

viz: — rotary, horizontal and vertical. A cam is fixed on
the table, (in the illustration tooth-shaped). A lever, that
controls the movement of the vertical slide, is provided
with a hardened steel roll which pushes against the cam.
A counterweight attached to the other end of the lever
raises the vertical slide so that the lever must be continu-
ously pressed
down against
the cam by
hand. If the
pressure ceases,
the lever, and
with it the work-
ing cutter, im-
mediately rises.
The horizontal
feed of the verti-
cal slide with
the cutter is auto-
matic. The divi-
sion of the teeth
is provided for by
means of a simple
notched disc into
which a plunger
is pressed by
Fig. 164.
means of a spring.
Profile milling machine by Hure. The cam is an
enlarged copy of
the profile of the cutter so that any possible irregularities or
imperfections are communicated but slightly to the cutter.
Hure has since reconstructed this machine as shown in
fig. 164.
The work piece has now automatic horizontal feed so that,
only a vertical movement is imparted to the working cutter.
Formed cutters of greater width can now be taken be-
tween, the centres. The table can be set at an angle, has
96 Milling Machines
transverse movement and is vertically adjustable, whilst the
dividing head permits of the cutters being given different
numbers of teeth. Although redesigned the principle of
this machine is similar to that shown in fig. 163. For so
far as formed cutters with fine pitched teeth are still used,
(not backed-off ), this is one of the current types.
As a sign of the application of the different types of
cutters, it may be mentioned that this type
of milling machine is no longer constructed
by makers of milling machines in the
United States, England and Germany,
though the machines represented in figs.
163 and 164 have been included in

Fig. 165.
Plain index centers.

Hure's latest catalogue, from which one may gather that

although the backed-off formed cutter has entirely superseded
the cutter with fine teeth in the United States, England
and Germany, the latter are still in use in France so that
there is still a demand for the machines mentioned above.
II. Cutters witfi^oarse pitched straight teeth.
The milling of cutters with straight teeth is of a simple
nature. They can be made on every plain milling machine
by simply mounting on the table the attachment shown in
fig. 165.
For a different number of teeth, dials with a corre-
sponding number of holes must be used. As, however, these
cutters can be milled just as well on the universal milling
 97
and Milling Practice.

Fig. 166. Universal milling machine.

machine and the description of the manufacture of cutters

with spiral teeth practically includes those with straight teeth,
we shall not go now into details with reference to these
cutters in order to avoid unnecessary repetition or a
7
98 Milling Machines

premature description of the manufacture of spiral cutters

but shall now proceed ta describe the manner of milling
cutters with spiral teeth.
III. Cutters with coarse pitched spiral teeth.
The milling of cutters with spiral teeth is performed on a
machine, the general type of which is shown in fig. 166.
But few skilled workmen really understand the theory of
the universal dividing head and those who really do under-
stand it most times guard their knowledge even more
jealously than is the case with the knowledge of thread
cutting on the lathe; moreover, for so many the difficulty
exists that they have no opportunity of becoming practically
acquainted with the universal milling machine and its dif-
ferent operations and further it is impossible to explain
it in a few words. Furthermore, to understand the universal
dividing head aright, more than a mere superficial know-
ledge of mathematics is requisite than is generally possible
for a workman to acquire. It so often happens that workmen
are able to use the machine, but only with the assistance
of the tables appurtaining to the machine; and it is just
those who are obliged to use the machine with the assistance
of the tables, who will be glad to know how the figures
given therein are arrived at, so that for the future they
can use the tables for their convenience without being any
longer entirely dependent on them.
It is not intended in this chapter to treat of the com-
plete universal milling machine with all its accessories but
solely the universal dividing head with its index and worm
wheel mechanism.

c. DIVIDING HEADS.

The dividing head on the milling machine serves to divide

the circumference of a circle into a number of equal parts.
Dividing heads may be separated into three classes.
Plain index centres by which only a very limited
number of divisions can be obtained for milling three, four,
six, eight or more sides.
 and Milling Practice. 99

b. Dividing heads by which all divisions are possible by

means of index plates, the rotary movement being commu-
nicated to the workpiece by means of a worm and worm wheel.
c. Dividing heads by which all divisions are possible by
means of gear wheels which transmit the rotary movement
of the worm and worm wheel to the workpiece.
Plain index centres, such as those mentioned under a,
have already been shown in fig. 165. The cutter blank or work-
piece is taken between the centres, the spindle rotating in
the headstock at the rear of which a dial is mounted, the
circumference of which is provided with notches at regular
intervals.
A plunger
at the top of
the head-
stock above
the dial
is pressed
into the
notches by
means of a
spring and Fig. 167.
so locks the Plain index centres.
spindle. It
is evident that divisions can be made and the circle can
only be divided into as many equal parts as there are
notches in the dial and as the factors of the number
of notches. If the dial, for instance, is divided into 24
parts, the following divisions can be obtained, viz: — 24,
12, 8, 6, 4, 3 and 2.
Fig. 167 shows a similar set of index centres, arranged
however, for further divisions, though in this construction
also the index plate is placed direct on the spindle. The
dial is provided with a different number of holes on circles
of various diameters. A tapered plunger inserted in the
holes by a spring locks the spindle while cutting. This
plunger can be set at the various circles. As a large number
of holes can be drilled in the plate and each circle has a
 100 Milling Machines
different number of divisions, this permits of a considerable
number of divisions being obtained.
If, for instance, one of the circles is divided into 120
divisions, this number can be resolved into the following
factors, viz: —
2, 2, 2, 3, and 5,
so that the following divisions can thus be obtained by
this circle alone:—
2 2X2X3 =12
3 3X5 =15
2X2 = 4 2X2X5 =20
5 2X2X2X3= 24
2X3 = 6 2X3X5 =30
2X2X2== 108 2X2X2X5= 40
2X5 2X2X3X5= 60
and 120

Although with this number of holes fairly consecutive

Fig. 168.
Plain iodex centres, rotary movement imparted to the spindle by worm wheel.

divisions can be obtained up to 15, the subsequent divisions

are rather far between, until finally there are no intermed-
iate divisions possible between 60 and 120. Fig. 168
shows a set of index centres similar to the foregoing, the
only difference being that the circumference of the disc is
provided with teeth in which a worm engages so that it is
no longer necessary to turn the disc by hand with the
possibility of turning slightly too far or making mistakes
but the disc is regularly adjusted by turning the handle.
If, for instance, this disc has 7 different circles of holes
 and Milling Practice. 101

containing the following divisions, viz: — 44, 48, 56, 60, 72,
84, 96, then in addition to these divisions the following can
also be obtained, viz:—
44 = 2 X 2 X 11 therefore 2.
2X2 = 4.
2X11 =22.
48 = 2X2X2X2X3 therefore 3.
2X3 =6.
2X2X2 =8.
2X2X3 =12.
2X2X2X2 =16.
2X2X2X3 =24.
56 = 2X2X2X7 therefore 7.
2X7 =14.
2X2X7 =28.
60 = 2X2X3X5 therefore 5.
2X5 =10.
3X5 =15.
2X2X5 =20. .
2X3X5 =30.
72 = 2X2X2X3X3 therefore
3X3 =9.
2X3X3 =18.
2X2X3X3 =36.
84 = 2X2X3X7 therefore
3X7 =21.
2X3X7 =42.
96 = 2X2X2X2X2X3 therefore
2X2X2X2X2 =32.
2X2X2X2X3 =48.
• The following progressive chain of divisions can conse-
quently be obtained with these centres, viz: — 2, 3, 4, 5, 6,
7, 8, 9, 10, 11, 12, 14, 15, 16, 18, 20, 21, 22, 24, 28, 30,
32, 36, 42, 44, 48, 56, 60, 72, 84, 96.
The same peculiarity is here noticeable as in the previous
case, namely, that in the higher division no intermediate
divisions are obtainable.
102 Milling Machines
Figs. 169 and 170 represent an indexing head of the class
referred to under b. The principal difference is at once to
be seen from the illustration; the index plate in this case
is not mounted directly on the spindle but on a worm
which is in gear with a worm wheel mounted on the
spindle. With the first mentioned index centres the dial
rotates and the plunger is fixed, in the head as shown
in fig. 169 and 170 the plunger revolves and the index plate
is fixed. If, in the case of the index centres mentioned
under a the spindle completes one revolution for one
complete turn of the index plate, in the dividing head
mentioned under b, the spindle only completes a small part

Fig. 169 and 170.

Dividing head without means for setting the spindle in an angle.

of a revolution for one complete turn of the crankhandle, that

part of a revolution being equivalent to the number of
teeth in the worm wheel, always supposing the worm to
have a single thread.
The worm wheel P is mounted on the hollow spindle B
carried in A, the nose of this spindle is threaded so as
to take a chuck. The worm C is in gear with this worm
wheel, the worm is turned by the crankhandle s in which
housing o a plunger with tapered pin is placed. Centered
on the worm shaft but fixed to the casting is the index
plate T against which the sector w1 is pressed by the
flat spring w8. This sector rotates on the worm shaft.
The end of the plunger / is provided with a knurled head
by which the crankhandle is turned. By means of the
 103
and Milling Practice.
slot in the handle, the plunger in the housing can be set
at any circle.
This dividing head is, however, unsuitable for spiral

Fig. 171. Fig. 172.

Universal dividing head.

milling; for this purpose a set of gear wheels between the

worm shaft and the spindle which effects the longitudinal
motion of the milling table on which the dividing head is
placed, must effect the rotary movement of the dividing
head spindle.
Figs. 171 and 172 illustrate a universal dividing head
constructed in this manner.
The housing J which swivels round the worm shaft d
carries the spindle B and is affixed to the external casting
A and can be set in any angle from a few degrees below
the horizontal to a few
degrees over the per-
pendicular. On the
spindle Bis placed the
worm wheel P. As this
Fig. 173.
worm wheel together Wedged worm wheel.
with the housing J
revolves on the wormshaft d, the worm will remain in
mesh whatever may be the position of the worm wheel,
whether the spindle B is slanting or perfectly vertical. The
worm wheel P is wedged and adjustable for wear in order
to prevent play, (fig. 173). The bolts a in the circular
104 Milling Machines
slot of the casting A serve to connect the housing J to the
external casting, whilst the angle at which I is set can be
read from a graduated scale.
This dividing head is adapted for spiral milling. The spiral
line is produced whenever the dividing head spindle and with
it the workpiece rotates slowly during the longitudinal motion
of the table and, consequently of the workpiece. -Two motions
are thus imparted to the cutter, viz:— a rectilinear and a
rotary, so that it is evident that the pitch of the spiral is
dependent on the relative proportion of these two motions.

Fig. 175.
Kcmpsmith universal dividing head.

For this purpose a bevel gear K is connected to the index

plate T, which runs loose on the worm shaft d. This gear
is meshed by another bevel gear K2, (fig. 172), which rotates
on a stud K in the casting A. The set of bevel gears K
and K» are driven by change gears, one of which is mounted
on the hub of the bevel gear K2, another on the feed
screw which gives the longitudinal motion to the table, one
or two intermediate gears being mounted on a stud at the
side of the dividing head. It is by means of these gears
that the spiral line is produced.
Figs. 174 and 175 represent a Kempsmith dividing head.
 and Milling Practice. 105

In the interior of the closed head are the worm and worm
wheel which are thus protected from dirt and chips which
might otherwise fall in. The worm wheel lies in one line
with the centre-line of the swivelling part of the head the
worm runs on top of the worm wheel. Between the bevel
gears and the worm there is still another gear wheel that
transmits the movement of the bevel gears to the worm.
To the third category of dividing heads referred to under

Fig. 176—178.
Reineckers universal dividing head.

c belongs the Reinecker

dividing head of German
construction shown in figs. 176—178.
In this dividing head the index plate is done away with, the
divisions as also the spiralline being obtained by gear wheels.
The change gears for the divisions are to be calculated so
that a complete revolution of the crankhandle is necessary
for each further division.
The housing a which can be set at any angle from
horizontal to the perpendicular in which the spindle b
revolves in the external casting a. On the spindle b is the
worm wheel e which is meshed by the wormy^ The bevel
gear K, (fig. 177), is set on the worm shaft outside the
106 Milling Machines
casting a. Behind this is fixed at d a cross head at the
studs g. g, of which are two idle bevel gears, h. h. which
mesh in K. These gears mesh another bevel gear i which
is mounted on a loose bush rotating on the wormshaft.
A change gear g mounted on this same bush /, which
is caused to rotate by one or two intermediate gears by
means of the gear wheel fixed on the spindle r. On the
spindle r is the index plate s which is provided with only
one hole into which the taper pin t is pushed.
The change gears which transmit the motion of the spindle
r to the bush / are calculated in accordance with the
number of divisions.
The transmission from the spindle r to the spindle b is
effected as follows: — The motion of the spindle r is trans-
mitted by the bush / to the gear wheels, the small bevel
gear i rotating at the same time as it is also mounted
on the bush / and as the two small bevel gears h. h. mesh
in i, these are also caused to rotate. The bevel gears h. h.
mesh in the bevel gear k. The gear h can, however,
rotate on the wormshaft, so that they run over the bevel
gear k, making a double rotation, viz. :— on their own
spindle and also on the wormshaft d. As, however, the
cross head on which they are fixed, is keyed to the worm-
shaft d, they must both rotate together, the spindle b being
also moved by the worm and worm wheel.
The rotating motion of the dividing head spindle for the
milling of spirals is effected as follows: — The wheel on the
feed screw o of the milling table causes the spindle ?;/ to
rotate by means of intermediate gears, and at the extremity
of this spindle is the bevel gear / which rotates k ; k rotates
the two small bevel gears h. h. on their own centre line
and as they revolve over the bevel gear i, they also rotate
on the wormshaft and since the cross head is connected
with these bevel gears and is keyed to the wormshaft, it is
caused to rotate, the worm wheel e and the spindle b being
rotated by the wormshaft d.
Opposite the dividing head is the tailstock which is
illustrated in fig. 165.
 and Milling Practice. 107
Dividing heads, especially those belonging to class b, are
made in various styles.

d. INDEXING WITH THE INDEX PLATE.

In the dividing heads described under b and c the worm
wheel is fixed on the spindle. As a result, if the spindle
makes one complete revolution, the worm wheel must, ipse
facto, do the same. If the worm wheel has 60 teeth and
the worm is single-threaded then, for each revolution of
the worm wheel, i. e. the spindle, the worm must make
60 revolutions.
If it is desired to divide the circumference into two parts,
each 180°, the worm wheel must make half a revolution
and the worm — = 30 revolutions ; for three divisions the
worm wheel must make J of a revolution and the worm
fiO
— = 20 revolutions ;
o

for4 divisions, the worm wheel make ^ revolution, the

60
worm —4 - = 15 revs. ;

for 6 divisions, -—=10

o revolutions;

for 10 divisions, — = 6 revolutions;

for 12 divisions, —\.a = 5 revolutions, etc.

Examples.
1) The worm wheel on the spindle has 100 teeth; a cutter
with 20 teeth must be cut. The worm is single-threaded.
The worm must, therefore, make — — = 5 revolutions for
each division.
If the worm is double-threaded, then, for each revolu-
tion the worm wheel will be moved over two teeth. A
worm wheel with 60 teeth will, consequently, have com-
108 Milling Machines
pleted one full revolution, when the worm has made
60
- = 30 revolutions.
2
If the worm is treble- threaded, 3 teeth of the worm
wheel will be turned over for each revolution of the worm,
and will thus have completed one revolution only after
fiO
o^- =20 revolutions of the worm.
2) The worm wheel on the spindle has 100 teeth. The
worm is double-threaded. 25 teeth are to be milled on
the cutter.
100
In this case the worm must make = 2 revolutions
for each division. 2X25
3) The worm wheel on the spindle has 60 teeth. The worm
is treble-threaded. 20 teeth are to be milled on the cutter.
(\C\

The worm must consequently make 5-^7-^7: = 1 revolution

for each division. 6 X ^0

The foregoing may be expressed in the following formula :—

The number of teeth on the worm wheel divided by the
product of the number of threads of the worm and the
number of divisions to
be made is equal to the
num ber of revolutions
of the worm required
for one division.
In order to allow of
all divisions being ob-
tained within certain
limits, the index plate
on the universal divi-
ding head is provided
with a different num-
ber of divisions, each
of which is placed
Fig. 179. index plate. separately in a different
circle, the number of
divisions being indicated for each circle (fig. 179).
 and Milling Practice. 109
Given that: —
t = No: of teeth of worm wheel.
g = No: of threads of worm.
o = No: of revolutions of the worm necessary for one
complete revolution of the worm wheel.
v = No: of divisions.
n = No : of revolutions of the worm necessary for one division.
it follows that:—

(1) y = o. (2) o.g=t. and (3) -£-= <?.

further

and as
— = o. (7) —v = n. and (8) v . n = o.
g
It should be noted that g = No : of threads of the worm
does not refer to the pitch but to the worm being single,
double or treble-threaded.
A few examples, based upon the foregoing formulas,
will now be given.
*=80. <f=2.
Required. The number of revolutions of the worm neces-
sary for one complete revolution of the spindle.
/ 80
o = — = — = 40 revolutions.
g 2
The worm is treble-threaded. The worm wheel com-
pletes one revolution in 30 revolutions of the worm.
Required. The number of teeth on the worm wheel.
g = 3 . o = 30 . t is required.
^=3X30 = 90 teeth.
o = 40 . t = 120 . g is required.
g= —o = —40— = 3. worm is treble- threaded.

The number of teeth on the worm wheel is 100. The worm

is double-threaded. The number of teeth on the cutter is 25.
How many revolutions must the worm make for one division?
110 Milling Machines

/=100, ^ = 2, # = 25, n is required.

/ 100 . .
n = - - = . . . np = 2 revolutions.
g.v 2X25
The number of teeth on the worm wheel is 120. The
worm is treble-threaded. The worm makes two revolutions
for each division. How many teeth will be milled on the
cutter?
/=120, ^=3, #=.2, v is required.
* = — = -- = 20 teeth.
g.n 3X2
So far, cases have only been taken in which the revolu-
tion of the worm has consisted of whole numbers, so that
really one hole in the index plate would suffice.
It is evident that n is not always a whole number, in
fact, it is seldom that this is the case.
The following examples will now be given
40 in succession : —
/ = 40, g = 2, v = 40, n is thus = £ revolution.
40
/=40, /=2, z>= 80, n is thus —J —X — — = | re volution.
J X40 oU
/ = 40, g = 2, v = 1 60, n is thus = \ revolution.
For these divisions the index plate must be made use
of and a circle chosen which is divided into a number
divisible by 8.
On a circle containing, for instance, 56 holes, the crank-

Fig. 180—182. Dividing sector.

 Ill
and Milling Practice.

handle must turn over 28 in the first of the examples given

above, 14 in the second and 7 in the third.
In addition to being much too troublesome, it would too
frequently give rise to errors and mistakes, if it were neces-
sary to have to count these holes every time and so, in
order to simplify matters, the sector to be seen in fig. 183
has been introduced on the index plate. The legs of this
sector, which are clearly shown in figs. 180 — 182, can be
placed at any desired angle. If, for instance, in the last of
the examples given
above, the crank were
to pass over 7 holes,
the sector would be
so set that it would
take in one hole more
seeing that the locking
pin itself already oc-
cupies one hole.
The circle over
which the locking pin
must move is not al-
ways a proper frac-
tion of a revolution.
This is very seldom Fig. 183.
the case, as most times Index plate with dividing sector.
it proves to be an
improper fraction. To take the following example :
The worm wheel has 80 teeth.
80_1 The worm is double-
threaded.
No : of teeth on the cutter 32.
e.v 80 80 , 16 "
_ , 4'
t 2X32
Further, given that : —
h = No : of complete turns of the crankhandle.
q = No : of holes enclosed by the sector minus 1 .
p = No : of holes of the circle.
it follows that n*="A4-.P 64"
112 Milling Machines

Example.

/=100, ^-=2, z> =

= v = 40*

"7" 40'
So that:-
1st. The crankhandle must make one complete turn.
2nd. The crankhandle must make -J$ turn.
Consequently the sector must be set so that on a circle
with 40 holes, it encloses 10 -f- 1 = H holes.
The numerator and denominator of a fraction can be
either divided or multiplied by the same number, to be used
as occasion requires.
If, in the foregoing case, there is no circle with 40 holes
but only one with 80, then f$ can be employed and the
sector must enclose 21 holes; if -there be no circle with 40
holes, but one with 56, then •££ can be taken, the sector
enclosing 15 holes on a circle with 56.
It is advisable to prove the calculation before proceeding
to work.
According to (8) v . n = o, or .according to (6) v . n . g = t.
The number of divisions multiplied by the no : of turns
of the crankhandle is equal to the no: of turns of the crank-
handle necessary for one complete revolution of the worm-
wheel or to the no : of teeth on the wormwheel divided by
the no : of threads of the worm.
Taking the foregoing example, we get:—
v . n = o = 32 X H == 40 = no : of turns of the crank-
handle for one complete revolution, or v . n . g = t =

A number of examples will now be given.

(1) No: of teeth on wormwheel /=60.
Worm is double-threaded so that g = 2.
No: of teeth on cutter # = 35.
 and Milling Practice. 113
-, / 60
Therefore, o = — = — = 30.
o _30
= V=-35'
On the circle with 35 holes, the crankhandle must be
moved over 30 holes for each division.

Proof: 0.^. »==/== 35X2xt?DO = /=60 teeth.

(2) *=80, £-=2, * = 30.

o = — = 40.
g
o _40
= ="'

The cranckhandle must make one complete turn plus

10 holes on a circle with 30 holes.
Proof: v.g.n = t. 30 X 2 X H = 80.
(3) /=120. £-=3. z>=88

* = yX40.
n==^ o = ss40'
(4) / = 120. ^=3. z/ = 23.
^ = — = 40.
^
^? 40
^ = V = 23'
^ ,17 ,34 ,68
= ^+ = 123°r 146°rl92'

(5) A reamer with 5 grooves is to be cut on the milling

machine.

^ 60 10
= — =-—=12.
v 5
114 Milling Machines and Milling Practice.
For each division the crankhandle must thus complete
12 turns.
It is evident that the same difficulty is to be met with
here as in counting up the holes on the circle, viz:— that
the workman can easily make a mistake. As a matter of
fact, it is a much more serious matter here than in the
previous case, as the workman could recount if he had
made a mistake or were interrupted, or he could mark the
hole in advance in which the locking pin should come, but
in this case the workman has to turn the crankhandle, so
that, if interrupted or he loses count, the only thing to be
done in order to be correct is to turn back to the groove
which has been milled and recommence counting.
In order to do away with these difficulties, a mechanism
is to be found on some dividing heads which permits of
rapid indexing by turning the spindle by hand. The worm
can be thrown out of gear with its wormwheel.
The divisions on the index plates which are usually to
be found with universal milling machines are 15, 17, 19,
20, 21, 22, 23, 27, 29, 31, 32, 33, 37, 39, 41, 43, 47 and
49, usually on three index plates.
 Tables giving the No : of turns which the crankhandle
must complete for different divisions.
v = No : of divisions, h -f- -?—
P =p = division-circle,
*+
No: of turns which the crankhandle must complete on the
division-circle indicated by /.
Table IX.
Table in which the value of o = 40.
I /= 40. ^=1.12/ 2%, 8/,9
Suitable for ! /= 80. ^=2.
1(6/ /=120. ^ =10/ 3.
8/

^ ^ 2| ^
24/
30/
V P V P V P » ^33 P
l2'/3
9
20 /

2 _ 20 26
27
39
27
1%

i"/«
20
39
50 90 27
23
152
155
19
12/
%
3 39 1321/39 52 31 33
92 47
15/
4 — 10 28 49 I"/- 54 27 35 /
94 19 156 20
39
5 — 8626 29 29 1% 55 33
%/20
26 /
95 160
10/
%

/39 /39
24 41 %
39 53
1%, 56 49 96 %//2«8 164
20 /
6 30 39
5/49 29 20 / . 10/
165 33 73,
7 49 31 31 1%, 58
298
0/ 49
8 —
27
5 32 20 r/«1% 60 39
62 31
24 /49
/
/*9
100 39
104
20 10/ 168

170
10/
17
21 5/

9 4A\1l/27
33 33 I'A, 10/
27
13/
43 %

10 — 4321 34 17 I3fe 64
16 /39 8 /108
2 /49
172
%3
/33
39 33
/2
0 180
11 33 35 49 65 /31 15/ 110 8/ '73 %5
3% 33 184 3 27 /n
12 39 36 27 115 23 /39 1
2/
1%, 66 . //313
29 23 5/«
37 37 17 206 185
4% /39 / 116
33/39
13 68 37 8/37
702,5/
39 242/49
120 39
2,
49 188
kl
38 19
IV..
19
47
14 49 1V» 27
10/
190 "f
15 39 2IO/2» 39
O26/
& /39 39 72 /17 124
10/
%3
19S 5/ c
37 31
— 1 128 16 195 49
39
-,'*/•
16 20 40 74 20 1-21
/
20/ /i8
814/ %
26/n /
17 17 41 41 75 15 2
%
/49
130/ 39
1 0
2%, 42 19 200
21 %
//39
18 27 76 132 2733 31
20
22/,9 401 20/ /37 210
19 19 43 43 39 135
78 /15
136 17
/16
%
21
20 — 2 44 33 I*
"/.ISO
20 /19
/39
220 33
1'%, 40/
21 21 45 27 15/
82 41 20 /
15/
140 49 230 23
21 18 240
22 33 A /33 46 23 84
/39
/20 144 18
I27/
1%
47 47 40 / 17 145 248 31
23 23 85 /4 29 % %.
l'6/3 /23
43
l
280 49
48 18 15
9
24 39 1% /47 86 /«! 148 37 /49
49 49
25 20
/18
88 33
/1
150 15 /18 300 V-
/743
/49

/33
V.5
V.
7.5
 *+! Table X.
= 60.
A+l
Suitable for /=60. ^=1. /=120. <f=2. isy
/=180.
*+1 '*
£ = 5/33.7

1%
8/
20
V P P P , / . P
P
P h-\- - 20/ 47
12/ 10/
- 30 20 % 101 235 26 "
/W
2 - 37 37 !"/» 80 138 23
20 19 1%
3 38 140 21 240 20
- 15 81 27 2%7 101
4 39 245 49

71
- 12 39 20 21
82 41 %
*/« 144 %
40 1% 84 24 91
5 - 17 % 145 29 In 260 39 12/
10 33

6 41 41 r*/« 85
86 43
147
148
49
37
264 44
7 29 20 /24 270 27
8lf/« 42 43
"/fl
21 21 !•/«
1% % %o
8 24 7% 43 87 150 • 6/ 276
15/
23
/49 J6
9 27 #*!„
44
33 !«/„ 88 155 31 In 280 14 6I
39
22 %
15/«
10 6 45 83 156 26 290 29
lH/33 90
11 33 5% 46 158 79 300 20
— 5
23 !'/„ 92 23 15/23
12 47 93 160I?/ 16 /31 310 it/
31 %,
47
20 !13/47
1%
6/1
9
Vto
31 2°/31
13 48 164 41 320 16
39 4M/» 94 47 »/«
14 21 4%, 49 I3/,, 95 19 20 / 165 33 1330
5/ 33
12/19 Vn
15 43'% 50 4920 I11/*
14/W 96 16 10/16 170 17 %l
8% 51 17 340 17
98 49
/4
16 20 IS/ I
901
172
29 101 345 23
17 17 9 52 Vn
99 33
3'8/3
174 360 18
5/1
7
39 !6/39
100 20 18
18 39 33/,, 54 27 !•/„ 180
101/49
370 37
18510/ 37
"/
1 I/33
19 19 55
DO
00 -IS/'/it 102 */ 41
I1/. 17M IB/
47 3 /43 372 31
—
20 3 56 28 !«/„ 104M/ 26 188 4
380 39
19
Vn
12/
57 19 it;In
43
21 21 105 21 21 15A. 20 /tt
/ 190 3/2l '
In i0/
390 20 %
Si"/..' 192 19
39
108 27 In
/18
400 %7
2% 58 29 16 5/16
/37
/47
23 23 2% 60 —
1
110 33 ftf 195 49 %
210/,o 196 39 «/» 410 41
24 20 62 31 30111 137
227'» / 5/n 20 % 420 21
25 20 % 63 21 "
114 '19» /33 200
2% 430 43 %
26 39 64 16 115 23 "/« 204 17
% *°/
43 440 22
27 27 39 116 " 29 %//37 205
% / 450 15
2%, 117 „"39 41
19
28 21 66 33 /« 210 21
27. 10/io 215 % 460 23
29 29 68 17 120 20 43 470 47
16
30 2 69 23 /33
123 41 '%. 216
nj

21 15/8, 220 33
18 %
5/is 480
31 31 "/» 70 124 31 I0/
"In
ti 510 17
"/« 72 18 222 27
32 24 126 21 540
tii 74 37 10/37 20
33 33 37 129 43 225
15 4/i5 900
34 17 20 191
130 39 18; 228
19 5/.9
V-
35 21 7:,
"A, 76
19 132 33
23 6/23
36 39 !"/. 78 135 18 % 230 39 '%,
%
7.s 234
 *+f
*+l Table XL
8/

= 80. Suitable for/ =80.

*+J
g=\. /=160. ^=2. ^ = 240. ^= 1
v P * P V P . / . P
16/
27, \
320 16
37 37 176
2
3
40
39 2626/39 38 19
2*/» 27,9 86
88
43
33
-/«
3733 180
33
18 7is •
151
328
20 / 41
330 33
4 — 20 39 39 90 184
27 24/27 7,e
5 16 40 2 92 23 27,3 185 23 10/a
/as 336 21
1 3 % 94 188 37
47
'•/„
»/47 17
6 39 41 41 47
18 4747
% 340
I39/ 19 7l9 43 %

7 21 11%, 42 21
137/
96 190 344 /33
I19/ 18
8 109l 43 43 1 /43
98 49 195 360
c/i8 4749
20 : 7i0
114/
18
196
39 368 23
9 18 44 33 100 49
%
!17/2 20 "/„
10 — 8 45 18 3
104 200 370 37 8/2
-I33/ 39 3739 /49 3
11 33 7%3 46 23 105 205 41 w/«
/39 376 19
47
6"/i8 27
21 %
l% 208 39 !739 16;
7l8 6
12 18 47 47 1-J26//47 108 380
66/39 33 % 3/
13 39 48 39 i /39
110 210 21 i % 390 39
CIS/ 27 % 10/400
20
O /21 49 49
1 /49
14 21 112 26 /
55/l5
131/
21 uln 215 43 l% 410 7l9
15 15 50 20
1121//20 115 no
60 16/
30 /a
/ 216 41
16/
1 1J/89 220 %
%7
16 — 541 52 39 116 29 27-29 33 420
2/n
225 21 720
17 17 54 27 120 39 45 430 43
48/is 24 /
33
11 18 4'/19 55
1 In
1% 124 31 20 /
16/
230 23 10/
440 74i
33 l15/38 10/ 29
19 19 56 21 128 16 232 460 23
39
/39
10 / 235 47
/33
470 47 743
20 4 58 29 130 18 723
21 60 18
I7l8
132 33 /31 240 /29
/45 480 18
21 733
321/3
r/2o 27 490 %
3 1%1
22 33 62 31 135 /39 245 49 49
3U/23 17 25
i'/» 136 500
161
23 23 64 20 /33 248 31
313/3
9
1%9 20 / 25 Us
510 39 %

24 39 65 39 140 21 %/27
250 /47
34Ao 27 256 27
25 20 66 33 144 16 540
26 39 3739
2%
68 17
17.7

1%1
1% 145
29 %
la
16/
16 /
260
20/
39
27
8/
/49
12/
560
21
29
739
27 27 70 21 148 270
/31
725
580
218/L 37 17 15
28 21 18 15 81 272
7l6
600
222/2 72 1737
150 20/

29 29
9
19 10/ 280 21 620 31 Vw
2% 74 37
729
15 152 /37
16
155 18 640 721
r/i9 288
!Vl5
30 39 75
218/3l l'/39 31 - 7*27
2
7,9
290 7i7
31 31 76 19 156 39 /is 743 29 660
« /» 680 33
18 %
32 20 214/ 78 39 40 /
~ /*160
]
16 /31 296 37 721
%
7l6
/15

33 33
3
910:3 80 — 164 300 15
7l8 17 8/n
26/n
1 16 / 41 /39
19 % 720
34 17 82 41 168 21 304 800 20
733
% %
2%, 170
35 21 84 21 /41 17 /46
/41 310
31 %

36 18 2Vl. 85 17 172 21 312 39 % /20

7n
/17
 30/

k+\ 40;

Table XII.
4%

" o = 120. Suitable for / = 120. g = 1. / = 240. g = 2.

p
*+t
V V *+'f
•2-' ,-
P * P 18/
V P f

2
lI3/39 146 w
5 __ 24 47 17 39 73 mi
49 212 53 /79 296 37
20p k-r-
6 — 20 48 20 2101 90 23 401
213 71 241
QO !7/23 147 215 43 300
7 21 175/,, 49 49 2%/20 93
«^ —
31 !9/3i 148 37
20
301
27 151 43 305
8 50 20 2%, 47 19
149
216 308 61 246I
15 94 MlIn 219 77 3°7T
51 17 2%
** •" 30 /
18 138/,8 95 19 I5/* 7152
1% 150
' DO 401/55
/53
13 310 3140/ 12/3i
10 _ 52 39 2I2/39 96 20 15/20 153 51 220 73 /71 312 39
21 15/3»
11 22 12 77 222 37 »/„ 121
53 27 97 97 I*/* 154 In
/20
315
/19 225
60;
- 1in-'"
0 „ 54 53 2%
2'4/M 31 15 8/15 318 53
%
12
98 49 l"/i9 155 39 228
18 !*''» 55 33 2%2s 99 33 !7/33 156 79 241 19 "/„ 320 16 6/i6
14 49 /. 230 23 12/23 328 33 41
53 231 17
15 — 08-7'% 57. - 49 27/49
19 22/19
100
102
20
17 !3/n
1% 158 159 16 121 77 «/„
330
20 7 29 104 39 232 29 »/, 335 67
K, 1/,, 58 1%!3/33 160 27 201In 234 340
17 17 59 59 22/59 105 21 !3/28 In 47 241 43
>

53 !7/33 164 41 301/53 236

162
— 2 235 39 =%
is 39 6a/» 60 106
165 33 59 301 344
345 23
29 %
19 19 61/,, 61 61
1 /«!
108 27 83 241 12

6 31 l59/
1% 110 33 I3/ ll/n166 21 601121 240 237 79 *°l
10;
IS/
•-n21 Ibl*141
20 /59
348
49 5M/48
515/» 63 21 I19/.,! Ill 28 168 / « si
37 170 17 121133n 244
40' 15/ 35035
22 33 56/a 64 16 114/16 112 I3/ 61 23
301
In 35459
172 2 »/„ 121 245
28 23 I2/ /79

24 — 5
65 39 l:a«u 114 19 I1/.* 175 43 22 4/2 183
5% 246 49
25 24/49 36018
66 33 1%; 115 23 35
/61
370 19
in; 29 59™k\ 24/35 4 1 20/4i 15380 120
25
67 67 I53/*? 759 248 / 37 6
20
26 39 4'% 117 39 l]/29 178 a
390 39
1 19
4% 68 17 1I3/17
17(i 250 31 15/3n/25 20
Vl8

27 27 4% 69 23 I17-,, 118 39 eo/

o*7
QQ %789 252 400
iy» 177
59 12°
180 7 24
409 43
91 % 255
/
49 I4f — 1 2
17 8/17
/3
u n
21 ^ 420 41
10/« 9
28 49 4" 43 %
1%1 l/7i 12
120 61
71 47/T3 2 182 256 32 15/32
40/

29 29 4' 21 '/a
30-4 72 39 !"/» 124 183 61 IS/24 258 13 %
73 31 184 23 fc 260 430
31 31 3- 125
126 25 1S5" 37 33 440 22
21 13195 264 450
32 20 3' 71 37 241 733
460 15
33 33 2 75 20 l12/.^ 127 127 15/ie 186 188 47 201 265 53 24/53 470
143/
1 In 301 267 89
^7 »/„ 23
34 17 39/i7 76 l"/i9ll28 16 190 1942/49 268 % 480 "/
20 5/2o
35 49 3' 77 77 !10/» 129 43 i;! /37
67 »/„ 25
49 %
36 33 2% !'.»
78 39 t21/39
lI3/2
7 130 39 192 *39
16 10/ifl
/19
270 490 47
/
1L'1T
5

«?
20 132 33 49 12 141 276 500 39
1

37 37 3" %
27 1"/" 134
*i/ /49

67 196 33 /
280 23 10/23
38 19 33/I9 81 198 1 7 20/47 510 17
11 !• 135 27 282 ',;
39 39 33/39 82 £ 136 200 67 20 /49
284 1Q
71 •1' 2I/w/7i 520
1" 3 83 89 17 /19
530 53
41 41 2 49 138 23 201
17 140 49 17 285
288 540 27
42 21 2' 204 n -i "/» 550 55 */«
141 47 205 1 1 24/4, 7 290 29
43 43 2r /6
600 20 4/»
44
45 33 224/33 87 29
43 !"/» 142 71 M/7.
la/,8 207
208 26 % 292
» 40/« 294
78 »/;
49 M/19 700 35 6/2o
39
46 23 a% ss
2"/»
33 1% 144
89 89 !"/» 145
18
29 "/» 210 i'.l <28/49 295 59 »/,
800
15
20 2/15
in
:!ii
" " 900
1000
25

~
tn
 f
*+f
%$ Table XIII. 20/

*+0=180.
15/

"V
Suitable for /= 180. g=l. /=360. ,f=2.
! P
12 /
18/

37«
P V P
22/
P V P
^ V P
S*/* 2Va 89 18/
312/20 47 1 /47 49 36/
10 _ 18 49 49 88 22 200 181 294
141 1113/In 17 20
18/

12 33 50 20 89 89 142 20 119/
1% 204 20 300
30/
16'2/33
—
71
12 — 15 51 17 39/17
90 2-|29/
1 -I/as 144 205 41 361 305 18/
49 /49
310 61
43/
13 39 IS33^ 52 39 318/39 92 23 i22/ 145 29 !7/29 1
207 23 /20
31 10/

14 49 93 31
1 /31
146 4 / 20
210 21 315 /20
1242/49 53 53 1 /47 147 73
l?/38 In 18/
321/53 47 l17/73 212 7 53 /41 ' /61
15 — 12 54 27 94 1U/1B
% 30/320 BO/
148 49 ln/49 1215 43 33
19/5 16 /
39/27 I17!/i941/49
16 16 H4/16 55 33
36/28
95 19 37 !8/37 330 32 67 Ml/49
39/33 /23
150 20
127/
33/19 96
17 17 1010/17 56 28 16 216 48
220 % 335 /32
18 — 10 57 19 98 49 44 36 /21 340 In
9 152 38 61
/ 18 /
19 19 9/io 350 34
A /33 133
58 29 33/29 99 33 153 222 35 18/

20 110/20 154 51 225 20

20 — 9 100 20/
59 59 360 37 20 I'll
8% 33/59
258/ci 102 I13/n 156 39 77 1%9
!13/77 36 / 60/ /67
21 49 60 — 3 17 l3!357^/ 228 38 /44 370 25
86/33 26 !19/2653158 1 4 /41 /37
134

22 33 n!9/ 61 61 104
32 lH/79 230
1%l3/33231 77 36 /
1%7 46 375 /35
18/
23 23 « /23 105 49 160
79
380 38
7'% 62 31 228/31 301f/a /20
162 27
45 /20
24 20 68 4L i o18/
01 ^ /2i 106 234 47 390 39
53
27 !18/27 164 !2/28 /38 20 /37
74/20 235 39
25 20 64 16 913/ 108 41 /46 30 400
& /16 12/
18 /25
/
6% a2% /38 12l1/ 1?/33
28J165 !3/34
237 36 / /
410
26 39 65 39 920/ 110 33 33 21 91 18/
37 l23/37 166 !2/38
240 48 79 /39 420 41
27 27 A18/
0 /27 66 33 2"/6, 111 43 /39 28/
28
-I13/
28
83 !7/831% 27 18430
/»
28 49 0fi21//49 67 67 2"/l7 112 -l
1 /iiie/ 168 243
lllm
60 / /
44 20 /
66/29 19 170 34 la
/79 440 27
29 29 68 17 2"/23 114 I11/ /41
23 227« 115 1%244 61 2 7
30 — 6 23 1 /23
171 38 245 49 30 /48
/ 3
450 460/ /21
C25/ 69 2s8/,, A /29
/ 12/

31 31 29 172 43 1V29 246 41 460

& /32 70 49 116 1 /38
1131/ /27
5% /w 174
32 16 71 71 2M/» 117 39 -|10/ 29 248 465 31 /43

r/59
121/ 20 /
6u/» 72 234/7 62 IB//61 470 47 /4
33 33 20 3 118 175 249 83 4
55/,, 2 ' 73, 120 59
20
-I1
1 /290/ 35
176 44 25036/ 25 36 /
60/
/49 /27
34 17 73 73 /41 60/
480 36/
49
91
18 /
490 24
5'/49 1 /61 1V89
35 49 74 37 2%, 122 129/ 177 45/ 252 42 /62 25 18 /
/46

36 — 54 75
2'/,
9
123
61
41
1 /41
178 59 260 33 500 /31
20 I /si
18/
/83 12/
% 2 2 89
— 30/ /25 26
37 37 76 19 7 7, 124 -I13/
180 1 261 29 30/
31 I14/
1 /26 20 / 510 34 /24 la
38 19 4'V,
9 77 77 A 125 25 61 264 44
424/39 1
111/ /21 183 45 / /42 520
39 39
IX
227,9 126 46 1265 53 18 //33 30/530 27 /49
78 39 Q12/ 21 1!"/aa
19/ /« 184 8/

40 20 4-720 79 79 27» 128

1%
185 37 267 89 /29 540 53 /25
416'41 32 30/
/61 270
55 /34
41 41 4% 80 20 129 43 -|12/ 186 31 /46 27 24 /44/
30/
28 /26
39 47 275 55 550
42 21 4% 81 27 2727 130 188 24 / /53
560
274! 1123//33 /37 276 /89
43 43 82 41 2U/83 132 33 189 21 46 570 38 /27
/53
A-L /27
/67 45 fa
/ 28 18 /27
/
44 33 4733 83 83 134 67 l"/34 190 19 / S I 280 29 %
— 272, 27 l'/2
3 30 / 47 580 20
45
46 23
432
'/23
84
85
21
17
27.7
24/«
135
136
19/
1% 195
192 26
32 /21
282
285 38
/55 600
35
/»
/28
/38
337« 22/19 34 49 /19 288
/46
700
47 47 86 43 138 23 196 48 /28
48 20 3"/» 87 /32 /47 800 40
19 140 49 198 290 29 90020 %
735
33 IX
/38 1000 50 720
/48 740
/49
/33
/29
120 Milling Machines

e. COMPOUND INDEXING.

A large number of divisions are given in tables IX — XIII.

If the numbers of holes given in the tables are not to be
found on the index plates but another fraction of the same
value can be% obtained, the denominater of which is under the
number of holes on the index plates, this can be employed
in place thereof, but a large number of divisions will have
to be passed over as it is absolutely necessary with this
manner of indexing that one of the factors or a multiple
thereof should appear among the divisions on the index plate.
It is however, possible by the compound system of indexing
to cut a large number of intermediate divisions, which are
either indivisible or if divisible, neither of the factors are
included among the number of holes on the index plates.
Instead of working with one circle of holes and one
crankhandle two index settings are taken, both circles
being on the same index plate, one on the front and
one on the back, (see figs. 184 and 185). Let the first
circle be termed p, the holes enclosed by the sector q -f- 1,
the fraction will consequently be — .
Let the second circle be termed z, the holes enclosed by
the sector jy + 1, the fraction will thus be — .
Taking the two circles together, the resulting fraction
will then be -2. + 3L.
p z
To make this quite clear, let the circles contain respec-
tively 11 and 13 holes.
The ordinary locking pin will be in circle 11, the second
locking pin in 18.
If the locking pin is set one hole further the worm will
have made ^ revolution.
If now the locking pin the circle z be moved on one hole,
the worm will have again completed ^ revolution. The total
rotary motion n of the worm will thus be equivalent to:—
«=-L + ! = -L+! = Ji+!i__2i
P « 11 13 143 143 " 143'
 121
and Milling Practice.
122 Milling Machines
If, on the contrary, the locking pin on circle z be moved
back one hole, i. e. in a direction contrary to that in which
the crankhandle over p moved, the rotary motion of the
worm of yY revolution caused by the first crankhandle
will be diminished by Tlff revolution, the result being:—
1 j^ 1 1 13 11 2
:p = 11 "" 13 == 143 ~ 143 ~ = 143'
A second case :— locking pin of circle p is in 5.
» »» » ^ » » "•
Locking pin of circle p moved on one division = \.
9 W » » ^ » »» J> • ~%'

Result « = $ + * = A +* = H-
Locking pin of circle / moves on one division = \.
» * * * , back „ = £.
Result n = l-^ = ^-^ = ^.
Acting in this manner, a large number of intermediate
fractions can be found in the higher divisions. The number
must, however, comply with one condition, viz: — It must
be possible to resolve the number into 2 factors. Numbers
which are wholly indivisible cannot therefore be taken into
consideration, whilst the circle of holes used must contain
one of the two factors. If, however, the number can be
resolved into two factors, which are generally small, there
will be a circle of holes in which each of the two factors
appears.
If the division is accomplished with both crankhandles
in one direction, the following formulas may then be
generally accepted :—
(9) *-X+£

In a contrary direction (]Q)n ==-+- — — ,

p z
as a consequence, it follows from (7) — = n.
 and Milling Practice. 123

(1) Example:- ^=80. g=2. z> = 51.

_^ = 80 = 40.
g 2
= = — ^~
-- 40 2346
3 andv 17 pare thus the513X17317~51
factors to be found in the number51'
of holes on the index plates, one of which is the circle /,
the other the circle z.
17 and 21 can usually be found. 21 is therefore adopted
for circle p and 17 for z. From these the fractions \% -f- T2T
are obtained, which an together equal to ££.
(2) Example:- ^ = 40. g=\. 0 = 57.
40 40 _i
~""i T_ ~~_19 21
"^*
573X
3 and 19 are the factors to193 57 number
be looked for19in~~the
of holes on the index plate. Taking 21 and 19, the fractions
-, which together equal %%, are obtained.

The dividing head of Brown & Sharpe and Le Blond

shown in fig. 186, is used for obtaining divisions which are
unobtainable in the ordinary manner with index plates and
is far more effective and easier to calculate than the
compound indexing with two circles of different numbers
of holes. At one side of the dividing head is a shear with
gear wheels. These gear wheels are not used for milling
spirals, for in that case one of these wheels would be
mounted on the feed screw of the table, but work in
connection with the index plate.
The head spindle, on which the worm wheel is mounted,
has a projection out of the head on which projection is-
keyed a gear wheel; a small side shaft, placed somewhat
higher up at right angles to the worm, is made to rotate
by means of intermediate gears imparting motion to the
index plate by means of two bevel and two spur gears,
the two set of gears being in the ratio of 1:1.
The manner of working is as follows: The crankhandle
is keyed to the wormshaft, so that if the taper pin does
not lock the index plate, the worm and index plate are
124 Milling Machines

disconnected. By turning the crankhandle motion is trans-

mitted to the worm ; through the worm the wormwheel ;
through the wormwheel the spindle; through the spindle
the gear wheel on the spindle outside the head ; through
this gear wheel the change gears with the side shaft;
finally, through the side shaft and the two sets of bevel
and spur wheels, the index plate.
The result is that in turning the crankhandle over the
index plate, the latter is also set in motion either faster or
slower according to the ratio of the change gears.
By the use of two intermediate gears instead of one

Fig. 186. Le Blond dividing head.

between the gear on the head spindle and the gear on

the side shaft, (two gears on one spindle as shown in
fig. 186, effect the same purpose, as far as direction of
motion is concerned, as one gear), the index plate can
also be made to revolve in an opposite direction.
To take a simple example: — The worm wheel has 40
teeth. The worm is single-threaded. Two gears with
the same number of teeth are placed one on the head
spindle the other on the side shaft with an idle gear
between, the number of teeth on this idle gear make no
difference whatever), and it is treated as if 40 divisions
had to be made, i. e. the crankhandle is given a complete
turn, the locking pin being thus returned to the same hole
 and Milling Practice. 125
in the index plate. What has, however, taken place in the
meantime? Seeing that the ratio of the change gears
between the spindle and the index plate is 1:1, not only
has the spindle been turned but the index plate has also
made -£$ revolution in the same direction as that in which
the crankhandle was turned; the crankhandle must, conse-
quently, having completed one turn, still be turned -fa
revolution farther in order to place the plunger in same
hole of the index plate so that after 39 turns of the crank-
handle by which the locking pin is placed each time in the
same hole, the spindle will have just completed one revolution
and the workpiece will thus be divided into 39 divisions.
If a second idle gear be inserted, (the no : of teeth being
chosen at will), the index plate will revolve in an opposite
direction to that, the spindle will have only completed one
full revolution after 41 turns of the crankhandle and the
workpiece will be divided, as a consequence, into 41 divisions.
It is evident that by varying the gearing between the head
spindle and side shaft, (the two spindles are parallel to one
another), any number of divisions can be obtained.
A few examples will serve to make this still clearer.
(1) Example :
The worm wheel has 40 teeth, the worm is single-
threaded the required divisions being 93.
/=40. <f=l. *> = 93.
In place of v some approximate number is chosen that
can be obtained with the index plate in the ordinary way,
say, for instance, 100.
t 40
o = - = — = 40.

g
_o_
~~~~
1
W_ J5_
'

The locking pin must thus be placed each time 6 holes

further forward on a circle with 15 holes but this of
course, would give 100 divisions. Only 93 divisions are,
however, required, so that, during one full revolution of
the spindle, the index plate must be advanced 7 X A == rl-
To obtain this, a wheel with 42 teeth is mounted on the
126 Milling Machines
head spindle and one with 15 teeth on the side shaft, an
idle gear being chosen at will. Should there be no wheel
with 42 teeth, a compound gearing is used to serve as an
auxiliary : —

15 3X5 15X25*
35 is mounted on the head spindle.
25 „ „ „ „ side shaft.
15 and 30 are mounted as a compound gear, so that 15
meshes 35 and 30 meshes 25.
The following examples are self-evident and need no
further explanation: —
(2) / = 40. g=\. z/ = 107. 0 = 40.
v is taken as =100.
o 40 6
= v = ~100™15'
the no: of divisions must, however, be 107.
The spindle must consequently be retarded 7 X A- The
42 30 ^ 35
gears must thus be -— 15 = 15 X. J5 with a fifth idle gear
chosen at will.
(3) /=80. g=-2. z> = 67. 0 = 40.
v is taken as = 60.
o 40 10
n = —v = —bU = —15 , thus, 7 divisions short.
7^2 40 ^ 35
The spindle must be retarded ^o = 15 Xf^ ^0 with the
addition of a fifth idle gear chosen at will.
Or, v may be taken as equivalent to 65.
o 40 8
= V±=6F =T3* m w*"cn case t*16 spindle must be
n vx Q -I o

retarded ^ -R W^ tw° i(*le £ears cllosen at wil1-

(4) /=120. ^ = 2. 2/=117. 0 = 60.

z' is taken as = 120.
o 60 1
n - = r^rn = -JT-, /. <?. 3 divisions too many.
 and Milling Practice. 127

The spindle must therefore be advanced f = f $ with

any idle gear at will.
(5) *=80. ^=1. v = ll. 0 = 80.
v is taken as = 80.
n = — = 1 , i. e. 3 divisions too many.
The spindle must be advanced f = |-g- with any idle
gear at will.
(6) *=60. £•=!. z> = 241. 0 = 60.
v is taken as = 240.
o 60 1 5 .

5 25 \f 20
The spindle must be retarted 1 X ™^0 = 50
^A /\
0 40
AC\ wit^ an^
idle gear at will.
(7) /=120. <f=2. 0 = 37. <? = 60.
v is taken as = 40.
o 60 ,1 ,10 .
n = —v = —40 - = 1—J = 1—<iO , 2. £. 3 divisions too many.

The spindle must be advanced 3 X ~~r — ~r = 40 V 90'

(8) *=80. ^=1. » = 53. ^? = 80.
^ is taken as = 50.
o 80 ,3 ,9
72 = —v = —50 = 1—5 = 1—15 , i. e. 3 divisions short.

The
TU
spindle
' A^
must...'i
be retarded
,
3 X ~F~
V ^ Q V/
5 == ~F~
8
o = OK
24
s^ 80
30 X
^o /\ OA*
^0
The gears used for this purpose are usually the same as
those used for spiral milling, as division of indivisable
numbers with gear wheels and spiral milling cannot take
place at the same time.
An exact number of divisions is, moreover, only neces-
sary in the case of gear wheels and other work of the kind.
Whenever spiral grooves have to be milled, as in the case
of cutters, etc., a definite number of divisions is, as a rule,
not imperative, and the divisions can generally be deter-
mined according to the number which can be obtained with
the ordinary indexing without recourse to differential
indexing.
128 Milling Machines

f. PRACTICAL DIRECTIONS FOR MILLING CUTTER TEETH.

Finally, we will proceed to give a short description
of practical milling. The cutter is mounted on an arbor
placed between the centres and rotates with the spindle
of the dividing head by means of carrier. This, how-
ever, may not take place as is the case with lathe work;
the connection between
the workpiece and the
spindle of the divi-
ding head must be ab-
solute, or in any case,
of such a nature, that
it is impossible for the
workpiece to make the
slightest movement in-
dependent of the head
spindle. To effect this,
the head spindle nose

Fig. 187. Milling angular cutters.

is provided with a double-forked carrier. The arbor on which

the cutter blank is mounted is provided with a dog, the bolt
in the fork on the head-spindle screws up the dogtail placed
on the workpiece so that there is no play between the dog
and the carrier.
When milling angular cutters, they are mounted on a
spindle which fits with a taper shank directly in the conical
bore of the head spindle, (figs. 187 and 188).
 129
and Milling Practice.
The milling table is adjusted to the exact position in a
transverse direction in such a manner that the extension of
teeth, which cuts the cutting plane of the teeth, to be
milled passes exactly over the centre of the cutter blank.
After this, the working cutter is set at the required depth.
The required index plate is then mounted on the dividing
head, the locking pin being set on the crankhandle so
that its point corresponds exactly with the holes of the desired

Fig. 188. Milling double angular cutters.

circle. The sector is then set to the required angle; for

instance, if the crankhandle has to pass over 9 holes in
circle 21, the sector must cover 10 holes, (see fig. 183,
page 111).
The work can now be commenced. One leg of the sector
is placed against the locking pin ; when one groove has
been cut and the table has been returned, the crankhandle
is turned till the locking pin is just against the hole lying
immediately inside the other leg of the sector, into which
9
130 Milling Machines
it is pushed by the plunger spring, the sector being shifted
in the same direction as the crankhandle, with its leg
once more against the locking pin. The further progress
of the work is identically the same.
Care must be taken that the crankhandle is not turned
over too far so that it will be necessary to turn back,
since the least play between the worm and worm wheel
will result in an incorrect division. Therefore directly any
play is noticed, it must be remedied. It is for this reason
that the worm wheel is wedged as has already been shown
in fig. 173, page 103.
When milling angular cutters, the cutter it mounted in

Fig. 189. Milling small angular cutters.

such a manner that the cutting can be completed without

the necessity of dismounting.
Figs. 187 and 188 show the position of two angular cutters
of different form and need no explanation, whilst fig. 189
shows the manner of milling a small angle cutter which
forms one whole with the shank. It is mounted in a
universal chuck on the dividing head, the other end
carried by the back centre of the tailstock is arranged in
such a manner that it can be set lower than the centre
line of the dividing head. Of late, the back centre
on the tailstock has been altered in such a manner as to
permit of its being placed at an angle which effectually
prevents the possibility of any oscillation on one side of
the centre.
 and Milling Practice. 131

g. SPIRAL MILLING.
Thus far we have exclusively treated of the division of
the circumference of a cutter or other object into a certain
number of divisions. As the reader will have observed,
we have gone much farther than was necessary for the
milling of an ordinary cutter, as the necessity of dividing
a certain number of divisions to the exclusion of all other
approximate numbers will never really occur in the ordinary
milling of cutters. We have treated and in the following
pages shall continue to treat of the calculations which occur
and which are connected with the handling of the dividing
head on the universal milling machine but shall continue to
take the cutter as starting point.
So far we have exclusively dealt with the milling of a
cutter with straight teeth; during the process of milling
the longitudinal motion of the table was rectangular to
the main spindle of the milling machine whilst only the
working cutter rotated.
When, however, in addition to the longitudinal movement
of the table, a slow rotary motion is imparted to the work-
piece at the same time, the result is a spiral line.
In milling spirals the longitudinal -movement of the table
can no longer be rectangular to the main spindle, but both
form a certain angle. The spiral or inclination and the
angle at which the table must be placed are dependent one
on the other ; no spiral can be cut without fixing the angle,
no angle can be determined without the spiral to be cut
being known. Both are, however, calculated quite separately
and can, consequently, be treated independently.
The first difference between the milling of straight and
spiral teeth is that whilst in the case of straight teeth, care
must be taken that the index plate is locked up after the
crankhandle has completed the necessary turn, in the
latter case the locking pin must be free of the index plate .
as during the process of milling the crankhandle will rotate
over the index plate. The manner in which the head spindle
is caused to rotate during the longitudinal movement of the
132 Milling Machines
table has already been illustrated in fig. 174, whilst fig. 190
gives a still clearer illustration of the connection between
the feed screw and the spindle of the dividing head by
means of change gears.
On the feed screw U in fig. 174, page 104, which imparts
longitudinal motion to the table, is mounted the gear wheel
a which meshes an idle wheel chosen at will or as in
fig. 174, a set of compound wheels one of which meshes
the wheel b which is placed on the spindle of the dividing

Fig. 190. Dividing head set up for spiralmilling.

head and in this manner a permanent connection is brought

about between the feed screw of the table and the spindle
of the dividing head.
A simple example will show clearly what actually takes
place.
Given that the wormwheel has 60 teeth, that the worm
is single-threaded whilst the feed screw has a */« incn pitch.
Set one wheel, on the feed screw U fig. 174, another on
the side shaft P, both of same number of teeth with an idle
wheel on the stud O. When the feed screw U has com-
pleted one revolution, the worm shaft will have also revolved
 and Milling Practice. 133
once and the worm wheel will have shifted one tooth; the
spindle of the dividing head together with the workpiece will
consequently have completed -fa of a revolution; for one
complete revolution the feed screw must make 60 revolu-
tions whilst the table, and with it the workpiece will have
traversed 60 X i inch = 15 inches. The length of the spiral,
in this case will, therefore, amount to 15 inches.
When the feed screw has made 60 revolutions, the head
spindle and workpiece will have just completed one turn.
For the sake of explanation we first considered the gear
wheels; in actual practice it will be just the reverse, the
gears and the inclination depending upon the given length
of the spiral or the spiral and the gears on the given
inclination.
Let us take the simplest case, viz: — the calculation of
the change gears for a spiral of a given length, in other
words, the longitudinal motion of the workpiece for one
complete revolution.
This calculation is very similar to the calculation of the
change gears for thread- cutting on the lathe. In the latter
case, the starting point is the number of threads per unit
of length of the lead screw, whilst here we start with the
number of teeth on the worm wheel divided by the number
of threads per inch of the feed screw which is equivalent to
the length of the spiral. Thus, in the foregoing example
^=15 inches.
This, however, only applies when ^= 1, i. e. is a single-
threaded worm. If the worm has more threads, the number
of teeth of the worm wheel must be divided by the product
of the number of threads of the worm and the number of
threads per inch of the feed screw.
The number of threads of the worm must not be con-
fused with the number of threads per inch of the feed
screw. If in the foregoing example g=Z, the length of
the spiral would have been = 7£ inches.

Example: / = 40. £•=!.

Taking the number of threads of the feed screw per inch
p s\
134 Milling Machines
as ^ = 4 and the, length of the spiral to be cut as /=20
inches, the constant in this case will then be 44-= 10, whilst
the ratio between the change gears a and b in fig. 174
must be 20 : 10.
Assuming that: —
a is the gear on the dividing head, or, in the case of
compound gearing, the gears which are driven.

Fig. 191. Two wheels with one idle wheel.

b is the gear on the feed screw or the driving gear.

c is the constant obtained from — .
h l e
X is the lengt of the spira to be cut, we arriv at the
general formula:—
(11) a:b = K:c.
If no fraction can be formed from — r in which of the
g*
 135
and Milling Practice.

numerator as well as of the denominator, are change gears

with that number of teeth, the work can be accomplished
with 4 wheels.
Fig. 191 shows the manner of placing two wheels with
an idle gear at will, whilst fig. 192 shows the same for
mounting compound gearing.

F], Ffr

Fig. 192. Compound gearing between feed screw and head spindle.

The driven and driving gears may be interchanged,

though they may not be changed in pairs or separately.
The gear resulting from the constant c must invariably be
placed on the feed screw and serve as driving gear whilst
the gear resulting from X must be placed on the dividing
head or act as a gear which is driven.
We will now give a few examples which will serve to
explain the calculation.
136 Milling Machines

(1) /=80. ^=2. ^ = 4. /=24 inches.

4_~2
_2O~
£ = ~T
^_ 480
The gear with 48 teeth is mounted on the dividing head,
that with 20 teeth on the feed screw with an idle wheel
engaging both.
(2) /=120. g=2. J = 4. /= 60 inches.

a_ 60 IPX 6 50X80
b =~15~= 3X5 :" 15X25'
The gears with 15 and 25 teeth are the driving gears,
those with 30 and 50 teeth the gears to be driven.
(3) /=40. £•=!. J = 4. /=125 inches.
c=lQ. X = 125.
a 125 5 X25 = 25X 50 75 X 100
b = = 10 ="" 1 X 10 ~~ 10 X 10 "= 30 X 20
The gears with 20 and 30 teeth are the driving gears,
those with 75 and 100 teeth the gears to be driven.
(4) / = 180. 180g = 3. s = 4. / = 5 J inches.

b ~15
The gear with 22 teeth is mounted on *the dividing head, that
~~~30~~60
with 60 teeth being placed on the feed screw with an idle gear.
(5) /=60. £ = 1. J = 5.= 9J .
/=9| inches.

26

(6) / = 80. g = l. J = 5. /=28J inches.

33 X 70

4 X 16 " 20 X 32*

32'
 137
and Milling Practice.

The foregoing examples are sufficiently clear in them-

selves so that further explanation is unnecessary.

h. THE CALCULATION OF THE LEAD FROM THE

INCLINATION.

In what has previously been said, it has been taken for

granted that the length of the spiral, or what is just the
same, the lead, has either been known or been given. In
actual millling, however, it is usually just this length which
is not given, since it is customary to start from the angle
formed by the tooth of the cutter and its axis. Moreover,
what has previously been said is still incomplete as, before
the milling can be commenced, it is necessary to know
precisely at what angle the table must be placed in order
to secure a certain spiral line.
By constructing a triangle on the drawing table the exact
angle can always be determined when the lead of the spiral
is known, or vice versa, the lead of the spiral can be deter-
mined when the angle is known, since two elements of the
right angled triangle which is to be constructed are always
known, viz :— one side of the right angle and one angle,
or the two sides of the right angle ; the side of the right
angle which is always constant being the contour of the cutter.

A,

dir
Fig. 193. dir
Fig. 194. Fig. 195.

Fig. 193 represents the first case in which given

the lead of the spiral is to be determined.
Fig. 194 illustrates the second case in which given the
lead of the spiral, /_ A is to be determined.
This manner of working is, however, troublesome, not
accurate, and, we only mention it here in order to be complete.
The angle can be determined quickly and with mathe-
138 Milling Machines
matical accuracy by means of goniometry with which,
however, the workman is usually not so familiar.
For this reason we shall now proceed to explain just as
much of this subject as is necessary for our purpose, viz :—
to determine an angle when the two sides are known or
to determine a side, given one side and one angle. The
right angle is naturally always known and is 90°.
Fig. 195 represents a right angled triangle, the sides
being marked a, b and c, and the angles A, B, and C.
b : c is termed the sine of angle A.
a :c „ „ „ cosine A.
b:a „ „ „ tangent „ „ A.
a :b „ „ „ cotangent „ „ A.
c :a „ „ „ sector A.
c :b „ „ „ cosector „ „ A.
The principal object of plane trigonometry is to find
out from any three elements of a triangle, (not being all
angles), how to determine the remaining three.
Supposing the side a in fig. 195 = 5 and the side 3 = 4,
then Tangent A = 4=0.8
Cotangent A = \ = 1.25.
Tangent and cotangent are defined as follows: —
When a certain part in one arm of an acute angle is
projected on the other arm and in a line standing at right
angles to the other arm, the proportion of the second pro-
jection to the first is termed the tangent of that angle.
When a certain part in one arm of an acute angle is
projected on the other arm and in a line standing at right
angles to the other arm, the proportion of the first projec-
tion to the second is termed the cotangent of that angle.
Now, in the case of /B, fig. 195, b is the first projec-
tion and a the second.
b : a is consequently cotangent B.
a : b in the same illustration being tangent B.
Hence it follows that the cotangent of an acute angle
is equal to the tangent of its complement.
The tangent of an acute angle is equal to the cotangent
of its complement.
 and Milling Practice. 139

(The complement of an angle is the angle which must

supplement the first in order to obtain an angle of 90°).
Sine and Cosine are thus defined :—
The sine of an acute angle is the proportion of the pro-
jection of a certain part in one arm drawn on a line which
bisects the second arm at right angles to that arm.
The cosine of an acute angle is the proportion of the
projection of a certain part drawn on the one arm to that
part.
In the case of /_ B in fig. 195, b is the projection of
the part in the one arm, c being the part of the arm ; b : c
is consequently the cosine of /_ B.
Further, in the case of /[B, a is the projection of a
part in one arm drawn on a line bisecting the other arm
at right angles, c being the arm ; consequently a : c is the
sine of /_ B.
From this it follows that the cosine of an acute angle
is equal to the sine of its complement.
The sine of an acute angle is equal to the cosine of
its complement.
Seeing that sectors and cosectors are the proportions of
sides not required in the calculations which follow, they
need not be considered here.
The names of the goniometrical proportions are abbrevia-
ted as follows: —
Sine = Sin., Cosine = Cos.,
Tangent = Tan., Cotangent = Cotan.
If / A fig. 195 is 45°, then / B is also 45°, and the triangle
is equilateral, i. e. a and b are equal, so that
Tan. A = b : a == 1. Cotan. A = a : 6=1.
With an angle of 45° the tan. is thus = 1, the cotan.
being equal to the tan.
If /_ A fig. 195 is smaller, the proportion b : c, i. e. tan.
A is also smaller, until finally when ^_ A = 0°, tan. A
becomes equal to zero.
If /_ A is greater, the proportion b : c, i. e. tan. A is
also greater, until finally when /_ A = 90°, the line b was
140 Milling Machines
parallel to the hypotenuse and is thus immesurable ; this is
expressed by the sign oo.
It is precisely the same with the cotan. Tan. and cotan.
can thus represent each and every value lying between 0
and co. If tan. = 0, cotan. will be = oo; if tan. = 02,
then cotan. will be = 0.
As the sloping side of a right angled triangle is always
greater than one of the sides of the right angle and as
one of the sides of the right angle must always be divided
by the sloping side for sin. or cos., it follows that sin. and
cos. of an acute angle are always less than 1.
With 0° sin. = 0, cos. = 1.
With 90° sin. = 1, cos. = 0.
The goniometrical proportions are dependent on the size
of the angles but entirely independent of the size of the
triangle.
For example, if in place of the value given on page 138
for fig. 195, we take
side a = 15, and side b = 12, then
tan. A = ff = 0 . 8, cotan. A = |£ = 1 . 25
which is the same as when the sides a and b have the
values. 5 and 4,
The goniometrical proportions of all angles from 0° to
90° have been worked out and arranged in tables.
By this means, if one angle and one side of a right
angled triangle an known, the other sides can easily be
calculated. For instance, if in the foregoing example tan.
A = 0 . 8 and it is known that a = 15, it follows therefrom
that b is = 15X0. 8 = 12.
In tables XIV and XV the goniometrical proportions of
sin., cos., tan. and cotan. are given to the sixth part of a
degree which is sufficient for calculating the angles in
connection with the matter in hand. With the assistance
of these tables and the foregoing explanations, the angle at
which the table must be set for milling spirals can be
readily calculated from the data which is always at hand
in such cases or the lead of the spiral can be reckoned
 and Milling Practice. 141
from the given angle, since two particulars are always
known, viz:—
1st. The diameter, i. e. side a fig. 193 and the lead of
the spiral, i. e. side b ; /_ B being unknown.
2nd. The diameter, i. e. side a fig. 193 and the angle, i. e.
/_ B ; the lead of the spiral, i. e. side b being unknown.
The triangle, fig. 195 is the starting point in the calcula-
tion, all proportions such as diameter of the cutter, lead of
the spiral, angle, etc. being united therein, as follows :—
1. The diameter of the cutter = d= side a.
2. The lead or pitch of the spiral = side b.
3. The angle which the spiral forms with the side of
the cutter = /_ A.
4. The angle which the spiral forms with the axis of
the cutter '= / B.
In the following calculations little notice need be taken
of /A.
/_ B is the angle which the tooth forms with the axis of
the cutter is consequently the angle at which the table
must be placed.

The foregoing is summarized in the following table.

Given. Required.
•p> Solution.

A and a b b — a tg A.
B and a b b = a cot B.
a and b a\b = tg B.
a and b B
bja = cot B.
a and b A b\a = tg A.
A and b a a = b cot A.
a
J\.
A
and a c

cos A'
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146 Milling Machines
Examples-
To cut a miller with spiral teeth at an inclination of 20°.
Diameter of cutter = 1 V* inch / = 40. g = 1. s = 4.
a = 3 . 14 X 1 V* = 3,925 inch.
Cotan. B = 2,747.
b = a cotan. B == 3,925 X 2,747 = 10,781975 inch
or oo 103/4 inch.

According to (11), the constant c — — - = 10.

X = 10f.

a_ _X__10|_43
b ~~ ~~ c ~~ ~~ 10 ""40*
The gear on the worm must, consequently, have 43
teeth, that on the feed screw of the table having 40, an
idle gear chosen at will is used and the table set at an
angle of 20°.
A right hand cutter will be the result, provided, of
course, that the feed screw has a right hand thread, which
is almost always the case. Should a left hand cutter be
required, a second idle gear must be engaged.
(2) Diameter of cutter = 3 inch, the lead of the spiral
being 9 times the diameter.
/=60. ^=1. J = 4. ? = 23.
a = 3 . 14 X 3 = 9,42 inch.
£ = 9X3 = 27.

The table shows that tg 19° 10' = 0.348. / B is thus

19° 10', at which angle the table must be set.
X = 27 inches.
/ 60
c = -- =--=15.
£.s. 4
_a_ 27 54 2 X 27 _ 40 X 27
c : = b = ~ 15 ~~ 80 ~~ 2 X 15 ~~ 30 X 20'
(3) Diameter of cutter 3 inches; length of spiral 27 inches.
/ = 80. ^ = 2. j = 4.
a = 3 ir. l> = 27.
 and Milling Practice. 147

tg 17° 10' = 0.348

* 80
C=^=2X4 = 10-
X = _a_ 27 3 X 9 30 X 45
* ^ : £ = " 10 ~~ 2 X 5 ~~ 20 X 25*
According to table I, page 58, this cutter should have
from 22 to 23 teeth.
/yi — — _
/—
80
___ _ . — —
80
_ A* - . Ij \
a
J -
t 18
1 _

-*r~2X22~44- h/ ' 'ff

In table XVI for diameters up to 4 inches and for a lead
of spiral of 100 inches, the angle at which the table must
be placed is to be found by going through the columns
horizontally and vertically till they meet one another. The
backing-off of cutters, although really forming part of this
chapter, will be treated separately later on.

i. THE HARDENING OF CUTTERS.

The hardening of cutters forms part of the various opera-

tions which the blank must undergo before being fit for use
but which can only take place when the mechanical treat-
ment is as good as over and it is just this operation or
tr-eatment which may be regarded as one of the most
dangerous since it is during this process that the cutter
runs the greatest risk of being entirely spoiled.
The process of hardening may be briefly described as:
bringing the ivorkpiece up to a certain temperature and
then quenching it quickly. By this means the steel changes
to a state in which it can no longer be machined by other
steel tools.
From the foregoing definition of the hardening process,
the following questions arise: —
1. How is this heating to be effected?
2. To what temperature must the cutter be heated?
3. How should the metal be quenched?
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150 Milling Machines
Heating. The cutter should be heated as gradually as
possible. The heating of the outside takes place first, the
external parts transferring the heat to the internal parts *
through the metal.
From this point of view it would appear that the heating
should be effected very slowly were it not that for other reasons
it is preferable to effect the heating as quickly as possible,
the principal reason being that when red-hot, the carbon
of the steel unites with the oxygen of the atmosphere
forming oxyd of carbon which renders the quality of the
steel inferior. The longer, therefore, the cutter remains
red-hot, the longer this chemical process continues, the
more the carbon is abstracted from the external layers
of the cutter which are just the very parts required for cutting.
It is for this reason that the grinding of cutters after
hardening has proved such a great improvement since the
the external edges of the teeth, which are the first to be
heated and are heated the most, thus suffering the greatest
loss of carbon, are ground off.
The ordinary forge fails entirely to comply with the two
foregoing conditions, viz : — the gradual heating of every
part and the preservation of the carbon in the steel.
The fire in the open forge is raised to a certain temper-
ature and maintained at "that temperature by forced draught
which, however, occurs only at a fixed point so that it is
impossible to expose every part of the cutter to the same
heat. Attempts are sometimes made to surmount this
difficulty by constructing a small oven of fire-bricks over
the fire, but, nevertheless, it is impossible to prevent
the underside of the cutter being exposed to a higher
temperature than the upper part and sides. Moreover,
whether the cutter is heated in a fire which is fully open
or in a space above the fire so as to prevent the heat
spreading too rapidly through the surrounding atmosphere,
the fact remains that the temperature has to be maintained
by forced draught, i. e. oxygen, which is just one of the
obstacles that has to be contended against in the hardening
process.
 and Milling Practice. 151
Another detrimental factor to be taken into account when
heating in an open fire is the fuel and it should be noted
that in this respect the workmen are themselves much to
blame since if ordinary coals be employed the sulphur is
released and if this unites with the steel, the result will be
soft patches which completely spoil the cutter.
For lack of better means of heating recourse must be
had to the open fire but in this case charcoal should be
employed to heat the cutter since charcoal contains but little
sulphur and further because charcoal requires but little
draught to maintain its temperature with the result that
there is less oxydation during the heating. Should charcoal
be unobtainable, then cokes should be used but should the
use of coal be imperative, the coal should first be burned
dead to permit of the sulphur from the coal being consumed
before putting the cutter in the fire.
When the fire has been raised to a sufficient temperature,
a plate of adequate thickness should be placed over the
fire and heated to a red-heat, after which the cutter should
be placed on it. By this means, the forced air is prevented
as far as possible from coming into direct contact with the
cutter. If charcoal be employed, the cutter should be
entirely covered with it which will also prevent, as far as
possible, the surrounding air from coming into contact with
the cutter, the same treatment being observed should cokes
be used. If a long cutter, of not too large diameter, is to
be hardened, it should be put into a gaspipe which should
constantly be kept revolving in the fire.

The only means of ensuring that the quality of the steel

will not have deteriorated after the hardening, is to take
care, first of all, that the surface of the steel shall not be
exposed to the influence of the oxygen from the atmosphere,
secondly, that the surface of the steel does not come into
contact with whatever fuel may be employed, and lastly,
that the rise in temperature is spread gradually over every
part of the steel.
The foregoing can only be obtained by the use of a
152 Alilling Machines
proper heating furnace, a suitable type of which is illustrated
on page 80, fig. 125.
Ordinary coal is burned in this type of furnace ; the whole
muffler being surrounded by the flames on all sides, the
heating thus being perfectly even and regular. The cutter
is placed in the muffler, the opening of which is first closed
up with a fire brick, after which it is made air-tight by a
close-fitting flap. Other furnaces are those heated by means of
gas, the only difference in this case being the heating medium
employed, the actual process remaining precisely the same.
Of late, electric hardening furnaces have been placed on
the market, which, on account of the perfect regulation of
the temperature which they ensure, are highly recommendable.
Besides the hardening furnace there is still another method
of raising the temperature of the cutter to be hardened
whilst avoiding all injurious influences, viz :— heating in a
salt bath.
By bringing the cutter up to the requisite temperature
in a salt bath, it is safe- guarded against the risk of being
overheated, which is a matter of primary importance.
The melting point of salt is about 750° Celsius, and when
heated above 900° Celsius, the bath begins to boil, this
being a temperature which is not at all injurious to the
cutter. Moreover, seeing that the cutter is completely
immersed in the bath, it is fully protected from the influence
of the oxygen.
The salt is placed in a crucible, the bottom of which is
first covered with soda, and it can, if desired, be heated on
an open fire.
To obtain a thoroughly good mixture, a little potash or
chrome-acid may be added. As it impossible to prevent
the temperature being highest at the bottom of the mixture
when the crucible is heated from underneath, it is advisible
not to place the cutter at the bottom of the crucible but
to suspend it in the molten mass by means of an iron hook.
It is further advisible to warm the cutter slightly before
introducing it in the mixture, but above all, care should be
taken to see that the cutter is perfectly dry.
 and Milling Practice. 153
The heating of a cutter to the exact temperature simply
demands practice. The cutter should be looked at from a
dark place, at any rate not in broad daylight where it
would be impossible to distinguish the exact colour of the
steel. For this reason, the foregoing method of heating the
cutter in a salt bath is highly recommended, whilst, nowadays
the pyrometer is also largely used for reading the temperature
in degrees.
The temperatiire to which the cutter should be raised
depends to a certain extent on the brand of the steel ;
various tests have demonstrated that for fine quality tool
steel this temperature varies from 900° to 1100° Celsius.
The withdrawal of the cutter from the hardening furnace
or salt bath for the purpose of ascertaining the temperature,
cannot but exercise a deletrious effect on the hardening
process owing to the risk of oxydation to which the cutter
is then exposed.
Quenching. If it is possible to spoil the cutter, the
making of which has entailed so much work, during the
heating, in spite of the exercise of the utmost care, still
more care and attention are required as well as a great deal
more regular practice, to ensure a proper quenching.
The best liquid for quenching is either snow or rain-
water. At any rate, it must possess good heat-conducting
properties, for which reason the water must be soft. Should
the water contain lye or carbonic acid lime, these will be
deposited on the surface of the cutter and impede the
quenching. For this reason it is ad visible not to use spring
water; should neither snow nor rain-water be obtainable,
then running water should be used. If nothing but spring
water is obtainable, it is advisible to boil it first, or better
still, to distil it. To increase the heat-conducting properties
of the water, a little sulphuric acid or brine, salt or amonia
should be added to the bath. The water should not be
too cold, from 20° tot 25° Celsius being a suitable temper-
ature. Cold water hardens quicker but makes the outer
surface too brittle. If the cutter to be hardened is not
required for machining hard metals so that extreme hardness
154 Milling Machines
is not necessary, warmer water may be used : even at the
boiling point of 100° Celsius, the water will not have lost
its quenching properties.
The hardening bath should be close to the spot where
the cutter is heated, firstly, to prevent a diminution of the
temperature of the cutter whilst being carried to the bath,
and secondly, to prevent oxydation. The cutter must not
be taken hold of with cold tongs, nor on any account by
the teeth. The surface of the teeth, must not be covered.
Shell cutters, which from their form are difficult to take hold
of, should be plunged in the liquid by means of an iron
hook which has previously been put through the bore; on
no account whatever may the cutter be allowed to fall into
the liquid. The quantity of liquid into which the cutter is
plunged, must be sufficient to ensure the temperature
remaining constant during the quenching. When the cutter
has been submerged, it must be kept moving to and fro,
as during the quenching steam is generated and bubbles
will adhere to the surface of the cutter and prevent the
quenching being perfectly even.
A cutter with hard but tough teeth and soft core is
obtained by plunging the cutter into pure and rather cold
water for a moment and then, as soon as the teeth have
cooled sufficiently, taking the cutter out of the water quickly
and completing the quenching in oil. The time during
which the cutter should be kept in the water depends on
its size.
Another method, of hardening which also produces excel-
lent results consists in carrying out the hardening under a
jet of water. For this purpose, the whole breadth of the
cutter must .be covered by the jet and to effect this suc-
cessfully, considerable practice is necessary.
Before removing the cutter from the cooling liquid, care
must be taken to ensure that it is entirely quenched, inter-
nally as well as externally. Cutters of large dimensions
require some considerable time before this is properly effected ;
cutters of even 10 and 6 inches diameter which had been set
in a draughty place after insufficient quenching (notwith-
 and Milling Practice. 155
standing that the exterior surface was quite cold), have
been known to spring in two or more pieces with a loud
report.
The manner in which the cutter should be plunged into
the liquid depends entirely on its form and must be left to
the experience of the workman; a thin, flat cutter being sub-
merged on its side, a long cutter of small diameter being
put in vertically to the direction of its axis.
As far as possible the cutter should be hardened in such
a manner that it will at once acquire the required hardness,
so as to avoid the necessity of tempering. The following
further particulars are given with a view to ensuring any
possible tempering being carried out property, rather than
to encourage same, since a cutter which has received proper
treatment up to and' including its hardening, may still be
spoiled by tempering. For this purpose, i. e. tempering, a
thin, flat cutter may be placed on a plate heated over a
charcoal fire, a long cutter of small diameter being placed
in a heated gaspipe though a sand bath is far preferable as
in the latter case every part of the cutter is exposed to a
perfectly even temperature ; cutters, the diameters of which
are not too large and which have a bore, may be tempered
by mounting them on a heated arbor, taking care, however,
that this fits exactly. Care must also be taken beforehand
that the teeth are scraped clean at various places to permit
of the exact increase of colour being observed, whilst the
tempering must proceed regularly though not too quickly.
A cessation of the tempering will give no further assurance
that the increase of colour will indicate the precise degree
of hardness of the steel.
Formerly, and even at the present day, the process of
hardening was regarded as more or less of a mystery, full
of secret tricks known only to a few of the initiated. It
cannot, however be too strongly insisted upon that such an
idea is wholly erroneous. The methods of heating and
quenching are simplicity itself. The workman who has to
perform the work, has simply to know what he has to do,
must have the necessary means at hand and last but not
156 Milling Machines and Milling Practice.
least, have a clear idea as to what actually takes place during
the hardening process. It is, of course, advisible to let the
same person carry out the hardening work since, as in
work of every kind, practical experience will save him from
making mistakes. The principal thing to bear in mind is
a regular, rational, and, at the same time quick increase of
temperature, carefully avoiding all injurious influences,
raising the cutter to the exact temperature and good
quenching.
 CHAPTER VII.

Speed and Feed of Cutters.

With the cutter as with every other rotary cutting tool,

two different motions in operation at the same time have to
be taken into consideration.
First there is the rotary movement of the tool by which
the metal is removed. The principle contained in the
milling cutter, viz: the circular cutting tool, the contour
being provided with teeth which cut into the work succes-
sively and, after having completed part of a revolution,
are again disengaged, being succeeded in their turn by
other teeth, clearly indicates that with regard to this motion,
it is the workpiece that remains stationary whilst the cutter
rotates.
It is this movement which is meant by the term " cutting
speed" , i. e. the distance in a straight line traversed by a
certain point on the circumference of the cutter per unit
of time, as for instance, per second.
It is evident that the cutting speed can be obtained by
multiplying the number of revolutions completed by the
cutter in a given unit of time by the circumference of the
cutter.
The second movement is that by which the workpiece
is carried along a certain point on the cutter or visa versa.
This movement can be either in a straight line, circular or in
a curved line and is termed the feed. This motion should be
expressed as the feed in a straight line per unit of time
so that in accordance with the tensity of the metal, the
quality of the cutter, and the construction of the machine,
158 Milling Machines
the rate of speed and the rate of feed may be determined
independent of each other. The present construction of
so many milling machines leaves much to be desired in
this respect since the rate of feed is dependent on the
number of revolutions of the cutter and is consequently
expressed by a certain length per revolution of the
cutter. Now the possibility is not at all excluded that, for
instance, a coarse feed should be desired with a cutter of
large diameter whilst a fine feed is required with a small
diameter cutter. The feed is, however, dependent on the
number of revolutions of the cutter. The only thing pos-
sible in such a case is to choose the largest possible feed
for the large cutter and the smallest possible feed for the
small cutter. Notwithstanding this, it will still be quite
possible that even the coarsest feed will still be too slow,
whilst with the slowest feed, it will be too coarse.
Until quite recently the feed mechanism was driven
by a three-step cone pulley on the main spindle of the
milling machine, corresponding to an identical pulley on
the feed shaft. These cone pulleys were made unequal in
diameter so that, if required, they could be changed. By
this means 3 i. e. 6 different rates of feed were obtainable
for each speed of the main spindle.
Of late, however, (and this has generally been adopted
by all American makers of any importance), the feed is
no longer operated by a cone pulley but by means of
positive drive from the main spindle whilst by means of a
gear box, as many as 16 different positive rates of feed
have been obtained, which are, however, still dependent on
the speed at which the cutter rotates.
Some of the latest constructions, namely those of Brown
& Sharpe, Kearney & Trecker and the Cincinnati Milling
Machine C°., introduce a great improvement in this respect.
The different speeds at which the cutter rotates are no
longer obtained by means of a cone pulley but by means
of a gearing between the main spindle and a pulley of
large diameter rotating at a constant rate of speed. The
feed is driven from a shaft also running at a constant speed
 and Milling Practice. 159

and is consequently no longer dependent on the speed of

the cutter. The ideal method would, however, be that the
feed should be driven by a seperate countershaft entirely
independent of the machine. This however involves some
other difficulties which up till now have not been surmounted.
The speed at which the tooth of the cutter can move
through the material is chiefly dependent on the hardness
on softness of metal to be machined and the quality of the
cutter, always presuming that the cutter itself is well made
and constructed and that the construction of the machine
permits a reasonable rate of speed.
Fixed rules, holding good for every case, cannot be laid
down with regard to the cutting speed, which can only be
determined according to circumstances which are themselves
very divergent. In general, factories which make the manu-
facture of cutters a speciality, give the following figures for
the number of revolutions per minute.
200 for soft tool steel
diam. of cutter in inches and cast iron.
for cutters
n 200—240 for forcings and made
ordinaryof
diam. of cutter in inches steel.
tool steel.
n 320—400 for brass.
diam. of cutter in inches

Given that n = No. of revolutions per minute.

D = Diameter of cutter in inches.
V = surface speed in feet per minute,
then
for soft tool steel and for forgings and
cast iron. steel. for brass.
200 200—240 320—400
D D D
n =
12

D n is the constant value present in the numbers 200,

200—240, and 320—400 so that we can thus write:—
160 Milling Machines

V = -' —12 — = 52 feet per minute for soft tool steel and
cast iron.
:r200—240
V = - 1_ - = 52—58 feet per minute for forgmgs
and steel.

V = 12 - = 84—100 feet per minute for brass.

The surface speed V for cutters of high speed steel is
naturally higher and we find fairly divergent numbers,
amongst others :—
1. Weber.
Cast iron and tool steel 83—125 feet.
Steel 100—133 „
Wrought iron 150—200 „
Brass 200—250 „
2. Bonner Milling Cutter Works.
Tough steel 66 „
Medium tough steel 100 „
Brass 200 „
3. The Cincinnati Milling Company.
Cast iron 40 „
Steel 80 „
Brass 122 „
4. Ludw. Loewe.
Cast iron 83—125 „
Tool steel . 100—133 „
Wrought iron 150—200 „
Brass 233—265 „
The figures most divergent are met with
under 3 and 4.
Cast iron 40—125 „
Steel 80—133 „
Brass . 122—265
 and Milling Practice. 161

Differences thus of from 100 — 200 °/o. The reason of this

is that in the data given by Loewe only the surface speed
which can be imparted to the cutter as a maximum under
the most favourable conditions has been taken into consid-
eration. The Cincinnati Milling Company give the speed
according to the number of revolutions at which the milling
machine can run under variable conditions, including the less
favourable ones. As a general average the figures given
under 2 can be taken.
Although as explained above there are no fixed rules
relative to the surface speed of cutters, the data given
above may be generally accepted, since they have been laid
down as possible by manufacturers who may be regarded
as authorities on the subject. For the rest, practical experi-
ence must decide each case separately. Tables XVII and
XVIII give the surface speed and rate of feed for cutters
made of ordinary and high speed steel.

11
 TABLE OF AVERAGE CUTTING SPEEDS FOR CUTTERS MADE OF
ORDINARY TOOL STEEL.
Table XVII.
Steel Cast Steel Steel
Cast Cast
and Brass. and Brass. and Brass.
iron. iron. iron. forgings.
forgings. forgings.

90 48 56 100
Surface speed in 40 50 56 62 110
feet per min.

Diam. of 150 190 340 180 210 210 235 420

380
%o gfc6 * inches.
D D D D D D D D D
U a.

NO: OF REVOLUTIONS PER MINUTE.

11% 150 190 340 183 210 210 237 420

380 197
127 160 285 153 320 160 350
178
l3/8
1%
137 130 273 178
110 245 153 300
«3 95 120 215 114 134 238 153 148 262
0
223/« 77 172 91 190 134
107 118
o 2>/4 95 143 107 160 89
.g 63 80 76 76 201
3'/4 55 68 122 65 89 136 98 175
•~ 60 107 76 84 150
3V2 48 57 67 110 67 74
& 95 106 66 131
42 116
i
0
44!/4
43/4
38
35
5*3
48 86
78
46
51
42
59
53
48
95
87 53
59
48
59
105
43
40 80
73 54
O
5V,
5''/8 32 71 38 44 44 95
87
fc 29 37 66 35 41 68 41 45 81
•4-1
27 34 61 32 38 38 49
25 35 42
6 32 57 63 35 39
s
1
6'/4
28
30 33 59 75
70
24 30 53 65
7 21 26 47 25 30 48
53 27
33 37
23 27 33
8 19 43 30 29
24 27
9 17 22 39 21
18 24 24
21
3/4-2 23 58
42
10 15 19 42 47
52
34 21 38
l'/2-2V2
Fee d in inches 7/8-l3/4 21/2-31/-> 3-5
r ri>' i
ViVl
I>er min.
Vl'/4
THESE SPEEDS
VI ARE SUITABLE FOR THE FOLLOWING CUTTKKS:
Gear cutters. Module 10—12. Module 6— 9. Module 1—5.

Key way cut-

ters. 4 — 10 inch diam. 3 — 6 inch diam.
5-10 „ l'/2 — 4 inch diam.
Angle cutters. 3-4
Shell cutters. 4- 8 „
2V.-5 „
r/2-3
l'/i-3 „„
Shell and end Upto 12 inch length, Up to 6 inch length.
cutters. Up to 4 inch
up to 2 inch diam. length.
 Milling Machines and Milling Practice. 163
AVERAGE CUTTING SPEED FOR CUTTERS OF
HIGH SPEED STEEL.
Table XVIII.

Medium
Tough steel. Brass.
tough steel.

Surface speed in feet

66 100 200
r minute.

Revolutions Constant per min. 250

pe-pw- r .«, 390 780
per minute in inches. D D D

No. OF REVOLUTIONS PER MINUTE.

1 256 392 784

I3/. 6
218 327 653
!5/8 160 245 490
1 2 128 196
392
"a

.20 23/8 . 107 163 327

23/4
91 140 280
3'/4 123 245
30
fe
CJJ
31/2
1
^o

71 109 218
443/4 98 196
64
6$ 53 163
55/8 46 82
II 40 70
61
140
123
• -H 7 36 109
Q
M
8 32 54
49
99'/4 29 45 98
89
26 39 . 78
Feed in inches per min. l!/2-3 3—5 5-8

With the present construction of the milling machine it is

impossible to obtain all these rates of speed and the surface
speed given can only be approximately imparted to the cutter.
164 Milling Machines
The number of speeds on the modern milling machine
when using double back gear with two speed countershaft
amounts to 16 and from this number the choice has to be
made.
The following particulars are given as to the number of
speeds possible with the Cincinnati milling machine and
practically agree with those given by other makers:—
Table XIX.
Number of revolutions on the
I1/* Cincinnati milling machines.

Xo. 0 1 2 3 4 6Yi

_ 12
17.
10
9
— —
20
17 13 129
— — 14 15
— — 21 19 17
24 14
— — 28 26
22
— — 30 21
— — 34
40 37
32 34 26
40
— — 56
40 59 51
65
. 54 75
106 60 51
82 64 96 76
101 127 112 88
103 93
126 75 150 141 133 115
100 150
154 120 180 166 138
202 160 218 211 203 172
236 187 255 243 230 210
378 300 365
370 350 312

Only the number of revolutions given under the respective

numbers can thus be obtained on each machine. These
speeds can only be proportionately reduced or increased
when absolutely necessary for the work in hand, by changing
the speed of the countershaft.
With . motordriven machines the conditions are much
more favourable. A rheostat can then be introduced for
 and Milling Practice. 165
variable speeds so that the number of revolutions of the
motor can be regulated within the limits of 1 : 2 and in
this manner the desired surface speed can actually be
imparted to the cutter.
Although the proper surface speed of the cutter is of
influence on the time required, when considering the output,
the rate of feed is of much more importance.
Granted that the construction of the machine is such as
enables it to execute what may be required of it, the
rate of feed depends on the following conditions :—
1. The quality, construction and type of cutter.
2. The depth of cut and width of surface to be
machined.
3. The resistance offered by the metal.
4. The degree of accuracy required in the workpiece.
The most important factors in this respect are: — the
quality of the cutter, the depth of cut, and the resistance
of the metal.

Fixed rules can no more be given for the rate of feed

than for the cutting speed. In this case practical experience
is everything. It is true that certain figures are given in
the foregoing tables which may serve as starting points but
it will have been noticed that differences of 100 °/o and
more are given. The best advice that can be given in this
connection is certainly that given by Reinecker when speaking
of " Speeds and Feeds ", viz :— " Start with a feed that is too
slow and then increase the feed as far as the cutter, the
machine and the workpiece will allow of it, not overlooking
the quality of the surface which is being machined."
The rate of feed possible on the milling machine will be
fully dealt with in the chapter treating of the construction
of the milling machine.
The thickness of the chip can be calculated by dividing the
feed per revolution of the cutter by the number of teeth of the
cutter. With a feed of x/4 inch per revolution of the cutter, (one
of the quickest possible feeds on the newest type of milling
166 Milling Machines
machine), and
a cutter with 25 teeth, a chip is obtained
25
having a thickness of — - = 0,01 inch for each tooth which,
in comparison with other cutting tools, as for instance the
lathe tool which nowadays works with a thickness of chip
up to */8 inch, is certainly very small. However, no quicker
feed average is adopted than 0,05 inch per revolution of
the cutter, whilst it is often much less, and in this case with
a cutter with 20 teeth the chip will have a thickness of

-^-
«u = 0,0025 inch.
It is only possible to comply with all demands with refer-
ence to cutting speed and rate of feed, when the cutting
speed can be regulated according to the metal to be cut,
and further when the feed can be regulated according to
circumstances entirely apart from the cutting speed so that
the proper speed is obtainable by the desired feed. With
the milling machine with cone drive, this is an impossibility
us will be clearly shown in the chapter dealing with con-
struction of milling machines. This is possible with a
machine which is specially constructed for a particular
purpose, since the workpiece and the cutter to be used are
taken into consideration in constructing the machine.
The following examples taken from actual practice will
serve as points of comparison for others in their own
work and will, at the same time clearly demonstrate that
the rate of feed and cutting speed cannot be laid down on
hard and fast lines nor can they always be so combined
as could be desired.
It should further be remembered that all these examples
are given to show, not how slowly but how quickly the
work can be performed and should consequently be regarded
in general as the maximum.

1. A cutter with inserted teeth, 4*/2 inch diameter,

cutting speed 40 feet per minute, takes a cut 3/32 inch to
1 •, inch deep from castings having a width of 81 4 inch, the
 and Milling Practice. 167

feed being . 252 inch per turn of cutter which is equivalent

to a table travel of 81/* inch per minute.
A surface, 81/* inch wide and 8!/2 inch long, is conse-
quently milled in 1 minute.

2. A composed cutter, with diameter varying from 5'

inches to 3 inches, rotates at a speed of 31 revolutions
per minute and with a feed of . 075 inch equivalent to
2.325 inches per minute, removes about 1js inch metal all
around. Metal, cast iron. Total width of surface H3/4 inch.
3. Two sets of composed milling cutters, the larger having
a diameter of 13*/2 inches and milling the sides, make 12.5
revolutions, the surface speed being 40 feet per minute, the
rate of feed . 10 inch per revolution of the cutter, equi-
valent to lx/4 inch per minute.

4. A shell mill with spiral teeth, 23/4 inch diameter,

takes a cut 23/4 inches wide and ^le inch deep from the top
and bottom of a workpiece 23/4 inches wide with a feed
of 3 inches per minute. Metal : cast iron.

5. A shell cutter with spiral teeth, 4*/2 inches diameter

and 6 inches face having a surface speed of 47 feet per
minute takes a cut of 3/32 inch from a piece 10 inches wide
with a feed of . 076 inch per turn of the cutter, equivalent
to 3 inches per minute. After this, the feed is reduced
for the finishing cut to . 036 inches per turn of the cutter,
removing .010 inch. Metal : cast iron.

6. A face cutter with inserted teeth, 8 inches diameter

takes a cut of 1js inch deep in cast iron at a feed of 1.025
inch per turn of cutter.

7. An end mill with spiral teeth, !5/s diameter, cuts a

rectangular slot of the same width l1^ inch deep with a
feed of 1 inch per minute; surface speed 36 feet per
minute; feed .012 inch per revolution of the cutter. Metal :
cast steel.
168 Milling Machines
8. A face cutter with inserted teeth, 8 inches in diameter
makes 19 revolutions per minute, equivalent to a surface
speed of 40 feet per minute, the feed being . 138 inch per
revolution of the cutter, equivalent to a table travel of
2.63 inches per minute, cuts away */g m°h metal. The
"surface of the casting is 57/s inches wide. Metal: cast iron.
9. A shell mill with cast iron body and inserted teeth,
4J/2 inches diameter, makes 34 revolutions per minute,
equivalent to a surface speed of 40 feet and, with a feed
of .168 inch per revolution of the cutter, equivalent to a
table travel of 53/* inches per minute, takes a cut in cast
iron of 3/32 inch deep and 61/* inch wide.

10. A face cutter of 41/* inches diameter, makes 51

revolutions per minute, which is 60 feet surface speed
per minute, feed . 252 inch per revolution of the cutter,
equivalent to nearly 13 inches per minute. Depth and
width of cut 1/at inch X 43/ic inches; metal cast iron.
11. Two cutters, working with their front teeth and
having a diameter of 41/* inches, make 34 revolutions per
minute, which is a surface speed of 40 feet per minute.
With a feed of .10 inch per revolution of the cutter,
equivalent to 3.4 inches per minute, each of them takes a
cut of 3/32 inch. Thickness of the workpiece 8 4 inch ;
metal cast iron.

12. A 6-fluted end mill cuts into solid cast iron bars
1 inch thick a slot of 8/4 inch, wide, surface speed 72 feet
per minute, feed .Oil inch per turn of cutter, equivalent
to 4 inches per minute.

13. 4 cutters on one arbor mill key ways, each V* incn

wide, in 4 steel shafts placed side by side. Diameter of
the cutters 2 V* inches ; no : of revolutions per minute 60 ;
surface speed 40 feet per minute ; feed . 075 inch per turn
of cutter, which is equal to a table travel of 41/* inches
per minute.
 and Milling Practice. 169
14. Slots of \\ inch width are milled in two pieces with
backed-off cutters mounted on the same arbor. The metal
is 40 carbon steel. Feed . 033 inch per minute equivalent
to a table travel of 1 inch per minute.

15. A face cutter having a diameter of 6 inches makes

26 revolutions per minute, equivalent to 40 feet surface
speed per minute, removing with a feed of . 20 inch per
turn of cutter, equivalent to 5.2 inches per minute, J/8 inch
metal. Width of casting 35/s ; metal cast iron.

16. A spiral cutter, diameter 3 inches, makes 56 revolu-

tions per minute, removing with a feed of . 05 inch per
turn of cutter, equivalent to 2.8 inches per minute, 3/64 inch
metal. Width of surface is 5 inches ; metal 90 carbon
tool steel.

17. Two cutters of 5 inches diameter, work on the front

faces at 32 revolutions per minute. With a feed . 05 inch
per revolutions of the cutter, equivalent to 1.6 inch table
travel per minute, each cutter removes about 1I& inch metal.
Width of surface 2 inches; metal cast steel.

18. A shell cutter of I1/* inch diameter makes 166 revo-

lutions per minute, equivalent to 60 feet surface speed per
minute and, with a feed of . 05 inch per revolution of the
cutter, equivalent to 8.3 inch per minute, takes a cut of
5/8 inch wide and removes Vie inch of stock; metal 40 carbon
drop-forged steel.

19. Two cutters on one arbor, the one an end cutter

of 4 inches diameter and the other a shell mill of 2 */* inch
diameter, make 112 revolutions per minute equivalent to
a surface speed of 65 feet per minute of the shell cutter,
and, with a feed of . 050 inch per revolution of the cutter,
equivalent to a table travel of 5.6 inch per minute, take a
cut of l7/8 inch wide removing V16 mcn of metal ; metal
40 carbon drop-forged steel.
170 Milling Machines

20. Two cutters on one spindle, 2*/a inches diameter,

having a surface speed of 38 inches per minute, spline two
shafts. Width of key way V* inch; metal 40 carbon steel.

21. A composed cutter, the greatest diameter of which is

3 J/2 inches, makes 37 revolutions per minute feed . 05
inch per turn of cutter, which is a table travel of 1.85 inch
per minute; the width of the surface milled is 61/* inches,
removes J/s inch metal all around; metal cast iron.
22. A gear cutter of 2 inches diameter works with a
surface speed of 80 feet per minute and a feed of . 10 inch
per turn of cutter, equivalent to a table travel of 15.4 inches
per minute. The cut is 5/W inch wide and 3/32 inch deep :
metal tool steel.

23. A composed formed cutter, milling partly on the

contour and partly with the front faces, with diameters of
71/*, 5*/2 and 3*/2 inches, makes 28 revolutions per minute
feed . 063 inch per revolution of cutter, equivalent to
a table travel of more than l7/s inches per minute. The
total width of the surface milled is 9 inches, the average
depth of cut V* mcn and the metal cast iron.
24. A . face cutter with inserted teeth has a diameter of
10x/2 inches and makes 17.5 revolutions per minute feed
. 300 inch per turn, equivalent to a table travel of 51/* inches
per minute. Total width of surface milled is 2 inches ; depth
of cut */s inch; metal cast iron.
25. A formed cutter mills cast iron racks 16 pitch in
one cut. Diameter of cutter 21/a inches, feed 8/4 inch per
minute. The teeth are °/io inch deep and one rack is finished
in 1 minute.

26. A cutter made of novo-steel works at a surface

speed of 80 feet per minute and a feed of 2 inches per minute.
The width of surface milled is I8/* inch, the depth of cut
V» inch— 8/4 inch and the metal cast iron.
 and Milling Practice. 171

27. A composed cutter, working- chiefly on the contour

but also with the front faces, has a largest diameter of 6
inches, makes 33 revolutions per minute, feed 51/* inches
per minute. Width of surface milled 8 inches, removal
J/s to 3/i6 inch stock ; metal cast iron.

28. A cutter, 2J/2 inches diameter, making 34 revo-

lutions per minute, feed . 108 inch per revolution of the
cutter, equivalent to 3s/4 inches per minute, takes a cut
from 1/s to 3/i6 inch deep and 23/4 inches wide. Metal
cast iron.

29. A cutter of novo-steel having a diameter of 2 inches,

makes 243 revolutions per minute, equivalent to a surface
speed of 130 feet per minute. The feed is .150 inch per
turn of cutter, equivalent to 36 inches per minute, and the
metal cast iron.

30. A cutter of novo-steel is undercutting T slots.

Diameter of cutter 1 inch by 1/-2 inch face. No. of revolu-
tions per minute 243, equivalent to a surface speed of 53
feet per minute. Feed . 050 inch per revolution of the
cutter, equivalent to 12 inches per minute.

31. A cutter, S1/^ inch diameter 3/s inch face, mills a

slot 1 inch deep in forged steel in one cut. No. of revolu-
tions 56, feed per revolution of cutter . 075 inch. A slot
of 41/* inches is thus milled per minute.

32. A shell cutter, 2l/a diameter, removes from casting

21/* inches wide ]/« to 3As inch metal. No. of revolutions
per minute 46, feed . 20 inch per revolution. A table
travel of 9.2 inches per minute is consequently obtained.

33. A shell cutter, 3 inches diameter, making 56 revo-

lutions per minute, feed . 050 inch per revolution, equiva-
lent to a table travel of 2.8 inches per minute, takes a cut
J/s inch deep from cast iron pieces 6B/s inches wide.
172 Milling Machines
34. A shell mill of 4 inch diameter makes 32 revolutions
per minute cutting a slot I13/i6 inch wide and x/2 inch deep
in crucible steel. Feed . 024 inch per revolution equivalent
to . 77 inch per minute.

35. An angle cutter mills the teeth of a spiral mill of

novo-steel with coarse pitched teeth. This spiral mill, is to
be provided with 12 teeth, . 275 inch deep and 3 4 inch
wide on top. The angle cutter on the arbor has a diameter
of 2*/2 inches 80° including angle and makes 53 revolutions
per minute ; the feed being . 042 inch per turn which is a
table travel of nearly 21/* inch per minute.

36. Two angle cutters side by side on the same arbor

are milling the teeth of cast steel racks, two teeth being
milled simultaneously. The cutters have a maximum
diameter of 4J/2 inches and a feed of . 075 inch per revo-
lution. The pitch is 7/s inch, depth of teeth 7/ie inch.

37. A shell cutter of Novo steel having a diameter of

3x/2 inch makes 90 revolutions per minute equivalent to a
surface speed of 90 feet and with 3 inches face takes a
cut varying from Vie to 3/32 inch, having a feed of 0.300
inch per revolution equivalent to 27 inches per minute.
The metal being milled is cast iron.

38. Two composed cutter of 53 4 maximum diameter,

milling square bars of 50 carbon steel make 20 revolutions
per minute equivalent to a surface speed of 30 feet, the
feed being 16/ie inch per minute. The width of the surface
milled is 9 inches with a depth of cut of ' 4 inch.

39. A shell mill cuts cast iron plates 12 inches wide.

The cutter, which has a diameter of 4 inches, makes 60
revolutions per minute with a feed of . 075 inch per revo-
lution which is a table travel of 41 -i inches per minute.
The depth of cut is ! s inch.
 and Milling Practice. 173

40. Subsequently, slots, having a total width of G1/^ inch

have to be milled in these plates. The cutters which have
a diameter of 4 inches make 60 revolutions per minute,
the feed being . 075 inch per revolution, making a table
travel of 4*/a inches per minute.

Table XX in which all the foregoing examples have

been set up, enables the reader to see at a glance the
results which can be obtained on the milling machine under
different conditions on diverse metals. Probably one or
other of these examples can be used for purpose of com-
parison, in which case the manner in which the work is
performed must not be lost sight of. The chapter dealing
with actual performed work on the milling machine will
treat of this point more again.
 Tat
"E,

•s
1)
Diameter
Kind of metal
of cutter
milled. in inches. Type of cutter.
d

4V.
1 Cast iron Shell cutter with inserted spiral te<
2 n n 3
2°/* Shell cutter
3 n i) Face cutter with inserted teeth
4 W )>
134V*
"9 Shell cutter
5 W W !6/8 » n
6 » » 8 Face mill with inserted teeth
7 Crucible steel Shell cutter
8 Cast iron 8
4Va Face mill with inserted teeth
9 n » Shell cutter with spiral teeth
10
11
„

n
„

n 4!/2
l'/4
24/.
End mill
Shell end mill
12 n n End mill
13 Steel Shell cutter
14 n 6 End cutters
15 Cast iron 6 2% Face mill with inserted teeth
16 Crucible steel A
I1/. Shell cutter
17 Cast steel 5 Shell end mill
18 „ „ Shell cutter
19 » » n n
20 n n » n
21 Cast iron Shell end mill
22 Steel
i2o V Shell cutter
23 Cast iron Formed cutter
7Ya,58/8,3B/8 End mill
24
25 —
M M

2</8
26
„ „
Composed cutter
r> n
57/8-37/8
Shell cutter
27 n n Shell cutter and face mill
28 n n 2 Shell cutter
29 r> »» 1
35/8
2'/8 End mill
30 » Shell cutter
31 Drop forged steel r

32 Cast iron 3'/8

3
2'/8 M

33 » » 3% »

34 Crucible steel » n
35 Novo-steel
36 Cast steel Angle cutter
w w

37 Cast iron 57/8

Shell cutter
38 Steel 37/8
w n

39 Cast iron 8V. n

40 n
n »»
 Surface Feed in Width
No. of Feed in Depth
ner in which the inches per af surface
evolutions speed
feet and in inches
turn of cut in milled in
cutter works. inches
7/
inches. 3/G
4
per min. cutter. inches.
per min. per min.
&/G 2J/4 8V*
39' 4V
4

3 circumference 34 23/4
9V.
r/+
*6

41 23' 7V !/
4
4

78/4
n
39' 4V 8/92
—
side surfaces 12.5 ,,
8V* — 8/3 •8
2 /4
circumference — — ",' 3
47' 3V •4
38 ,C4
32% !B/a2
57/8
side surface — — — 8
l3/8

v
13/
80
5'
7/6 16
circumference /Gl
4
1
53/4
39' 4V
side surface 19
circumference 34 39' 4V 33/8
8/64

35' 6"
v«
9/64 *7«g *'i *3/

side surface
64
51 39' 4V V8 8/82 4\/4
5'Vi
138/4 \'8

„ surfaces 34 86

v*
4
'/•*
circumference 335 3" t.
89'59'4V
1 l/
»•/.-, 8
„ 60 42' 2V V 3/6
31
8/82 41
B
4
111 3/82
26 39'65'40V" Vet 3/6
28/4
side surface '1/•
« Vs 17/
2'/32
64
circumference 83/4 5
56 43' 4"
3/6
4
side surfaces 32 42' 3 V 'A
5'/2 21/.
2 *
116 41/"
3/3
, circumferences
„ 112 !7/8 2
is^
1 V'2

„ ' 3" —
134 37'57 2V Vs
13/
646V4
, side surfaces 65' 0"
/2

, circumference 37
156 53' IV "/««
I3/*
V- 6
23/
64 61

V*
25/
28 39* 4V 3/6 64
> 9
4

5V* 63/

17.5
64
» 2
r/*
3/6 36 13/
4 4 64

, side surfaces — — —
S/
4
8
'
— 78' 9" 5Y« Ve
„ surface 48' 4"
— 2
v« 23/4
33/4
3/6 51/
4 8/688/6
33 4 4 64

„ circumference 22' 7V
13/
64 »/, 13,
„ „ 34 78' 9" 36 V*
243
7/6
4 48/8 —
„ '„ 52' 1" s
V21/*
» 243 '/•
*

12 63/i
125' 0"
5/6

„ side surface
4

56 30' 7V 23/4

„ circumference 46 54' 2"

%4 26//
el
9'/3-2
19'
V8
/64 l8/4

« w 56 53' 3" S/64

!7/8

„ „ 32 34' 5V
„ 56 28' 6 8V*"
43' "
B/64
'/8S

I 90
271
19
3
9V«
61/4 9

»• w
20 61' 10 V 4V2
1

» » 60 ' 9"
79'I IV* 12
„ 60 61 OV
29' 7"
—

/6t
y82
 PART II.

MILLING MACHINES.

CHAPTER VIII.

Construction of Milling Machines.

In the first part of the present work we discussed the

milling cutter; we now come to the milling machine itself.
Seeing that the object of this work is to afford a general
review of the milling machine, it goes without saying that
a not inconsiderable portion should be devoted to the dis-
cription of the milling machine itself and for this reason
this part of the work may be considered the principal con-
taining, and we are here reviewing one of the finest types
of machines employed in metal working.
Fruit of the modern development in the building of
machine tools, the milling machine may be regarded as a
minion, a tool to be constructed and reconstructed, which
attracts to itself the attention of the finest intellects of this
branch, in a word, a tool constructed first and foremost by
the leading firms in which manufacture has been brought
to the highest point of development.
In the same way that the milling cutter was developed
in a comparatively short space of time in a manner that no
other cutting tool has been developed, so also the milling
machine, after once having taken its place in the general
line of machine construction, has now been so universally
 Milling Machines and Milling Practice. 177

Adopted that its use far exceeds that of the greater number
of other machine-tools and it is now placed on the market
in such a variety of constructions and applications, that an
adequate description of the existing types of milling machines
alone demands a far greater volume than would be required
for a number of other types of machine tools together.
Does the milling machine owe its development to the
milling cutter, or vice-versa ? They are indissolably associated,
the one with the other, still, one thing is certain, i. e. that
milling machines in their present-day forms and constructions
are a natural sequence of the need which existed for machines
to carry out the work which could be executed with the
milling cutter.
Although in the first part of the present work when
considering milling cutters in general, we may, perhaps,
having gone somewhat fully into the question of the
development of the milling cutter, it would, however, carry
us altogether too far to attempt to write the true history
of the milling machine, however interesting such a theme
might be. We shall thus confine ourselves to a general
review of the milling machine as at present constructed,
taking from time to time a glance at the infancy of this
machine in order to afford the reader some idea of the
difference between " then " and " now " and by so doing to
demonstrate what a really valuable tool the genius of the
present day has given us in the milling machine.
In order to afford anything like a review of this subject,
it will be necessary to divide milling machines into certain
main groups.
This, however, entails certain difficulties since the question
as to whether to divide them according to their construction,
according to the manner in which they perform their work,
or according to the work which can be carried out on the
machine, is one which it is not at all easy to answer, since
many of the machines, although widely different in other
respects, frequently have at least two of the foregoing
factors in common.
Seeing that the construction and manner of working are
12
178 Milling Machines
the two factors most closely connected, we will, divide
milling machines into three main groups, viz:
I. Horizontal milling machines.
II. Vertical milling machines.
III. Milling machines which are a combination of types
I and II,
and thus, passing over the special types of milling machines,
we can take the general types of each of the principal
groups seriatim and afterwards treat of the special machines
of each type separately.

Fig. 196.
Universal milling machine of the year 18fi5.

Grouping the machines in the manner indicated above,

the chief varieties can be subdivided as follows :
Column and knee type milling machines.
Slab
Circular „ „
Thread cutting „
Gear
Vertical milling
Profile
Two spindle „ „
Key seat
Special
Combined
 and -Milling Practice. 179
As regards the various forms, the column and knee milling
machine, which is the fundamental type, has preserved its
original form to a marked degree as is clearly shown in
figs. 196 and 197, there being a difference of a good 40
years in the construction of the two machines. As regards
the vertical milling machine, its form bears a strong resem-
blance to that of the slotting machine, whilst the slab miller
greatly resembles the planing machine; the thread cutting
machine is not unlike the machine it supercedes, viz: the

Fig. 197.
Universal milling machine of the year 1909.

lathe, whilst the newer types of milling machines, such as

gear bobbin g- and key seat milling machines, etc., have all
more or less their own special forms.

The column and knee type milling machine.

Fig. 196, illustrates the universal milling machine first
manufactured by the then firm of J. R. Brown, patent for
which was granted on 21st February 1865, whilst the opposite
illustration, fig. 197, depicts a universal milling machine of
180 Milling Machines
the very latest construction turned out by the present firm
of Brown & Sharpe.
Notwithstanding the great difference in the construction
of these two machines, the fundamental principles of the
original constructor as well as the general appearance of
the machine have been preserved up to this latest type.
The machine has been improved upon and altered, but has
still retained its characteristics.

Fig. 198. Universal milling machine with cone drive.

 and Milling Practice. 181

(a). THE MAIN SPINDLE.

In the universal milling machine, a general illustration
of which is given in fig. 198, the spindle, its housing
and the method in which the spindle drive is effected are
some of the principal points of its construction.
The main spindle has a hole through its entire length,
the front end being provided with a conical bore to take
arbors, cutters, drills etc. The spindle nose projecting beyond

.....j

Fig. 199—200. Morse-taper.

the housing is threaded to receive large cutters, or a universal

chuck. The thread on the spindle nose is the same as the
thread on the spindle of the universal dividing head so as
to permit of the use of the same universal chuck. In order
to prevent any possible injury, the thread is protected by
a cap.
The greater number of manufacturers have accepted for
the conical bore the standard fixed upon by Brown and
Sharpe for the taper. A few manufacturers on the continent,
such as Loewe, have their own special standard tapers.
The Morse-taper, which is in general use for twist drills, is
182 Milling Machines
seldom used for milling machines owing to its being too
taper. The dimensions of the various tapers mostly used
are given herewith.
As regards the dimensions of the Morse-taper, these are
very divergent, there being no generally accepted dimensions.
Reinecker, a German maker of milling machines, proposed
in the " Verein Deutscher Maschinen-Ingenieure " to sub-
stitute for the Morse-taper a metric cone of the dimensions
given in table XXII. However, nothing definite came 13Aofu it.
Table XXI. 6/
8

Morse-taper. N°. 1—6. 1R/

5/l« 82
Taper
No. of taper. a c+ d / e g
28/8 per foot.
29/16 2*/8 .356 .475 .600
•n

1 Inches
4'A .556 .700
2 - 3Vie 3»/16 .602
3 w
38/4
48/4 .759 .938 .602
4 » 58/4 .997 1.231 .623
5 6
6B/6 1.748 .630
6 » 8 2.077 2.494 .626

V<
Table XXII.
1.446"
Metric-taper. N°. 1 — 6.
No. of taper. 1 2 3 * 5 6

a mM. 64 104 124 144 165

b „ 4 844 4 4 4 5
c •f 52 70 106 12416 142
n 10 18
d „ 8 18 12
88 32
14
e w 12 24 40 50
» 9 14 26 33 42
19
g 5 6.5 8 14 17
*
11
Degree of
5
taper per 100 mM.
 183
and Milling Practice.

Table XXIII.
Loewe-taper. N°. 3—12.
No. of
3 5 8 9 11
taper. 3a 12
5a 6*
a mM. 88
94 127.5 117 122
171.5 173.5 217 259.5
b „ 4 5 5 6 6 8 8 9
c „ 70 77 105 93.5 94 136.5 140 178 216
10
22 30
<* „ 14 12 17.5 17.5 27 25.5 33.5
e „ 10.63 14.27 19.81 18.49 23.25 32.84 31.65 41.63 50.8
/ , 10.73
5.6
10.34 14.34 15.22 18.59 26.26 25.03 32.27 41.27
9 14.5 15.5
g „ 5.1 7.6 7.6 12 12

Fig. 201.
Loewe-taper.

Table XXIV.
Loewe-taper. letters f—p to fig. 201.

Cone letter. f * k i i m n P

a mM. 99 115 135 152 186 201 218 251

b » 5 5 5 6 8 8 9
C » 90 105 125 140
170 185 200 230
11
10
d w 4 5 5 6 8 8 9
e 20 24 28 31.5 39.9 44 48
/
n

15.5 18.75 21.75 , 25.088 32.08 34.75

60
»
38 48.5
 184 Milling Machines

*/
4

8/
8

lh
'/
"
Fig. 202—206. B. and S. taper. 6/
88/
16
Table XXV. 6/32 8/
8

8/l«
Brown and Sharpe-tapers. N°. 1 — 18.3/8/16 »/
4 M
1/ 7/82
No. of D P i« H K L w T
7/
n/8
8 t
taper. 7/ .

1 .20 IV" I11/.*

1B/16
n/16
.135
8

7/l«
tapered

.500
1*/16 15/16
2 .25 I8/* r/a l23/82
.166 '/!«
1B/8
.500
l31/32 2 B/ie
3 .312 2V- .197 SB/8
.500
6/ie
!18/64 1B/1 8
3 .312 2
I1/* l*/8
% .1976
V .500
I11/!*
1B.228 n/8
«
4 .35 2%
!8/4
!7/8
219/64
/16
.500
5 .45 .260 9/l6 .500
2V.
38/3 .500
7/18
6 .50 3U/64 7/t e
.291
*v».
ai/
2a9/32 «3
6 .50 31* 3l/8
.291 .500
8/
4
4J/8 3a9/82 ai/« 7/16
7 .60 3 .322 « 7/l6
.500
V-
8l/
88
7 .60 4
329,64
l!/8 .500
39/l6 3n/ie 3'/8 .322
8 .75 4*/8
1 .353 .500
427/82 16/16
9 .90 4 5*/8 .385 % .500
5l7/88 1B/I6 i7/8
10 518/16
.447 9/.5161
ie
1.0446 5 16
5ll/ *7/
1
16/16 8S
10 1.0446 6/8%2
67 .447 9%/116
.1561
6U/82 le/16
10 1.0446 6*9/82
151
6 .500
6V-
I1/*
67/8
6lB/i6 .447
11 1.25 7 'A .447 .500
12 1.50 7*/8 79/16 .510 V.
%
.500
13 2.
1.75 7l/8
8l/4 •
7*4 8»/8
1V«
1U/16
I11/" .510 .500
87/8 817/82
14 8V32 !7/8 .572 .500
15 2.25 8", 9»/8
.500
.572
9*4
16 2.50 97/8
9 .635 % .500
17 2.75 984 — — .500
i6v«
— — —

18 3.00 108/8 — — — — — .500

v.
 and Milling Practice. 185
The hole through the main spindle serves for drawing

Fig. 207. End mill with taper shank.

and pushing in and out the milling arbor which is fixed in

the spindle. The simplest way of mounting is that in
which the cutter or arbor is just placed in the conical

Fig. 208. Counterweight.

bore without further fixing. Fig. 207 shows an end mill

of this description.
The cutter or arbor is thrust out by a rod, the end of

Fig. 209. Milling arbor with taper shank.

which is provided with a ball for the purpose of adding

weight to the rod. (Fig. 208). Other makers provide
either the end of the cutter or of the arbor with an

Fig. 210. Headstock main spindle.

internal thread and the arbor is drawn in the conical bore

by means of a bolt through the spindle. (Fig. 210).
186 Milling Machines
It is clear that back thrust is no longer possible as this
would injure the thread and render it useless. The same
bolt which is used to draw the arbor in the bore, is, in a
very simple manner, employed to push it out (fig. 210).
By means of a crank handle on the square the bolt b is
screwed into the arbor. The rod is provided with a collar b.
If screwing the rod into the arbor, the collar will have
its end thrust against the edge in the end of the main
spindle and consequently draw the arbor into the conical
bore and thus fit it tightly in the spindle. At the end of the

Fig. 211. Headstock main spindle and milling arbor.

spindle is a stop screwed in it. If now the bolt be turned

in an opposite direction, the collar will thrust against the
stop in question, thus forcing the cutter or arbor out of
the bore. Another means of preventing the taper shank
from rotating in the bore is to provide the cutter or the
arbor with two flats, the spindle nose being recessed
correspondingly. (Fig. 211).
Some makers employ the first-named device as illustrated
in fig. 210 exclusively, but a combination of the two systems
shown in figs. 210 and 211 is also met with.
As another means to ensure the cutter or the arbor having
a tight fit in the bore, the difference in pitch between two
threads, the so-called " differential thread" is made use of.
 and Milling Practice. 187

This manner of fixing is much in use on milling machines

the spindle of which has no hole. A differential nut,
(fig. 213), fits on the threaded front end of the spindle
which is, for example, */T inch pitch.
The nut, however, has still a smaller bore provided with a
finer thread, for instance, 1 1 threads per inch, the same thread
being also on the cutter. Each turn of the nut causes it
to travel forward 1/j inch on the spindle, but only !/ii mcn
on the cutter, the cutter thus being driven into the bore

Fig. 212. Milling arbors of different forms.

the difference between l\i inch — J/n inch=4/T7 inch per

turn. Care must be taken when screwing up the nut not
to drive the cutter fast into the bore at once, as otherwise,
the cutter will be firmly secured directly the nut has
travelled over one or two threads, which is unsufficient.
To remove the cutter, all that is necessary is to turn the
nut back which releases the cutter from the bore.
The differential screw is based upon the same principle.
(Fig. 214). The end of the screw fits in the cutter, or arbor
which, for instance, is provided with a 3/4 inch thread with
10 threads per inch. At the other end of the rod and at
the rear of the hole in the spindle is a finer thread, for in-
188 Milling Machines
stance, 12 threads per inch. The cutter is now thrust into the
bore by the differ-
ence of Vio inch -
V" each
at inch turn ='/.o ofinch
the
rod as just described
above. As the dif-
ferential thread is
- 213-with differential nut.
Fixing the milling arbor . . .
absolutely reliable,
there is no fear of this means of fixing working loose.

Fig. 214. Fixing the milling arbor with differential screw.

(b) THE HOUSING OF THE MAIN SPINDLE.

The spindle is carried in bronze, babbit or cast iron bearings.
In order to ensure accurate work, it is a matter of primary
importance that the spindle should fit its bearings perfectly.

Fig. 215. Sectional view of Le Blond headstock.

 and Milling Practice. 189

Fig. 216. Le Blond main spindle.

The form of the headstock with the bridge for the over-
hanging arm on top prevents the use of bearings in halves.
It is, nevertheless, imperative that the spindle can be housed
in the bearings with
perfect accuracy whilst,
at the same time,
re-adjustment for
wear must also be
possible. The front
journal is almost uni-
versally conical, the
Fig. 217. Le Blond front box. rear one being cyl-
indrical, whilst the
method of re-adjustment is very divergent.
Fig. 215 gives a sectional view of the headstock of the
Le Blond milling machine. Fig. 216, shows the spindle
separately, figs. 217 and 218 the front and rear boxes. The
front journal is conical and hardened.
For this reason, the journal consist of
a hardened steel bush pressed on the
spindle. (See figs. 215 and 216). The
front journal runs in a cast iron box.
(Fig. 217).
The two surfaces which thus come
in contact with one another and run Fig. 218.
Le Blond rear box.
one on the other are hardened steel and
cast iron. As wear or roughening by a very hard spindle
is impossible by efficient lubrication, the internal surface of
190 Milling Machines
 191
and Milling Practice.
the cast iron box will quickly become perfectly smooth so
that the ultimate wear will be almost imperceptible. The
rear journal of the spindle is cylindrical and carried in a box
with cylindrical bore and tapered on the outside. (Fig. 218).
This box is split, and can be drawn in the column to take
up the wear centrally. The end thrust is taken up by one
hardened steel and one babbit collar. (Fig. 217). An oil
slot is milled in both boxes which is filled with felt which
absorbes and filters the superfluous oil, thus providing
efficient lubrication for the spindle in its bearings.
In some makes the adjustment is effected by the spindle
and the front box
not being adjust-
able whilst in
other construc-
tions on the other
hand, the wear is
taken up by the
adjustable split
box. The first
named is the prin-
ciple adopted in
the construction
shown in fig. 215.
Fig. 220.
To adjust the Sectional view main spindle.
spindle in the
front bearing, the nut at the rear of the front journal, is tight-
ened, whilst for the rear bearing the nut on the box is tightened.
The nut on the spindle, (fig. 216), draws it towards its taper
bearing, enlarging the space between it and the gear wheel and
taking the end thrust against the box. The nut on the rear
box draws it into the column compressing it on the journal.
Fig. 219 shows a totally different construction. Both
bearings are conical. The spindle is adjustable for the
front bearing, the box for the rear bearing. Both journals
of the spindle are tapered in the same direction. The front
box A, is fixed in -the column by the nut B on the mside.
The cap A' serves to protect the bearing from dust and dirt.
 192 Milling Machines
The spindle is enclosed in the front bearing in a transverse
direction. On the front, the raised edge of the spindle thrust
against the front
of the box, on
the back-side, the
hub of the gear
wheel M thrust
against the box
A. The nut at
the back of the
Fig. 221.
box also acts as a
Headstock main spindle of fig. 220.
dust cap. Should
it be desired to adjust the spindle in the front bearing, the
nut E should be tightened which will cause the spindle to
be drawn toward the
conical bore, since the
cone pulley with the gear
wheel M is placed between
this nut and the front box.
The rear box, and this is
the principal point in this
form of construction, is
thus entirely independent Fig. 222.
Front box of main spindle of fig. 220.
of the spindle and can
be adjusted by .turning the nutcollar I forward or back-
ward, which causes the box to be moved forward toward
the tapered journal of the
spindle. Both bearings have
ring oiling, an oil-pocket being
provided for each in the
column.
In fig. 220 the front box
is tapered inside as well as
Fis- 223. outside. In order to adjust
Rear box of main spindle of fig. 220.
the spindle, the screw B which
by means of a brass shoe locks the nut A firmly against the
thread of the spindle is loosened. After being loosened, the
nut A can be tightened, drawing the spindle in the conical
 and Milling Practice. 193

bore. This spindle is also self-oiling by means of felt.

The construction of the rear box is as shown in fig. 215.
Fig. 221 illustrates the spindle. The nose is threaded to
receive a chuck. F is a hardened steel washer behind
collar H on spindle ; the threaded dust-cap is placed behind
the edge H of the spindle. The front box B is illustrated
in fig. 222.
This solid bronze box is tapered in and outside and
tightened by nut C. A is the dust-cap of the bearing.

Fig. 224. Sectional view main spindle Cincinnati milling machine.

Fig. 223 illustrates the rear box.

Figure 224 shows another construction of the main spindle.
In this case the spindle is carried in a conical babbit lined
box. The spindle is provided at D with a notched key-
way ; the face gear F is mounted on the spindle, together
with the ring H which is attached thereto, by means of
the notched feather-key C which meshes the notches of the
keyway. In order to adjust the spindle, the nut G is turned
against the face gear F. This locknut is placed on the
extended portion of the front box and serves to thrust the
13
194 Milling Machines
face gear backward and with it the spindle in the conical
bore. If the spindle has been repeatedly adjusted, it is pos-
sible that the space between the front box and the face gear
has become too great. In order to remedy this, the lock
screw B with feather key C is loosened by means of the
wrench A; the locknut G is turned back to its original
position ; the cone pulley and face gear can be drawn forward
by hand against the nut G, after which the spindle can be
again properly adjusted in the bearing, by means of the

Fig. 225. Sectional view main spindle Cincinnati milling machine.

nut G, the feather key C being first properly fixed. The

exceptional length of the front bearing should be specially
noted. The rear box is of the split type, tapered exter-
nally with a cylindrical bore; the spindle oiling with felt.
This construction of the Cincinnate millers, was employed
up to 1904, when it was discontinued, its place being taken
by the construction shown in fig. 225. The in and outside
tapered babbited spindle box at front have remained, as als<>
the construction of the rear box, but the manner of adjust-
ment of the front ' bearing has been changed and now
 195
and Milling Practice.

Fig. 226.
Main spindle Cincinnati milling machine.

corresponds more closely with the constructions which have

already been described.
The spindle is threaded behind the front journal (figs.

Fig. 227. Fig. 228.

Rear box Cincinnati milling machine. Front box Cincinnati milling machine.

225 and 226), and a lock nut is tightened against the rear
end of the front box, thus drawing the spindle in the bearing.
A totally different construction of the front box is shown
in fig. 229. The spindle is car-
ried in a solid, bronze box with
conical bore. The edge of the
spindle is covered by a cap at-
tached to the column by ad-
justable screws; on both sides of
the edge is a hardened steel
washer, whilst between the box
and the steel washer next to it,
that is the surface which has Fig. 229.
Front box Garvin milling machine.
to take up the thrust and is con-
sequently liable to wear, is a- babbitt ring.
196 Milling Machines
c. THE DRIVE.

Owing to the fact that only light work was carried out
on the milling machine on account of the then undeveloped
state of the science of milling, the milling machine was
formerly only direct driven by the cone pulley on the spindle
and, consequently, the number of speeds
which could be obtained was limited
by the number of steps on the cone
pulley, (fig. 230). When, however, at
a later period, work of a heavier char-
acter was performed on the milling
Fig. 230.
machine, it was provided with back
Plain cone drive. gear, (fig. 231), by means of which,
with a certain number of revolutions
of the cutter, the speed of the cone pulley was from 8 to
9 times faster, the belt thus being able to transmit con-
siderably more power.
With the increased use of high speed steel and the greater
demands as regards capacity which were made upon the
milling machine, the power of the belt proved a serious
obstacle. To surmount this dif-
ficulty, two things were possible,
viz: — (1) to increase the width
of the belt, (2) to raise the
ratio speed of the belt to that
of the cutter, in other words,
to increase the driving belt
speed. In either case, how-
Fig. 231.
ever, fresh difficulties were en- Cone drive with back gear.
countered.
1st. If the width of the belt were increased, this would
have to be done at the expense of the number of steps
on the cone, i. e. the number of speed variations, and this
could not be dispensed with, 2nd. If the ratio of back
gear were increased, an exact geometric ratio of speed was
impossible. By combining the two, the advantages of both
were obtained with none of the disadvantages. The number
 and Milling Practice. 197

of steps of the cone pulley was reduced from 4 or 5 to 3,

whilst double back gear, (fig. 232), was introduced, the first
with a smaller, the second with a greater ratio, for instance
3. 6 : 1 and 13. 1 : 1. The ,~
result was a considerable 5~ /-*— ~* »»'•""•""'• i | -
increase in the width of t
belt and an increased
belt speed whilst a cor-
rect geometric ratio was
also rendered possible.
Moreover, a double fric-
tion countershaft took
the place of the ordinary
fast and loose pulleys Fig. 232.
Cone drive with double back gear.
which had previously
been employed, so that the countershaft could run at two
speeds and in this manner with only a three-step cone
pulley 2X3X3 = 18 spindle speeds were obtained. It
goes without saying that this kind of gearing is only
applied to the heavier types.
An additional improvement was also introduced, in that
the connection between the spindle and the cone pulley was

Fig. 233. IL4-

Sectional view of double back gear shaft.

no longer obtained by means of a pin M, (see fig. 224), but by

a friction actuated by a lever placed in front of the machine..
The back gear, figs. 232 and 234, can be disengaged
eccentrically by the lever on the right hand side. (figs. 233
and 234). It consists of a double set of gear wheels, two
198 Milling Machines
wheels of different diameter are fixed to the cone pulley, and
two wheels, also of different diameter, are carried by the back-
gear shaft. Both these wheels are disengaged whenever the
lever in fig. 232 is in the vertical position. This lever moves
the sleeve F, (fig. 233), with key E. The two gear wheels A
and B are recessed whilst each of them has a separate friction
ring C. The friction rings are split and in the opening is a
key D which, on being moved upwards, opens the ring C
and engages it either with the wheel A or with the wheel B.

Fig. 234. Coue drive with double gearing in front.

The keys DD rest on the key E which is sloped to either

side. If the friction lever be drawn to the left, the right
hand key is raised, the large wheel A being engaged ; if
the lever be drawn to the right, the left-hand key is raised,
the small wheel B being thrown in.
The most recent improvement in this construction is shown
in fig. 234 which shows the double gear no longer at the
back of the machine, but at the front and consequently in
easier reach of the operator.
Although this construction cannot yet be said to belong
to past history, it is still decidedly out of date, or, should
this definition be deemed too strong, it has been replaced
by entirely new and modern constructions.
 and Milling Practice. 199
Of late years the milling machine has made rapid progress,
so rapid in fact, that certain manufacturers have simply
passed over the newer constructions described above and
now arrange the spindle drive as illustrated in fig. 235.
With the cone pulley drive, the belt cannot be stretched
as tightly on the pulley as one could wish. It must always
be possible for the opera-
tor to shift the belt from
one step to the other.
Moreover, the width of
the belt is rather limited.
In the machine illustrated
in fig-. 235, the cone
pulley has disappeared
entirely and the drive is
effected by one pulley
without the necessity of
changing the belt. The
number of spindle speeds
is obtained by a set of
gear wheels enclosed in
the column. Fig. 236
shows those gears with
the cover removed and
thus makes their position Fig. 235. Single pulley drive.
quite clear.
A pulley of large diameter and of such width as is
considered desirable is mounted on a shaft at the back of
the machine. On this shaft, which runs inside the column,
is placed a gear wheel which can be meshed with any one
of the six gears of the cone by means of a handle. In this
manner six spindle speeds can be obtained and, seeing that
the machine is also provided with double back gear, eighteen
spindle speeds can be obtained from one speed of the driving
pulley. The upper handle on the column in fig. 237 either
engages or disengages the spindle for direct drive or drive
by means of back gear, whilst the lower handle gears up for
either first or second back gear. By means of a hand wheel
200 Milling Machines
placed at the back of the machine, the spindle can be turned
by hand either to mesh the gear wheels or to turn the spindle

Fig. 286. Gear mechanism of single pulley drive-.

as desired for the adjustment of the cutter. This construction

is eminently adapted for direct electromotor drive. (Fig. 237).
A fuller description of this single pulley drive mechanism
is given on pages 232 to 250.
 201
and Milling Practice,

(d). FEEDS.
In the case of the column and knee type machine the cutter
rotates in a fixed position whilst the workpiece, which is
fixed on the table, is fed along the cutter. This movement
must be vertical and in the horizontal plane in transverse

Fig. 237. Single pulley drive machine direct driven by electromotor.

and longitudinal direction to the main spindle. It must,

therefore, be possible to impart three different motions to
the workpiece, whilst by making the table swivel in
the horizontal plane, every angle varying from transverse
to longitudinal to the main spindle, is obtainable by setting
the table at a certain angle to the main spindle.
The construction of the feed mechanism is of just as much
202 Milling Machines

importance as the construction of the main spindle and its drive

and forms together with the latter and the universal dividing
head, the principal parts of the horizontal milling machine.
Originally the column, (see fig. 196), was a box-formed
casting, with flanged base so as to obtain sufficient stiffness.
( )n the front side is a planed surface to which a knee is
attached. On top this knee is planed and on this the saddle

Type 1862. Type 1881. Type 1897.

Fig. 238-2 H. Type 1899.

1908.
Fig. 242. Different forms of knee.

bearing the table fits with a taper gib whilst on top of the
saddle, square on the knee, it affords guidance to the table.
The saddle of the universal milling machine consists of two
parts which swivel in a horizontal plane one on the other
and by turning the table and upper part of the saddle the
table can be shifted from the square and set at any angle.
If the workpiece be moved vertically, then all the above-
mentioned parts will be moved; if it be moved parallel to
the main spindle the position of the knee remains unchanged,
 and Milling Practice. 203

the saddle moving with the table ; if which is frequently the case,
the workpiece be
moved square to
the main spindle
or at an angle to
it, then only the \
table is moved.
It is evident
that in order to
obtain a rigid
smooth cut, the
knee must be of
ample strength
to resist the strain
exercised on the
workpiece and
also that the con-
nection to the
column, which is
only of a tem- Fig. 243. Sectional view of headstock and knee.
porary nature,
must be so as to make it practically one piece.
In proportion as the
ICh|p» - work to be performed on
the milling machine is
heavier, the -knee must
be more rigid. Figs.
238—242 illustrate five
different forms of knee
showing the constructions
of one maker fram 1862 to 1908.
The knee is moved vertically along
the column by means of a telescopic
screw g, turning in a bearing of the
Fig. 244. knee, (fig. 243), and which runs in a
Knee section.
long nut fastened in an extension on
the base. Originally the screw spindle was fastened on
the knee, a thread being cut in a handwheel bearing
204 Milling Machines
in the extension piece on the base, so that when the
handwheel was turned, the screw g and with it the knee
was moved up and down. It was then necessary to have
a hole under the base to receive the screw when the knee
was at its lowest
position. The work-
man was then oblig-
ed to bend down on
the base in moving
the knee and thus
lost sight of the
work. For this rea-
son the handwheel
was replaced by a
nut fastened in the
extension piece on
the base, the spindle
being moved by
means of a hand-
wheel mounted on
a spindle which im-
parted motion to the
screw g by means
of two bevel gears
or a worm and
wormwheel (fig.
244). This hand-
wheel is placed on
the knee in easy
reach of the operator
so that he can de-
Fig. 245. vote his attention
Sectional view of telescopic screw. to the work. The
sectional drawing, (fig. 243), shows one of the bevel gears,
the handwheel, which is at one side, not being visible.
Fig. 244 shows how the movement from the handwheel
to the screw by means of worm and wormwheel is trans-
mitted. This illustration also shows the telescopic screw, a
 and Milling Practice. 205

sectional drawing of which is given in fig. 245. This con-

struction does away with the necessity of making a hole in
the ground under the base.
The bevel gear on the vertical feed screw which has to
take up the pressure of the knee, is provided with a ball
thrust bearing so as to ensure the least possible friction.
Fig. 246, shows one of the latest constructions of the
Garvin Machine Co. In this case the screw is once again
made fast, being fastened not to the knee but to the base ;
the nut attached to the knee
is moved by a hand-wheel
and bevel gears which move
the knee vertically. A ball
thrust bearing is placed just
were the knee bears on
the nut.
When the knee has been
brought to the requisite
position, it is connected to
the column by means of a
steel taper gib, fast-
ened by clamping
bolts or levers, which
fills up the space
between the guides
F. 246 of the knee and those
Telescopic screw. of the Column. Fig.
247 illustrates a very
simple and efficient clamping device. By giving the clamping
levers half a turn, the knee is firmly secured to the column.
The dimensions of plain and universal milling machines
have been considerably increased of late years, the weight
of the workpieces which are handled on the machine and
which the knee consequently has to bear being also increased.
The greater part of the weight has to be borne by the
telescopic screw, for which reason this has latterly been
made much heavier and more rigid.
In order to give the knee sufficient strength to resist
206 Milling Machines

collapsing strains and to efford proper support to the work-

piece, some makers have of late built a knee support on
the base which is bolted to the knee, thus obtaining a box
form, the upper surface of which is formed by the top of
the knee. (fig. 248). Any danger of an undue top weight
and consequent bending of the knee or variation from the
dead level is thus effectually prevented.
This construction has not facilitated the handling of the
machine, though in certain cases where the work is excep-
tionally heavy, it may be necessary.

Originally the table was made to be moved automatically

Fig. 247.
Clamping device of knee.

square to the main spindle. Fig. 249 shows one of the first
constructions of feed mechanism. The cone pulley 1, which
is driven by a belt from a counter pulley mounted on the
main spindle, drives the telescopic shaft H, which is provided
on either side with a universal joint and which can
follow the table motion in a vertical direction. It drives
the worm, which meshes the worm-wheel 3 mounted on
the table feed screw T which moves the table. Should it
be desired to move the table automatically in an opposite
direction, the belt driving the cone pulley 1 is crossed.
Between this construction and what nowadays is demanded
and realized in this respect, lies a great distance which the
 and Milling Practice. 207

milling machine has rapidly traversed in the course of but

a few years. The milling machine of to-day is provided
with:
1. Automatic
vertical feed in
either direction.
2. Automatic
longitudinal table
feed in both di-
rections.
3. Automatic
cross feed in both
directions.
4. The rever-
sal of all feeds
takes place
in-
dependently of
the drive, which
continues unin-
ter uptedly inone Fi* 2i8' Knee suPP°rt
direction.
5. All feeds are driven from a common shaft.
6. All feeds can be automatically disengaged in either
direction.
7. The feed drive is positive, in other words, without
belts, whilst there is a fixed ratio between the spindle
speeds and the feed shaft by means of gearing.
8. The number of feed changes with the same spindle

Fig. 249. Plain table feed.

208 Milling Machines
speed, originally three, has been increased to 12 or 20, all
of which are reversible whilst the machine is running by
a simple movement of a lever.

Fig. 250.
Chain drive
mechanism.

9. All feeds can be manipulated from where the operator

is standing, i. e. in front of the machine.
By some makers the feed shaft is driven by gear wheels,
by others by means of a chain and sprocket wheel (fig. 250),
by others again by means of a shaft driven by bevel gears,
 209
and Milling Practice.

(fig. 251); in each case, however, there is a fixed ratio

between the speed of both shafts.
A gear box is placed between the feed shaft and that
which further transmits the movement and by shifting
levers, different gear wheels can be meshed in, each of which
causes a different ratio between the driving gear and the
one driven, and by this the shaft behind the gear box is
caused to rotate either faster or slower, the feed being
dependent on the speed
of the last named shaft.
Certain manufactu-
rers, as, for instance,
the Kempsmith Mfg.
Co. (figs. 252 and 253),
and Brown & Sharpe,
(fig. 254), unite all these
changes of speed in
one box ; others, on
the contrary, such as
the Cincinnati Milling
Co. divide them over
two boxes, (figs. 251
and 255).
The gear box of
the Kempsmith mill-
ing machine is pro-
vided with an index Fig. 251. Upper feed drive of the Cincinnati
milling machine.
plate, which is clearly
visible in the illustration, (fig. 252). The feed changes are
effected by means of three levers, one on either side of
the box, and one on the top. The lever on the top is
turned either to the right or to the left, i. e. to H or G.
The lever on the left-hand side can be set in four positions
viz:— A. B. C. and D.
The lever to the right can be placed in three positions;
the middle one to disengage the feed, the upper and lower,
E and F, for meshing different gears; by this means
2X4X2=16 different rates of feed are obtained 14for each
210 Milling Machines

spindle speed varying from 0.004" to 0.15" feed per revolu-

tion of the spindle.
With the upper lever, (fig. 252), turned to G, and the
right-hand lever in E, 0.004, 0.005, 0.006 and 0.008" feeds
are obtainable when the left-hand lever is moved from A
to D. If the right-hand lever be brought over to F, 0.01,
0.013, 0.017 and 0.022" feeds are obtained by shifting- the

Fig. 252. Ki-injisinith feed gear box.

left-hand lever again from A to D. If the upper lever be

brought over to H and the righthand lever again placed
in E, then 0.027, 0.037, 0.047 and 0.06" feeds are obtained
consecutively with the left-hand lever and 0.074, 0.094,
0.118 and 0.15" feeds consecutively with the right-hand
lever in F.
In the larger size machines the difference between the
finest and coarsest feeds is somewhat greater, varying
 211
and Milling Practice.

Fig. 253. Open feed gear box of Kempsmith milling machine.

from 0.005" to 0.175" per revolution of the spindle.

Fig. 253 shows the open
feed gear box of the Kemp-
smith milling machine
whereas fig. 256 gives a
sectional view in which all

Fig. 254. Fig. 255. Lower feed drive with feed gear box
Brown and Sharpe feed gear box. of the Cincinnati milling machine.
212 .Milling Machines
the gears are shown as z/they were lying in one plane, which,
however is not actually the case. A is the sprocket wheel
driven from the spindle and mounted on the shaft B so that
its speed is always in relative ratio to that of the main spindle.
A double clutch C engages by means of D either on the
left-hand side the
gear wheel E or on
the right-hand side
the pinion F so that
two speeds are im-
parted to the shaft G
viz: — a slow speed
by F and a faster
speed by E. In ad-
dition to the corres-
ponding wheels on
E and F, a set of 4
gear
erent wheels
diameters of dif-
are
mounted on the
shaft G. Another
set of wheels corres-
ponding with the
wheels on shaft G
run idle on the
shaft H which trans-
mits the motion.
The wheels on the
shaft H are enclosed
in a swinging cage
Fig. 256. Sectional view Kempsmith feed gear box.
I actuated by the
lever L and driven by two intermediate gears, one of which, K,
is to be seen in fig. 256. Together with the lever L these
intermediate wheels bring in mesh the gears on the shafts G
and H. A gear wheel M mounted on a stud in the shear X .
drives the pinion O ; P and Q are clutches, keyed to the shaft
H. A sleeve R, has a helical groove which is operated by
lever S (see fig. 253) to engage either P or Q. If Q be
 and Milling Practice. 213

engaged, the wheels on the shaft H drive the shaft direct, if

P be engaged, by means of the transmission M and O.

The smaller sizes of the Cincinnati milling machines have

12 changes of feeds, the larger sizes 16, varying- in the case
of the smaller machines from 0.04" to 0.2" per revolution
of the spindle, and for the larger from 0.006" to 0.3". The
feed mechanism consists of two parts, (figs. 251 and 255) ;
fig. 257 gives a sectional view of the mechanism shown in
fig. 251, whilst fig. 258 shows the gear box of fig. 255 open.
The upper gear box, (figs. 251 and 257), imparts two speeds
to the vertical shaft which transmits the motion to the lower
gear box. By means of a lever to be
seen in fig. 251, the vertical feed shaft
speed can be increased from the large
to the small wheel or slackened
from the small to the large
wheel fig. 257.
The vertical shaft shown in
fig. 255, to which 2 speeds
can thus be imparted, drives
by a set of bevel gears a
horizontal shaft on which two Fig. 257.
gears of different diameter are Sectional view upper feed drive
Cincinnati milling machine.
keyed, which in their turn
drive two sets of cone gears, each consisting of 4, all
of which run idle on the same shaft, each set independ-
ent of the other. The large upper wheel meshes the
smallest wheel of the one set, the small upper wheel
meshing the largest wheel of the other set, so that these
two sets of cone gears run with a great difference in
speed. From the 8 gear wheels of these two sets which
run together in pairs though each with a different speed,
motion is further transmitted through an intermediate
gear sliding on its shaft along a keyway by means of a
rack and sector and placed into different positions to mesh
each of the 8 gear wheels. This is the lower lever in
fig. 255. Of the 8 wheels lying to the rear, the intermediate
214 Milling Machines
gear would, however, only be able to mesh with two of the
gear wheels if the position remained unchanged. However,
to enable the front wheel to mesh with the other gears, the
upper lever, shown in fig. 255, moves on its hub by means
of a helical groove when the lever is moved, the whole
of the under part of the mechanism, sector, rack, wheel and
shaft being also moved.

The precise manner in which the drive of the feed

mechanism should
be brought about
is a question on
which diverse opini-
ons have been ex-
pressed by special-
ists as well as by the
leading makers. It
is generally agreed
that the method
which has so far
been adopted is far
from being the ideal ,
being dependent on
the spindle speeds.
The spindle speeds
are chiefly fixed by
Fig. 258.
the diameter of the
Open feed gear box of Cincinnati milling machine. cutter, whilst it goes
without saying that
the rate of feed has nothing whatever to do with the question
as to whether a cutter has a diameter of .8/4/x or of 8", and yet
for certain classes of work a cutter of the former diameter can
be used equally as well as one of the latter. The plan has
been considered of driving the feed mechanism independently
of the speed of the main spindle direct from the countershaft,
but this has one great objection, viz:— that should anything
go wrong with the main drive of the machine, such as the
breaking of the driving belt or something of the sort, the
 and Milling Practice. 215

feed mechanism would continue running with the result that

both machine and workpiece would run the risk of being
ruined. The type of milling machine now built by Brown
and Sharpe, Kearney and Trecker and the Cincinnati Milling
Machine Co. with single pulley drive goes very far towards
the solution of this question. The gear box as per fig. 254, is
driven by B. and S. from the pulley spindle of the machine by
means of chain and sprocket wheel ; seeing that in the case of
single pulley drive,
this spindle rotates
at an invariable
speed, the feed can
be determined per
minute independ-
ent of the number
of revolutions of the
cutter. With the
N°. 2 A machine of '.'.
Brown & Sharpe,
the feed can vary
from V*"— 6". with
the N°. 3 A from
5/8" to 20" per
minute, which for
small cutters gives a
feed varying from Fig. 259.
0.0016" to 0.053" Sectional view B. and S. feed gear box.
and from 0.0017"
to 0.054", and for large size cutters from 0.041" to 1.333"
and from 0.039" to 1.25" per revolution of the cutter.
Fig. 259 gives a sectional view of the mechanism of the
Brown and Sharpe gear box illustrated in fig. 254. The
sprocket wheel A drives the long faced pinion B. An idle
wheel, not indicated, but mounted on a stud in the swing plate
D, engages with either of the gears a, b, c, d, e or/by the
lever E at the right hand side of the gear box, which lever
can be set in a fixed position by means of a plunger which
fits in a hole at the side of the gear box. In fig. 259, the
216
' Milling Machines
wheel b is in mesh with g on the feed shaft F, but by
giving the lever G a half turn to the right, g is slid out,
and h put into engagement withy.
Fig. 260 shows the feed mechanism of the Garvin ma-
chines. The greater part of the mechanism is enclosed in
the column, the lever K being on the outside. With this
mechanism 18 different feeds are obtainable.
The sprocket wheel A is driven from the main spindle.
By means of a sliding clutch, this wheel engages with the
spur gear B,
which is in
mesh with the
gear C, which
is keyed to a
short shaft on
which three
gears, D, are
mounted ;
these three
gears are in
mesh with
three corres-
ponding gears,
E, which run
idle on their
shaft and can
Fig. 260.
Garviii feed gear box. each be cou-
pled to their
shaft by means of a sliding spring key, to be seen on
the shaft itself. This shaft also carries to the right side
another cone of three gears, F, keyed fast upon it, which
communicate the motion derived from either one of the
gears E. to three others G. idle on a short shaft; this
shaft has no connection with that on which the wheels I >
are keyed ; the motion of the gears G is then transmitted
to the feed shaft by the mitre wheels II . For any one
position of the sliding key in the wheels E there are
three changes available by the key engaging with the
 and Milling Practice. 217

wheels G, so that 3X3 = 9 speeds of H are possible. And

besides, as the gears B and C are reversible, the series of
nine changes can be doubled, thus making a total of 18
speeds possible, varying from '/a 70" to ^\±" per revolution
of the main spindle. Each sliding key is provided with a
lever a and b, having notched sectors c and d, each of
which is locked by the locking lever K. This lever when
lifted, disengages at the same time sprocket wheel A from
gear B, so that by changing the feed, the gears are stopped
though the machine continues running.
All positieve feed mechanisms are provided with index
plates indicating the different positions of the levers, stating
the rates of feed which these will give, whilst there is also
one position which disengages the feed shaft.

Starting from the feed shaft, the motion is imparted to

three different points, viz :— for the vertical travel of the
knee, and the longitudinal and cross travel of the table.
Figs. 261 — 262 show the construction of the automatic travel
of the Hendey milling machines.
All feeds are instantly started, stopped and reversed by
the lever A, (fig. 261). When A is thrown to the right
standing in front of the machine, all feed screw handles turn
right handed and the table moves to the right, toward the
column, and up. The handle D, (figs. 262), throws in the lon-
gitudinal movement of the table, the handle B, (fig. 261), the
cross movement and the handle C, the vertical movement.
Each feed has its own mechanism independant of the other feeds ;
consequently all may be engaged simultaneously or separately.
The machine is provided with 4 hand wheels for operating
the various movements by hand. The cross movement of
the table is effected by the hand wheel in front of the knee,
the vertical movement being obtained by the hand wheel
at the left hand side, whilst there are also two handles at-
either end of the table. The handle on the left hand side
is connected directly to the feed screw spindle ; each revolu- •
tion of the handle causes the table to move over a length
equal to the pitch of the feed screw.
 218 Milling Machines
On the right hand side is a handle, illustrated in fig. 262,
for the quick movement of the table.
In the position shown in fig. 262, the handle is set for
the quick return of the table. The handle is connected to
the right hand gear and runs loose with this gear over its

Fig. 261—262. Sectional views of knee of Hendey milling machine.

 and Milling Practice. 219

stud, imparting motion to the upper compound gear, the

left hand gear of which meshes the gear beneath it, which,
in its turn, is mounted on the feed screw.
From the feed shaft fig. 261, a third mitre gear is set in
motion by two other mitre gears; this gear is mounted
on a shaft which, in its turn, drives another set of mitre
gears, the hub of the last gear being a spur gear. This
gear meshes another gear which runs idle on a sleeve on
the shaft lying underneath, (see fig. 262), which is provided
with a clutch; by means of the lever to the left, this gear
wheel is coupled to the shaft and, at the same time, engages

Fig. 263. Automatic longitudinal movement mechanism of milling table.

the spur [gears. As can easily be seen from fig. 262, this shaft
drives the vertical telescopic screw. As will be seen from
the illustration the automatic longitudinal and cross feeds
are obtained by the large mitre wheel mounted on the
shaft parallel under the cross feed screw (fig. 262). For
the cross feed, a spur gear is mounted on the end of this
shaft, which meshes a pinion that runs idle on the cross
feed screw, but which by means of the lever B, (fig. 261),
can be connected with a clutch on the cross feed screw.
For the longitudinal feed of the table, the movement is
transmitted to the feed screw of the table by three mitre
gears. The further gearing is not visible in fig. 262.
220 Milling Machines
Fig. 263, however, shows the underside of the table of the
Leblond milling machine, which, as far as this part is
concerned, is similar to the Hendey machine. The upper
mitre wheel on the vertical shaft in fig. 262, meshes the
mitre wheel to be seen underneath the table, which, mounted
on a sleeve, rotates free over the feed screw of the table.
On the spindle is a clutch which, on being coupled with
the mitre wheel by means of the lever D, fig. 262 causes
the spindle to rotate by means of a key in the cluth and
by this the table is moved. All automatic feed movements
are thus engaged by clutches, being disengaged by trip dogs.

Fig. 264- 265. Garvin feed mechanism.

The trips for disengaging the vertical automatic feed can

be seen to the left in fig. 262, and can be properly adjusted
by means of the knurled screw E.
Figs. 264 and 265 show the automatic feeds of the Garvin
milling machine. I is a universal joint, receiving power
from the feed shaft, which drives the driving shaft J of the
feed movements. On this shaft is mounted the reversing
tumbler gear S, which meshes the gear 8 to be seen in
fig. 265, and also another small gear wheel. Both these
gear wheels run idle on studs carried in the rocker
casting U. This casting serves at the same time as an oil
bath, so that the gears S run continuously in oil. The
movement from the shaft J is transmitted to the gear wheel
 and Milling Practice. 221

O by means of the gears S. In fig. 264 the gearing takes

place with one idle wheel; by reversing the knob R, the
casting U is also moved and a second idle wheel is engaged,
(fig. 265), by means of which the movement is reversed.
The gear wheel O drives the worm shaft D with the worm
C which meshes the worm wheel A mounted on the table
feed screw. The shaft D is carried in a casting provided
with an oil bath, in which the worm C runs. This casting
can be dropped on the latch pin K and can be fixed in

Fig. 266.
Automatic longitudinal movement mechanism of table feed of German construction.

the position given in the illustration by which worm and

worm wheel are in mesh by means of the pivot pin L.
The table feed is disengaged by hand by means of the
trip knob P. This can however, take place automatically
by means of the trip button M, which acts on the hardened
steel trip plug N, which is kept in the position shown in
the illustration by a spring, but is pressed down by M, thus
allowing the pivot pin L to fall, with the result that the
worm C drops out of the worm wheel. In order to again
engage, the handle Q, which is attached to the casting in
which the worm shaft is carried, is pulled up.
 222 Milling Machines
Although in most American constructions, the longitudinal
feed screw drive is usually in the middle under
the table, German makers, on the other hand,
generally drive it to one side by means of a worm
and worm wheel. Fig. 266, gives a sectional view
of such a construction. Worm wheel 3 runs
idle on shaft T, but by means of the clutch
K which is mounted on the shaft T by means
of a sliding key, can impart motion to the
feed screw.
Fig. 267
shows the
German con-
struction ofan
Fig. 267.
automatic Feed trip mechanism of German construction.
feed trip me-
chanism. By means of the lever h the feed can be
either thrown in or out by hand. To throw out the feed
automatically which is attached
the moveable trip button which
to the table, acts against the pin b which moves the latch
s in the direc-
tion indicated
by the arrow ;
this latch ^ is
connected
with the lever
h and disen-
clutch ofgages the
the
worm wheel.
In fig. 268,
the worm
wheel 3 is
Fig. 268. mounted on
Feed trip mechanism of
German construction. feed screw whilst the worm
is carried in the swinging bearing
2 which swings with the shaft c.
The lever h is mounted on the same shaft z, so that it is
 and Milling Practice. 223

in a fixed position with the bearing which carries the

worm. This lever is locked by a notch of the lever b.
Lever h being locked, the lever b meshes with the worm
wheel 3 by worm 2. When,
however, the trip button a
which is attached to the table,
acts on the notch of the lever
b, h is released with the result
that the bearing with the worm
drops by its own weight.

In connection with the feed

mechanism of the milling ma- Fig. 269.
chine, the following construc- Position of B. and S. handwheels.
tions are of special interest:
1. The position of the hand wheels for hand feed.
2. The position of the handles for disengaging the auto-
matic feeds by hand.
3. The micrometer adjustment of the hand feed.
4. The micrometer adjustment of the automatic stops.
The longitudinal movement of the table by hand is
effected by means of hand wheels or crank handles, one on
each side of the table. The one on the left hand side is
for regular movement, that on the right hand side for quick
return of the table.
The hand wheels for the cross and
vertical feed are placed in the front
of the machine in such a way that the
operator can use both at the same
time.
Fig. 270. Fig. 269 shows the position of these
B. and S. feed trip
levers. hand wheels on the Brown & Sharpe
milling machines, which is the same in
most of the up-to-date milling machines. Hand wheels and not
crank handles are preferable for this purpose, as the operator
is then enabled to follow with his hand the circumference
of the wheel, and thus keep his hand in the same position.
The hand wheel for the vertical feed is placed at an angle,
224 Milling Machines
so that the operator can move both wheels at the same
time or separately with both hands without coming in
contact with either.
Fig. 270 shows the position of
the levers for throwing in and
out the automatic feed by hand
as adopted for the Brown and
Sharpe milling machines. They
are placed, as in the case of
most other makes, on the right
hand side of the knee. The lever
at the extreme right is used to
Micrometer of handfeed. engage or disengage all the feeds;
the two others are for throwing
in and out the automatic cross and vertical feeds; the lever
for throwing in and out the automatic longitudinal feed is
placed in the front of the table.
To ensure the perfect adjustment of the table longitudi-
nally, crosswise or vertically, the feeds screws are fitted
with bevelled graduated collars (fig. 271) indicating thou-
sandths of an inch. These collars are loose on the feed
screw spindles and are bound by a knurled screw, so that
the graduation of the collar
can be set at zero, thus
preventing the possibility

\m
of any error being made
in the reading. ^pyQ^N, r~&^ti*.
The trip dogs which dis-
engage the automatic feed,
are provided by some makers
with a vernier by means of Fig. 272—273.
which the feed can be disen- Micrometer adjustment of feed trip dog.
gaged at a certain fixed
point. Figs. 272 and 273 illustrate such a vernier as is fitted
to the Brown and Sharpe milling machines. The scale A
is 24" long. This divided scale is screwed to the table,
the trip groove over the entire length of the front of the
table being used for this purpose.
 225
and Milling Practice.
The vernier B is screwed to the saddle, as can be seen in
fig. 273. A is the clamping screw of the vernier; b the
micrometer screw by which it is adjusted to zero. With this
vernier, the automatic
feed can be adjusted to
thousandths of an inch. ^
Figs. 274
illustrate another and con-
275 ~~t| j'O way Stop Screw
JBlcromet'er Dial Stop Scre
struction of the micro-
Fig. 274—275.
meter table stop as used Micrometer stops.
on the Garvin machines.
The head of the micrometer screw, by the end of which the
feed is tripped, is graduated, each division corresponding
to a linear movement of the screw of 1/iooo^1 inch. The
clamp in which the screw is placed is split transversely
over the threaded hole and the micrometer dial can be
bound by a bolt. When loosened the micrometer dial can
be easily adjusted. When it has been correctly set, the bolt
binds it again.
The feed most used either automatically or by hand, in
the case of the column and knee type machine, is that for
the longitudinal movement of the table. This movement is

Fig. 276. Table movement by worm and rack.

effected by means of a feed screw with square thread. A

thread with a nut is by no means an ideal manner of table
feed, especially when heavy work has to be carried out on the
machine which entails a fairly heavy strain on the feed screw.
The rack, as it is used on the lathe for the longitudinal
15 move-
226 Milling Machines
ment of the carriage, is far more suitable for this purpose. In
the case of the universal milling machine the use of a feed
screw is imperative for two reasons, firstly, because it must
be possible to set the
table at any angle for
spiral milling, for which
purpose a set of mitre
wheels has to be em-
ployed, one of which
must swivel with the
table whilst rolling
over the other, and
Fig. 277.
secondly, because, in
Underside of milling table. order to obtain a spiral
line the workpiece
must rotate in a fixed ratio with the table feed and this
is only obtainable with a feed screw.
The difference between the universal and the plain milling
machine consists principally in the fact that the universal
dividing head is not included in the equipment of the latter
machine, nor can the table be swiveled at an angle.
Since in this case the use of the feed screw is not obliga-
tory with the plain
milling machine, the ._
longitudinal feed is
frequently effected
by means of a rack
and worm or pinion.
Fig. 276 shows such
a construction. In
the illustration the
underside of the
table is shown to Fig. 278.
Side view of milling table sho\s'ing the top.
permit of the rack,
which is placed underneath, being seen.

The milling table was originally a plain casting, the top being
fitted with "(" slots, the under side being fitted with bearings.
 227
and Milling Practice.

Owing to the increasingly heavy nature of the work

demanded of the universal, and more especially of the
plain milling machine (manufacturing type), the table was
constructed more rigidly in order to resist twisting strains
when the work is clamped to it, whilst for lubricating it
was fitted with oil pockets.
The table of
the modern mill-
ing machine is
now a stout
webbed casting;
fig. 277 shows
the underside,
fig. 278 a portion
of the top of the
milling table of
the Cincinnati
milling machine.

(e). THE SUPPLY

OF COOLING
LIQUID TO THE
CUTTING TOOL.
342

Owing to the
necessity of lu-
bricating the
cutting tool and
the surface to be
milled, the oil Fig. 279.
Lubricating parts.
pump hasbecome
an indispensable part of the milling machine. The pump
brings an abundant supply of lubricant to the cutter, which
collects in the oil pockets round the table, whence it is con-
ducted through piping to a small tank where it is purified from
all dirt and solid matter and then again pumped to the cutter.
The base is also provided with a raised edge so as to
collect that portion of the lubricant that overflows in one way
228 Milling Machines

or another, as well as the chips, so as to prevent the imme-

diate surroundings of the machine from becoming too dirty.
The construction of this lubricating parts can be seen in the
illustrations already given, as also in fig. 279.'

(/). THE ARBOR SUPPORT.

In the early days, when milling was used exclusively for
light work, the ar-
bor on which the
cutter was mounted,
was attached in the
main spindle, run-
ning entirely free
and unsupported,
(see fig. 280). With
the development of
the milling machine,
it became necessary
to support the end
of the arbor to pre-
Fig. 280. vent any undue
Old type of milling machine with free running arbor. play. The top of
the column was
constructed as a bridge in which an arm, the front of
which was curved, was mounted. Fig. 281.
The housing for the arm was split over the entire length,
the arm being clamped with two bolts (fig. 282). The
curved portion, reaching to the centre of the arbor was pro-
A^ C*t U\JM. W dO ^JL V

vided with a back centre screw against

the centre of the arbor: this screw was
set against the arbor by hand, being
afterwards clamped in* the arm. Later ^,-"- j.

on another slight improvement was in-

troduced by making the pointed centre :l>or281.
Fig. support
screw adjustable, after the arm had been
clamped, by means of a knurled screw (fig. 281). This
construction was in vogue for some considerable time.
 and Milling Practice. 229

The next improvement was to do away with the pointed

centre. A bore in the stay of the arm directly opposite the
centre of the arbor, was made to receive a split bushing,
(see fig. 283). The outer end of the arbor was carried in
this bush. In order to prevent any play of the arbor, the

Fig. 282.
Advanced construction of arbor support.

end of the. arbor is made to fit the bore of the bush precisely,
whilst the bush as well as the arm must be moved by
hand. To avoid this difficulty the bush is split into three,
being tapered in front on the outside and fitting in a cone
in the bore of the stay. By -means of a bolt in the front,
the bush can be drawn in the tapered bore so that the
230 Milling Machines
diameter of the bore
in the bush is made
smaller, thus fitting
the end of the arbor
exactly.
As the work car-
ried out on the
milling machine be-
came heavier, the Fig. 283. Arbor support in bush.
resistance offered
by the arm alone proved insufficient and some other support
had consequently to
be afforded for the
arm. The form of
the arm was chang-
ed from that shown
in fig. 281 into a
straight shaft with
Fig. 284. Bridge for arm. moveable stay
which could be
clamped in any position (fig. 286), to which bracings were
attached which tied the overhanging
arm and the knee together (fig. 285
and 287). A second stay was fitted
on the arm, which could be set at
any point on the arbor, giving sup-
port to the arbor close to the cutter
(fig. 286). By continually strength-
ening the bracings, the construction
shown in fig. 287 was finally arri-
ved at, which offers a perfect resist-
ance to the greatest possible strain. ™
Fig.
on the288machine.
shows this type of bracings \~ s
\

Fig. 285.
The term universal milling ma- Early form of bracings,
chine sufficiently indicates that this
machine can be used for a great variety of work.
 231
and Milling Practice.
By means of various attachments the attempt has been
made to make the machine really "universal", so that it
has been'metamorphosed
into a gear cutting ma-
chine, vertical miller,
slotting machine, prof-
iling machine, etc.
However accurately and
rigidly those attachments
may be constructed, or
Fig. 286.
Arm with double stays. however good their con-
struction, such attach-
ments can never be otherwise regarded than as accessories,
since they are only employed in cases when there is not
sufficient work to justify the purchase of a machine specially
adapted for the purpose, it being but seldom that the need
for such a machine is felt.
In such cases, these at-
tachments may prove an
inestimable boon, still, the
fact that the use, for in-
stance, ofa vertical milling
attachment on a universal
milling machine, will
never transform this ma-
chine into a vertical
milling machine, must
never be lost sight of.
In chapter X the prin-
cipal milling attachments
and their use will be
dealt with.
Whilst treating of the
universal milling machine,
the plain milling machine Fig. 287.
Latest form of bracings.
of the same type has also
been described, since, as has previously been stated, the
difference between the plain and the universal milling machine
232 Milling Machines
simply consists in the fact that certain parts, such as the
universal dividing head are absent from the plain milling
machine whilst' the table cannot be swivelled as is, the case
with the universal milling machine. All that has been said
about the universal milling machine applies also equally well
to the plain milling machine of the column and knee type.

Fig. 288. Bracings placed on the milling machine.

(g). CONSTANT SPEED DRIVE MILLING MACHINES.

The single pulley driven column and knee type machine
of Brown & Sharpe is illustrated on page 179. For the
rest we have not gone further into the details of the single
pulley driven type of milling machine but have simply
touched it on the question of the feed and the unreasonable-
ness of the ratio between the feed and the speed of the cone
driven machine so as to give a description of this type of
machine separately.
 233
and Milling Practice.
The Milwaukee constant speed drive Milling Machine.
Fig. 289 illustrates a constant speed drive milling machine
built by Kearney & Trecker, which is of special interest on
account of its original disign. The drive is much lower on
the column than is the
case with any other
type of
milling

Fig. 289. Constant speed drive

milling machine.
machines, with the result that there is much more room left
in the column for the distribution of the gearing for the
speed as well as for the feed so that only one box is really
outside the column. This gives the machine a far less
complicated appearance. There are two times three crank
handles for changing the feed and the speed. As in the
case of the cone driven milling machines, the feed is not
234 Milling Machines
expressed per revolution of the cutter but per unit of time.
The column and knee, i. e. the two principal parts which
have to withstand all the working strain are box sections
with as few openings as possible.
It will be seen from fig. 290 that the knee is almost a

Fig. 290. knr«- \\itli . I..M-I! top.

closed box. This feature of the box knee completely closed

is one of no little interest; on the contrary, it has of late
come to be regarded as of the utmost importance and an
essential feature in the good construction of milling machines.
It frequently happens that cuts have to be taken with the
 235
and Milling Practice.

Fig. 291. Standard drive. Fig. 292. Right angle drive.

table heavily loaded drawn out far from the column, especially
on universal machines when cutting" spirals, and the saddle
must then be run out to prevent the table striking the ways
on the column. The
drive of the machine
under review is ob-
tained from a single
pulley of ample diam-
eter running at ample
constant speed. An-
other feature of the
constant speed drive is
that practically without
the necessity of mak-
ing any change, the
machine can be either
right angle driven
or driven by motor
by a simple alteration Fig. 293. Motor drive.
of the bracket. Fig.
291—293 show how easily the three different drives are-
shifted. They are interchangeable without any further pre-
paration or change of the machine itself. Fig. 294 gives a
236 Milling Machines
sectional view of the plain machine, showing all the gearing
for speed changing and parts of the feed gearing. Pinion
9 part of pulley shaft 1 engages with a sliding clutch gear
10 turning idle on the shaft 2 and connected with the starting
lever 13 to be seen in fig. 289. The opposite clutch gear

Fig. 294. Sectional view of column and knee.

11 on the same shaft 2 is engaged when the machine is

started. This gear drives gear 13 on shaft 3 at the back
of the feed box. A jaw clutch is used for starting and
stopping the machine, as owing to their great simplicity
and the fact that no adjustment is ever necessary, and as
they revolve at a comparatively low and constant speed no
 237
and Milling Practice.
shock occurs when the gears are engaged. Gear 13 on shaft 3
drives the main driving shaft 5 which in turn through the
sliding gear 15 on shaft 5, fig". 297 drives the three-step tumbler
gears 16 to 18 on shaft 6 by means of which the speed is
varied as follows: — Shaft 7 below the main spindle carries
two gears of different diameter, viz: — 19 and 20, and the
tumbler with the wheels 16 to 18 is so arranged that each
of these wheels can be engaged with each of the two gears
19 and 20 so as to give six speed changes to shaft 7.
These again are
multiplied by three
through the sliding
sleeve gear on the
main spindle which
is made to engage
with the main spin-
dle drive gear 23
or either of the two
gears 19 or 20. In
this manner eighteen
speed changes are
obtained in geome-
trical progression,
the ratio used being
1,225, and any speed
multiplied by this Fig, 295. Column plate — backside.
ratio gives the next
higher speed. The speed changes are effected by the crank
handles 19 and 18 turning over the plate and by the tumbler
handle 17, all of which are to be seen in fig. 289. The
tumbler handle 17 moves the tumbler cone gears 16 to 18
shown in fig. 294 and 297, whereas the crank handle 19
moves the gears on the main spindle and the crank handle
18 moves the tumbler gears in an axial direction. Fig. 295
illustrates the back of the column plate over which these
crank handles move and from this it will be seen that at
the back there are two gears each meshing in a rack, one
provided with a horizontal and the other with a vertical
238 Milling Machines
finger, the first one engaging the groove of the main spindle
sleeve 21 and 22, the other one en-
gaging the tumbler. On the front side
of this plate there is an index plate,
fig. 296, which shows the number of
revolutions fora given speed of the main
drive for each position of the handles.
Fig. 296.
Fig. 297 shows a horizontal section
Speed index plate. over the column and through the three-
step tumbler gear with wheels 16 to 18
and gives a clear view of the construction of this part. This
cone gear revolves on stud 6 firmly planted in the swinging
frame that is securely supported on both sides of the tumbler ;

Fig. 297. Tumbler support and spindle reverse.

on one side by the driving shaft, which for this purpose is

larger in diameter than is actually required and on the other
side by the teeth of the long pinion meshing the teeth
cut in the segment of the frame and by means of which it
is made to engage with the gears above. Fig. 297 also
shows how the spindle reverse is effected. The sliding gear
 and Milling Practice. 239
31 on the driving shaft engages, for right hand rotation,
with gear 13 on the feed box shaft 3 fig. 294 which also
engages the smallest step 12 of the reversing idlers 12 and 14.
When the sliding gear is in mesh with the large step 14
of the idler, it is out of mesh with gear 13 and the spindle
runs left hand.
There is a means of locking the spindle when tightening
the arbor nuts. This locking plunger 12 is to be seen in
fig. 289 and is cut as part of an internal gear of the same
pitch diameter as the main spindle gear so that when engaged
with gear 23, fig. 294 the teeth fit in all their curve throughout
a wide arc and the spindle is held securely. The starting
lever is automatically locked out when the plunger is
engaged in the main gear.
The feed is driven from the constant speed gear 13 on
shaft 3 previously mentioned as part of the drive train ; the
amount of power going into it automatically depends on
the conditions of the cut. Twelve feed changes are provided
by the mechanism in the feed box similar to that shown
for the drive. These feed changes are also in geometric
progression, the ratio being 1.35. The slowest feed is \
inch, the fastest 16 inches per minute, and, as mentioned
above, these have no reference to the speed of the main spindle.
Fig. 298 gives a top view of the feed gear box with
index plate showing the feed for any position of the handles.
As previously stated, the change of feed is effected in a
similar manner to the change of speed, viz : — by three
handles, two on the top of the feed gear box and one
at the side, (marked 16 in fig. 289), acting on a tumbler
gear cone. The foremost handle in fig. 298 gives three
speed changes, fast, medium and slow ; the rearmost handle
giving four other changes, making a total of twelve feed
changes in all. By this means finer feeds are provided
for small cutters at high rotative speeds and coarser feeds
for large cutters at low rotative speeds than can be obtained
by any other system of feed driven from the main spindle
regardless of how many changes are used. The power is
carried from the feed box forward by a universal joint shaft.
240 Milling Machines
The centre block is square and forms an oil reservoir to
keep the parts thoroughly lubricated. The drive of the feed
screws does not differ so much from what has already been

Fig. 298. Feed box — top vit \v.

described as to require any repetition. There is, however,

an originality in connection with this machine which deserves
special mention and that is, that the vertical, cross and table
 241
and Milling Practice.

feeds are so arranged that no two can be engaged at the

same time. The sectional view of the knee given in fig.
239 shows how this is accomplished. The shaft in the upper
right hand corner is for the table feed and the clutch on
this shaft is engaged only when the plunger at the left is
in the central position, at which time the double rocker arm
controlling the cross and vertical feeds is locked by this
plunger. In order to throw in either of the other feeds,
this plunger must be set to one side of the lever through

Fig. 299. Feed interlocking device.

which it passes and this disengages the table feed clutch

and makes possible the engagement of one only of the
other feeds according to which way the plunger is moved,
the knee being plainly marked to show which feed will be
engaged.
Careful attention has been devoted in this machine to the
question of lubrication of the running parts as well as of the
cutter and the work. The bearings, driving parts and gears
are flooded with streams of oil that is pumped with a simple
spur geared pump from the reservoir in the base and to the
16
242 Milling Machines
rear of the machine, and distributed to all gears and bearings
by means of a perforated pipe at the top. After flowing into
the pockets arranged to supply the spindle bearings with
oil, it overflows and cascades downwards, overflowing each
pocket and sending a steady stream through each bearing.
There is another reservoir in the base, also with spur geared
pump, specially for lubricating the cutter. This cutter lubri-
cation is guided by piping in the interior of the column
extending only a short distance out of the column to the

Fig. 800. Cincinnati constant speed drive milling machine.

cutter. From the sectional view given in fig. 294, it will

be seen that after the lubrication has reached the table and
has been purified, it returns through an internal channel to
the table base, thence through piping to the rear of the
machine and from there it is conducted to the reservoir
where it undergoes further purification. The construction
of this machine as regards lubrication is certainly one of its
most interesting features and proves that its designer was
fully aware of how much depends upon ample lubrication
not only of the running parts but also of the cutter.
 and Milling Practice. 243

The Cincinnati constant speed drive milling machine.

A front view of this machine is given in fig. 300. The
main driving pulley of the machine is not mounted directly
on the driving shaft but is journaled on a bracket bolted
to the column. The entire belt pull is therefore relieved
from the driving shaft and taken up directly by this bracket.
A disc friction clutch connects the driving pulley to the
driving shaft and the machine is started and stopped by

409

Fig. 301. inside of spindle drive box showing driving shaft, tumbler and chain
wheel for driving feed from constant speed shaft.

operating this clutch by the lever located at the front of the

column. When the clutch is out, every part of the machine
is stopped with the exception of the driving pulley. When
the clutch is thrown in, power is transmitted through the
main driving shaft and the tumbler gears shown in fig. 301,
and the driving gears shown in fig. 302. Sixteen changes
of speed are provided on this machine, viz: — two series of
four each through the back gears and two series of four
each direct through the sliding gears. The sliding gears
are connected together on a large sleeve, (fig. 302), which
244 Milling Machines

Fig. 302. Driving gears. Showing feed driven from spindle.

in turn slides on a second sleeve mounted on the spindle.

Transmission is therefore never through the length of the
spindle but at all times through these sleeves to the face gear
either direct through the clutch or through the back gears.
The drive is, therefore, always through a point immediately to

Fig. 803. Cone and backgears on their shaft.

 245
and Milling Practice.
the front box. The spindle is never subjected to torsional strain
throughout its length, but bending strains only, thus elimina-
ting torsional vibration in these parts. The small gear "A",
(fig. 301), is never used for transmission but merely serves
as a pilot when throwing the back gears into engagement ;
when the back gears are not in 'use, they are entirely out
of mesh and do not revolve. There are at no time any
gears in mesh except those actually used for driving. The
operation of throwing the back • gears out and engaging

Fig. 304. The spindle and driving gears.

the clutch on the driving sleeve with the face gear is

accomplished by a single movement of one of the speed
change levers. There is no position of the back gears in
which the gear train is locked. Fig. 303 shows the cone
and back gears, which are bronze bushed, mounted on their
shaft. This shaft does not revolve and is, therefore, not
subjected to torsional strains but bending strains only, thus
lessening the possibility of vibration in these gears. Fig. 304
shows the main driving gears mounted on the spindle. It
also shows the lock nut immediately at the side of the front
246 Milling Machines
bearing by which the spindle may be closely adjusted to
take up wear. This illustration further shows the liberal
proportions of the driving gears, all of which are 'of steel,
of coarse pitch and capable of transmitting the full power
of the driving belt under all conditions.
The tumbler construction which is to be seen in fig. 301 and
305 is so arranged that the operation of speed changing also
securely locks the tumbler through its frame to the slide of
the main frame of the machine from
which the tumbler is supported.
The swinging frame containing
the gears is mounted in the main
tumbler frame and rocks on the
trunnions "D". It is operated by
the turnstile on the outside of the
column through spiral gears shown
in the illustra-
tion, one of
which is
mounted di-
rectly on the
trunnion of the
swinging
frame. Its
operation is as
follows : — By
turning the Fig. 305. Section through tumbler.
turnstile to the
left as far as it will go, the tumbler gears are brought
out of mesh; then by a lateral movement, the entire
tumbler is shifted to the desired position, and by then
turning the turnstile to the right, the tumbler is again
engaged with the desired gear of the cone. The stop
pins u P" against which the lug on the swinging frame
presses, govern the proper meshing of the gears. It will
be seen that after the gears are in mesh, if the turnstile
is turned further to the right, the swinging frame, the
tumbler frame and the spiral gears act as a system of
 247
and Milling Practice.

levers and screw which lock the tumbler frame securely to

its slide on the main frame of the machine, thus holding the
support for the tumbler gears as firmly as if it were bolted
in place. On further reference to the illustrations it will be
seen that the entire tumbler mechanism is carried on its
slide on the main frame of the machine. The main driving
shaft " A" has clearance in the tumbler frame so that at is
not subjected to strains due to either the weight of the

Fig. 306. Outside of speed change box.

tumbler, the thrust of the cone gears while driving, or any

of the strains due to locking the tumbler in position.
From the foregoing it will be seen that none of the main
shafts are ever subjected to both bending and torsional
strains; the back gear shaft and the length of the spindle
being subjected to bending only and the main driving shaft
to torsion only. By means of this construction in connec-
tion with the locked tumbler bracket, all cause of vibration
in the main driving gears has been eliminated.
248. Milling Machines
Speed Changing. This is effected by means of the two
levers and turnstile shown in fig. 306. The lever positions
are marked " A B " and "CD" and the turnstile positions
are marked 1, 2, 3 and 4. Care has been taken to prevent
the possibility of any confusion to the operator in turning
the back gears in or out, in setting the levers to the right
or left, fast, medium or slow. In the same way, to determine
at what speed the machine is running, the turnstile is set
at 3 with one lever at "B" and the other at "C". The

Fig. 30"3. Interior of feed box.

position is, therefore, 3 — B C, which on reference to the index

plate corresponds directly to 115 revolutions per minute.
The machine having been stopped to change the speed,
the gears may interfere when shifting the levers and it is
therefore necessary to revolve them slightly. This is done
by the treadle shown in the illustrations. It is connected
to the main clutch lever and operates on an auxiliary disc
clutch. The operation of speed changing, therefore, consists
of selecting the lever positions for the desired speed, setting
the turnstile in position, moving the change lever as far as
 and Milling Practice. 249
it will go and then, if the gears interfere, exerting a slight
pressure on the treadle. This brings into play the auxiliary
disc clutch which starts the gears gently so that the lever
can be moved the remainder of the way.
Feed Mechanism. All the feed changes are contained
in the feed box itself, the interior of which is shown in
fig. 307. This shows all the gears connected with feed
changing. The feed changing is similar to that of speed
changing except that the treadle is not used as the machine

Fig. 308. The feed box.

is not stopped for feed changing. Fig. 308 gives an external

view of the feed box. From the illustration in fig. 300 it
will be seen that this box is located high above the floor,
which adds greatly to the convenience of the operator.
There are 16 changes of feed, which can be changed from
the one to the other throughout the entire series by a single
movement of the feed levers. Feed changing can be best
done whilst the machine is running. The feed gearing is
driven by a slow speed silent chain. The feed which can
be read in inches per minute ranges from -J inch to 20 inches
250 Milling Machines and Milling Practice.
per minute table travel. The feed is driven from the constant
speed shaft by the chain wheel to be seen in fig. 302.
For the general construction of knee and table, we refer
the reader to the general description of the column and
knee type machine already given. In general the various
parts of the constant speed drive milling machine are con-
structed much heavier and far more substantially than before,
though it does not differ so much in design as to necessitate
a detailed description being given.
 CHAPTER IX.

Different types of milling machines.

(a). PLANO-MILLERS.
As soon as the metalworking industry had learned to
appreciate the utility of the milling cutter for metal working,
the idea was quickly seized upon of carrying out on the

Fig. 309. Early form of piano -miller with vertical spindle.

milling machine a great deal of the work previously performed

on the planer, viz :— the machining of large surfaces, or to be
more accurate, to supercede the planing tool by the milling
252 Alilling Machines
cutter and whilst preserving the original type, the planer was
transformed into a milling machine.
Of nice form and design, these machines certainly were not.
Figs. 309 and 310 illustrate such machines of the planer type,
the one arranged for vertical and themilling.
other for horizontal

As far as the piano-

miller is concerned,
too much was expected
of this type after the
first successful trials.
It was thought that

Fig. 310. Early form of piano-miller with horizontal spindle.

the planer would soon be done away with for good and
all, at any rate as far as the machining of large sur-
faces was concerned. Experience has proved the reverse.
As a preparatory machine, as also for machining large
workpieces, the piano-miller is eminently adapted, but for
accurate finish of long and large workpieces, the planer
proved and still proves to be indispensible.
One of the first to put a piano-miller of good design
on the market, was Lincoln, who built the milling machine
 253
and Milling Practice.
called after him, (fig. 311), which at the present time is
copied, with certain slight alterations, by a large number of
makers. It is specially adapted for the. slabbing of work-

Fig. 311. Lincoln-type of milling machine.

 I Milling Machines
pieces of not too large dimensions and only for milling in
a straight line, either horizontally with milling cutters on the
arbor or vertically with end or face cutters. The saddle,
carrying the main spindle is vertical adjustable by hand

Fig. 312. Plano-millrr.

over a short column forming one casting with the bed.

The saddle bears on this column by means of broad faces
h ensure great rigidity. The cone pulley for the drive
is at the rear, the spindle being driven by means of gearing.
he ratio of speed of the cone pulley and the main spindle
is large, a high belt speed is obtainable, which consequently
 255
and Milling Practice.
increases the power the belt can transmit and as a rule heavy
cuts can be taken by this type of machine. The spindle
is supported in a vertically adjustable tail post.
The carriage has a transverse adjustment over the bed
by hand, the table has longitudinal power feed, i. e. rectangular
to the main spindle. The principle of this type of machine
is that of a powerful, simple tool with as few working parts
as possible, suitable
for milling plain
surfaces.

From this type of

milling machine, a
large number of
other varieties have
been devised.

Fig. 313. Piano-miller of German make.

In the machine shown in fig. 312, the types illustrated

in figs. 309 and 310 can be easily traced, though at
the same time, the general form of the planer is still
discernable.
The table of this type of milling machine is moveable
only rectangularly to the spindle, whilst the auxiliary column
is adjustable crosswise over a short distance parallel with
the spindle. The main saddle on the column and that on
the auxiliary column are tied by a 5 inch arm on which an
256 Milling Machines

auxiliary stay is mounted, thus making it possible to support

the arbor firmly between two bearings.
In still closer resemblance to the planer, the general
form of the machine shown in fig. 313 can scarcely be
distinguished from it. The drive is derived from the foot of
the bed, the main spindle being driven by means of a double
set of mitre gears and a double set of spur gears. Work-
pieces up to 8 ft. in length can be handled on this machine.

Fig. 814. Ingersoll piano-miller with four spindle heads.

mparatively few makes of heavy piano-millers,

those of the Ingersoll Milling Machine Co. certainly deserve
particular attention. This firm builds piano-millers of such
a size that they may justly be termed giants of their sort.
They vary from the small Lincoln type of machine to those
with 4 spindle heads, two horizontal and two vertical, in a
variety of combinations.
j. 314 shows one of the Ingersoll machines which gives
some idea of the enormous proportions in which this type
<»f milling machine is built. The two heads on the housings
 257
and Milling Practice.
can work
either sepa-
rately with
face mills
or be fitted
with an
arbor for
milling
large surfa-
ces with a
slabbing
cutter. Fur-
thermore,
both heads
on the
Fig. 315. Spindle bearing of Ingersoll piano -miller.
crossrail
can be fitted with face mills. The weight of the machine
illustrated in fig. 314 is over 300.000 Ibs.
Fig. 315 affords a striking example of the enormous
dimensions of the various parts of this machine, a workman
being seen in the
spindle bearing,
the cover of
which has been
removed.
Two workpieces
can be milled
simultaneously
on this machine,
whilst face mills
with a diameter
of 36 inches can
also be used.
Fig. 316 shows
such a machine
with face mills
mounted on
Fig. 316. Ingersoll piano-miller with four spindle heads. the Spindles. For
17
258 Milling Machines
milling the ends of
long workpieces,
these machines are
built with a remov-
able housing (fig.
317), so as to permit
of the milling of
workpieces of un-
limited length.
The machine il-
lustrated infig. 316
is arranged for belt
drive, but by far the
greater number of
these large machines
are arranged for
direct motor drive,
which, for the larger
types absorbing 60
and more H. P., is
practically a sine qua Fig. 317. Open -side piano-miller.
non. Fig. 318 shows the manner in which the motor is
coupled to the machine.
The construction of the hori-
zontal spindles is illustrated in
fig. 319. In this illustration A
is an unmovable bearing on
the crossrail, B the wheel
mounted on the spindle, causes
it to rotate, C
a movable
double bear-
ing on the
crossrail, D the
parallel
tion ofpor-
the
spindle, which
Fig. 818. Motor-driven piano-miller. slides in the
 259
and Milling Practice.

Fig. 319. Section over the horizontal spindle of Ingersoll piano -miller.

bearing of A, when C is adjusted longitudinally over the

crossrail. The arbor support E can also be adjusted on the
crossrail, so that the distance between C and E, between which
the cutter is mounted, can be adjusted according to the face
of the cutter. The bearings of C consist of two separate,
adjustable reversed tapered boxes. Both boxes are adjusted
on the spindle by the lock nut at the left hand side. These
boxes are of cast iron. The bearings are of bronze. The
milling arbor fits in the main spindle with a cone, being
tightened by a key between the bearings.

ifoo

Fig. 320. Fig. 321.

Sections over the vertical spindle of Ingersoll piano-miller.
260 Milling Machines

The vertical spindles of the Ingersoll piano-millers are

so designed that the spindle speeds can be changed by
clutches from fast to slow and vice versa in such a manner
that the spindles are driven by a worm and worm wheel or
by spiral gears. Figs. 320 and 321 represent two vertical
sections.
The hollow spindle A has its bearing in a sleeve B verti-
cally adjustable in the saddle casting C, which traverses the
crossrail. The sleeve B is adjusted by rack and pinion,
operated by the turnstile a and clamped by the screws b, b.
The rotary movement of the spindle A is derived in the
first place from the horizontal shaft D, splined to drive the
spur wheel E and the worm F. The worm F engages with
the wormwheel G, whereas E drives the spiral gears by H
which is on the end of the spindle that carries the small
spiral wheel J, engaging with the large wheel K. The
wheels G, H and K all run idle on their spindles and are
engaged by the clutches L, M, and N. L and N are
handled by the locking levers O and P. The worm and
spiral gears are covered by the casings Q and R.

(b). ROTARY MILLING MACHINES.

During the last few years the milling machine shown in
fig. 322 and known as the rotary miller has appeared as a
very serious rival to the lathe. Not that it can ever take
the place of the lathe for general lathe work, as it is only
suitable for workpieces which owing to their special form
are adapted to this type of machine and even then it can
only be used to advantage for repetition work. In the case
of the rotary miller, "repetition work" need not necessarily
be taken to mean that thousands of workpieces of identically
the same form have to be handled. For a small number
vorkpieces which are never likely to recur, neither the
setting up of the machine itself nor the cost of the special tools
required would prove remunerative. Where a few score of
workpieces have to be machined, the use of this type of
machine, even when those pieces are never likely to occur
 and Milling Practice. 261

again, would prove remunerative, but even so the profit

derived from such a small number with regard to the same
work out carried on the lathe, is not so great as to com-
pensate for the not inconsiderable expense of the special
cutters which could not be used subsequently. Should the
same workpieces recur from time to time, a few score of
such workpieces would make the machine pay for itself in
addition to covering the cost of the cutters, whilst in cases
where larger numbers have to be machined, the cost of

Fig. 322. Rotary milling machine.

production on the rotary miller will prove to be consider-

ably less than if the same work were carried out on the
lathe. In this connection, the fact that the rotary miller
requires but little attention must not be lost sight of^
so that one workman can look after a number of such
machines or superintend one or two rotary millers simul-
taneously with other machines. Work carried out on the
rotary miller has not such a finish and degree of accuray as
to permit of the performance of work requiring absolutely
perfect accuracy or in which the slightest deviation would
262 Milling Machines
not be permissible ; on the other hand the machine will mill
workpieces sufficiently well for a large number of purposes,
so that with the exception of workpieces demanding per-
fect accuracy, there is still a wide range of usefulness for
the rotary miller.
Figs. 323—327 illustrate various classes of work carried
out on the rotary miller together with the cutters used in
connection therewith.
Fig. 325 shows a handwheel, the semicircular circum-
ference of which has been milled. In fig. 323 is illustrated
a blank for a lathe change wheel, a mitre wheel will be

Fig. 823—327. Cutters and workpieces of the rotary milling machine.

turned out of the blank shown in fig. 326. Fig. 327 shows
the muffler of a friction clutch : fig. 324 a small rope pulley.
Not only small rope pulleys however, but even those varying
in diameter from 24—36 ft. are nowadays milled on their
circumference by the milling cutter.
The rotary miller has two principal motions, viz: — the
rotary movement of the cutter and the slow rotary feed of
the workpiece, both of which are actuated by the 3-step
pulley 1. (Fig. 328).
The main drive is imparted to the three step cone pulley
1 by a cone pulley of similar dimensions on the countershaft.
Pulley 1 is connected with wheel 2 and runs idle on the
main spindle 3. Wheel 2 meshes wheel 4, which is mounted
 and Milling Practice. 263

on a sleeve running idle on the shaft 9; at the left hand

side this sleeve is formed as a clutch, which can be engaged
with the clutch of gear 6 whenever the machine is set in
motion.
Wheel 6 drives not only the main spindle but also the
feed mechanism of the workpiece, since wheel 6 meshes
not only wheel 7 which is keyed to the main spindle, but
also drives shaft 9 at the same time by means of the spring
key 8, from the right-hand extremity of which shaft the

Fig. 328. Section over main spindle and back gears.

feed is derived by means of gear wheels. (Fig. 328).

The main spindle runs in cylindrical bearings, the front
bearing being adjustable. The spindle is bored to receive
a rod by means of which the arbor cone is drawn tight in
the spindle or forced out. The spindle nose is provided
with a slot in which two notches fit on the cone of the
arbor in order to prevent the cone of the latter from slipping
in the taper bore of the spindle and so becoming damaged.
The lever 12, (fig. 328), reaching from the rear bearing
of the machine to the place where the operator stands,
264 Milling Machines and Milling Practice.
permits of wheel 4 being shifted on shaft 9 so as to be
engaged with wheel 6, thus setting the machine in motion.
By moving wheel 4, the spring bolt 13 is also moved by
the fork 14 which is forced by the hub of wheel 4, the
spring behind the bolt 13 being compressed. Spring 15,
being compressed, will have a tendency to release which
would cause the ma-
chine to stop, but this
is prevented by the
hook lever 16, the
hook of which engages
a slot on the under-
side of the bolt. Figs.
_ 329—331 show the
mechanism.
The left-hand extre-
mity 17 of the hook
lever 16, which is
forced down by the
spring 18, is connected
with the long lever 20,
by means of the bolt
19, the handle or lever
20 reaching over the
front bearing of the
machine to where the
operator stands. To
stop the milling cutter
Fig. 329—830.
Mechanism for starting and stopping machine. by hand, it is only
necessary to press the
knob of lever 20 when the connecting bolt 19 is lifted and dis-
connects lever 16 from the slot in bolt 13, as a result of which
spring 15 is released and moves wheel 4 ; a leather thrust 21,
(fig. 328), reduces the shock between wheel 4 and bearing 22.
The automatic stop of the machine is accomplished by
means of the feed shaft 23 at the rear of the machine,
(fig. 332), driven by the previously mentioned shaft 9,
(fig. 328), by the gears 24, 25 and 26 and the friction
Fig. 331. Mechanism for starting and stopping machine.

Fig. 332. Back-view of rotary milling machine.

266
Milling Machines
discs 27, 28 and 29. In the housing 30, (fig, 333), shaft
23 drives the worm and worm wheel 30/31 as also the
spindle 33, to the lower end of which is attached a weight
34, the upper end being threaded. As already stated,
when the machine is started, bolt 13, (fig. 328), is shifted
to the left which causes the vertical bolt 36 to engage a
slot in bolt 13, which is just turned round far enough

Fig. 838. Side-view of rotary milling machine.

by the small lever 35, (figs. 329—331), to permit of

the cam block 37 engaging the thread of bolt 33. This
bolt will at once rise owing to its being driven by
wormwheel 32. At its top is placed an adjustable screw
38 which is forced by the bolt against the underside of
the hook lever 16/17 and releases the hook from the slot
in bolt 13, thus releasing the spring of bolt 13 and by
moving this spring to the right, stops the cutter and the
feed. The vertical bolt 36 is then turned by the lever
 and Milling Practice. 267

Fig. 334.

35 and the spring 39; the small block 37 is released from

the thread of bolt 33 and the weight 34 draws the bolt
dowr\ to its original position.
The automatic stop takes place each time the workpiece
has completed a full turn. The starting point can be deter-
mined by the operator according to the requirements of
each particular case, which is necessary since when an-
other workpiece has been put on the machine, it must be
fed in slowly to the rotating cutter by means of the hand-
268 Milling Machines
wheel 40 until the carriage strikes against the stop block.
Only then is the desired diameter to which the workpiece
must be milled, attained. During this handfeed, screw 33
is already raised so that the machine would be stopped too
soon and a portion of the circumference of the workpiece
would not be milled to the required diameter. To prevent

Fig. 336.

this, directly the cutter has been properly adjusted, the

operator taps knob 20 which stops the rotation of the
workpiece for a moment, screw 33 falls back and lever 12
stops the rotation of the workpiece. Screw 33 starts for a
complete turn of the workpiece, the machine being stopped
exactly after a full turn.
The feed of the workpi
The feedshaft 23 at the rear of the machine has its
 269
and Milling Practice.

motion imparted to it by the lower friction disc 29, (figs.

334—336), as well as by the bevel gears 41—43, which
are provided on
account of the
difference of cir-
cumference feed
required for in-
ternal and ex-
ternal milling and
can be engaged
by the lever 44
at the front of
the machine. The
other end of the
splined shaft 23
terminates in the
box 45 and by
means of the
Fig. 337.
worm and worm-
wheel 46/47, (figs. 337—340), imparts motion to the shaft
48 in carriage 49, (figs. 341—342). The feed motion is
transmitted to worm wheel 51 from shaft 48 by a second

Fig. 338.
270 Milling Machines
worm 50 and by the flange 52 to spindle 53. To adjust
the workpiece by means of the handwheel 54, the flange
and the wormwheel can
be disengaged by un-
screwing the four nuts 55.
The square 57 is em-
ployed for the feed of the
carriage 49 together with
the workpiece in the di-
rection ofthe cutter arbor.
The workpiece is moved
by handwheel 58 and
spindle 59. Both carri-
ages can be tightened by
means of clamps. Stop
Fig'm 60 is used for external
milling. As can be seen
from fig. 342, this can also be adjusted by means of the
square 61.
For internal milling two additional stops are introduced ;
stop 62 with nut
and lock nut for
feeding the work-
piece square on
the spindle and
stop 63 on the
front of the bed
for feeding
parallel to the
cutter spindle,
which is bolted ~
in the f slot 64
and against
which a button
of the carriage Fig. 340.
strikes.
The rate of feed of the workpiece is so arranged that the
feed remains practically the same for various diameters with
 271
and Milling Practice.
the same gears. This is obtained in the following manner :
A worm in box 65 at the end of spindle 59 in carriage
49 meshing in worm wheel 67 (fig. 342) drives shaft 68
which is provided with a keyway and is carried at the
other end in 69 where it drives the gear 70 and the clutch
71, whence motion is transmitted - by means of gear 72
and friction disc 70. This shaft has thus a fixed ratio of

— 154

Men—

Fig. 341.

speed with the spindle 59 and rotates as soon as the work-

piece approaches the cutter or retires from it. As the cir-
cumference of73 is provided with a spiral groove in which
runs a pin from the lever 74, the centre friction disc being
attached to this lever, the lever 74 with the centre friction
disc 28 is pushed either forwards or backwards by the
feed of the workpiece. In this manner the position of
friction disc 28 as regards the two others is changed, thus
bringing about a change in the feed.
272 Milling Machines
A small face plate 75 is mounted on the spindle for
milling workpieces with a bottom or with spokes, the carriers
of which drive the workpiece and consequently carry it
along with it.

Fig. 842.

(c). THREAD MILLING MACHINES.

The thread milling machine being a rotary miller of

special type, work can also be carried out on it which was
formerly done on the lathe. Fig. 343 illustrates such a
machine as built by Pratt and Whitney. It is built in various
sizes suitable for milling different diameters and lengths.
 273
and Milling Practice.
Practically every type of thread can be milled with the
single exception of a real square thread. A variety of types
of threads which can be turned out on these machines are
illustrated in fig. 344.

Fig. 343. Thread milling machine.

The machine itself is mounted on a box bed and pan.

(Fig. 343). The maximum diameter and length which can
be handled between centers is 6" X 132", but as the
headstock spindle is hollow and the tailstock spindle18 can be
Fig. 344. Various types of threads cut on the thread milling machine.
 Milling Machines and Milling Practice. 275
removed the workpiece can pass through both and seeing
that the thread can be picked up with perfect accuracy, the
length which can be milled is practically limitless.
On the rear of the bed, the headstock and tailstock
are carried on a single V and along a flat track at the
front of the bed. The carriage rests on both sides of the
bed on flat tracks, and is gibbed in a narrow angular slide
at the rear. The lead screw J is in the centre of the angular
slide. The cutter arbor is mounted in the head T connected
to the cross slide L on the carriage K by trunnions which
allow it to be tilted to any required angle for a given pitch
of thread. The construction is such that at whatever angle
the cutter may be set with T, the point of the cutter is always
level with the centre line of the work. By means of a
micrometer head S on the cross-slide screw, the depth of
cut can be regulated for any given thread. An adjustable
stop connected with the micrometer head S is provided for
fixing the cut at precisely the same depth for repetition
work. The blank being finished to size for outside of re-
quired screw, it is placed in the machine, the cutter being
brought forward by the cross-slide screw till one tooth of the
cutter just touches the external diameter of the blank, and
the micrometer is then set at zero. The carriage with the
cutter is moved along the bed to the end of the work and
the cutter set at the required depth as indicated by the
micrometer, in which position the cross-slide is then clamped.
Then the proper change gears are placed for the required
lead, the stop N1 being set at the required point to knock-
off the feed when the desired length of thread has been cut.
The machine is then ready for operation and requires no
further attention till the requisite length of thread has
been cut.
The carriage K can be moved over the entire length of
the bed independently of the change gears by turning
the small handle P at the back of the carriage which
revolves the lead screw nut through a worm gear. It is
thus a simple matter to set the cutter at any desired point
to begin the thread or to set a new cutter in its proper
276 Milling Machines
place whenever the necessity arises to replace the cutter in
use for a new one. When the carriage is properly located,
the lead-screw nut is locked in position by binding the
worm, thus ensuring direct connection between the lead
screw and carriage so that the carriage can then only be
moved by the lead screw.
The lead screw has a */* incn pitch whilst change gears
are provided for cutting threads from 12 per inch up to a
thread of 15 inch pitch. The method of calculating the
change gears is similar to that for lathe screw cutting.
The travel of the carriage is controlled by a lever M
at the front of the head stock. When this lever is
in its central position, i. e. vertical, the feed is tripped.
If the lever be pushed over to the left-hand side, the feed
is thrown in and when to the right-hand side, the carriage
is returned ; in the latter case the main spindle is driven by
the rope pulley G, thus giving a relative fast speed. During
the cutting operation this pulley remains idle on the spindle.
When cutting coarse threads of 1 inch pitch and upward,
the carriage must be returned by hand; for this purpose
the lead screw is provided with a square on which a handle
can be mounted.
For cutting threads of 2 inch pitch and upward it is
preferable to drive directly on the lead screw. This change
is obtained by slacking the capstan-screw in the link O3,
allowing the link to swing downward till it locks the lower
end of the lever M, thus locking the spindle clutch in its
central position. The lead screw clutch can now be engaged
by pushing in the knob on the front side of the head after
the knock-off rod has been drawn to the right as far as it
will go.
For cutting left-hand threads, it is necessary to reverse
the direction of rotation not only of the cutter but also of
the work and also to reverse the cutter on the spindle.
The cutter rotation is reversed by a clutch at the rear of
the cutter head, that of the workpiece, (when driven direct
from the spindle), by means of a clutch at the rear of the
feed box. It is further necessary to place an idle gear in
 277
and Milling Practice.
the train of change gears as the lead screw must rotate in
the same direction whether right or left-handed threads are
being cut.
Double, treble and multiple threads as also spiral gears

Fig. 845. Front view thread milling machine.

can be cut on this machine by a very simple arrangement.

The spindle which carries the rope pulley and the spindle
gear, is bored through its entire length and in this is placed
an inner hollow spindle carrying the nose piece and collet.
The inner spindle carries a notched index ring H, there
being a pawl on the outer spindle, which locks the internal
278 Milling Machines
and external hollow spindles together. To index for a
given thread, all that is necessary is to release the pawl
from the notch it is in and to turn the inner hollow spindle
that part of a revolution which is requisite to obtain the
desired division. As the notched ring is divided, the exact

5468
Fig. 846. Rear view of thread milling machine.
 279
and Milling Practice.
position can be accurately determined at once, after which
the pawl is again engaged in its notch, thus once more
connecting the two spindles. For a treble thread, for
instance, a ring with 12 notches is employed, the spindle
being turned over 4 notches. The divided ring supplied with
the machine has 48 notches so that it can consequently be

Fig. 347. Special cutters for thread milling.

divided into 2, 3, 4, 6, 8, 12, 16, 24 and 48 parts.

The cutter head as also the feed is driven by a 2V«
inches belt. A three-step cone pulley is mounted on the
end of the driving shaft, (fig. 345), which drives the main
spindle by means of a number of gear wheels in the gear
box in addition to driving the cutter head through the
vertical telescopic shaft and bevel gears. Three different
rates of speed can thus be imparted to the cutter by the
280 Milling Machines
cone pulley, suitable for different diameters of cutters and
the varying quality of stock to be milled. The cutter drive
is consequently direct so that it is impossible for the cutter
to be damaged by the driving belt slipping. The oil pump
is driven by a separate belt whilst the spindle is driven direct
by the rope pulley for the quick return of the carriage.
The number of revolutions of the spindle can be varied
by means of gears at the rear of the bed. By shifting two
levers, one of which has six positions, the other three,
eighteen changes of speed in geometrical progression can
be obtained for each of the three speeds of the driving

Fig. 848. Attachment for milling internal threads.

pulley, thus giving a total of 3 X 18 = 54 changes of

speed not only for the spindle but also for the lead screw.
By means of a reverse clutch these speeds can be engaged
for left as well as for right-hand threads. The handles and
mechanism can be seen in fig. 345 just above the cone pulley.
The cutters used on this machine are illustrated in
fig. 347. The teeth of these cutters are staggered. Only
one tooth cuts on both sides, the other teeth having but
one cutting edge. For the accurate grinding of these cutters,
a small special grinding machine has been constructed,
which is indispensable to the machine.
Next to the point at which the cutter operates, the work-
piece is supported by a rotating following rest arranged
 and Milling Practice. 281

for interchangeable hardened and ground bushings corres-

ponding to the diameter of the blank.
The machine can also be arranged for milling internal
threads. In place of the customary cutter head, an attachment
is mounted on the carriage specially for internal milling
(fig. 348), a collet being mounted on the spindle nose corres-
ponding to the diameter of the work to be milled, the machine
is then ready for internal milling without any further change.

(d). GEAR CUTTING MACHINES.

The first gear wheels with cut teeth were turned out on
the universal milling machine. The cutter was fed automa-
tically through the blank, whilst each time the cutter had
passed over the face, the table had to be returned by
hand, the dividing head being shifted by hand before the
milling of another tooth could be proceeded with. Although
the actual cutting was thus automatic, that is to say, the
machine required no continuous manipulation, gear cutting
on the universal milling machine was not fully automatic.
Although some 40 years ago, machine tools were almost
invariably supplied with cast teeth, now-a-day even machine
tools of very indifferent quality are supplied with cut gears.
On this account a lively demand has arisen, especially for
machine tool manufacturing, for cut gears, as also for ma-
chines for producing cut gears cheaply and expeditiously
and it was owing to this demand that the automatic gear
cutting machine came into existence.
When speaking of automatic gear cutting machines, a
distinction must be made between two entirely different
types, viz: — those by which each tooth is milled seperately
and is thus finished individually, and those by which the
whole of the teeth are milled simultaneously according to
the generating system.
The first type of machine is shown in fig. 349.
In practice, the manner of working is similar to that of the
universal milling machine; the teeth are cut one at a time,
the only difference being that the machine is fully automatic.
282 Milling Machines

The manner of working is as follows; — After the blank

has been placed on the machine and the proper change gears
are mounted, the machine is set to work and feeds the cutter
automatically through the metal; v/hen the cutter has gone
through, the slide with the cutter is returned automatically

V
_
Fig. 849. Automatic gear cutting machine.

at an increased feed; when the cutter has returned to its

starting point the gear blank turns over automatically one
tooth further and the cutter is again fed through the metal.
As soon, as the blank has completed a full revolution and
all the teeth have consequently been cut, the machine is
stopped automatically.
 283
and Milling Practice.
The main drive is obtained from the countershaft and a
four-step cone pulley which drives the cutter arbor by means
of a worm and wormwheel. The feed and return feed of
the slide are derived from this shaft as also the movement
of the blank.
To throw in the feed the lever in front of the bed is
turned to the right. Connected to this lever is a hori-
zontal rod provided with two adjustable dogs. These dogs
can be adjusted according to the face of the blank to
be milled.
A dog is also attached to the slide, which whenever it
strikes
- against
the
dogs

on the rod, shifts the

rod with the lever,
thus reversing the au-
tomatic movement of
the slide, at the same
time increasing the
feed return three or
fourfold. In order to
prevent the lever from
Fig. 350. falling back, it is pro-
Dividing mechanism.
vided with a short cross
arm, against which a
plunger is forced by a spring ; either the lower or the
upper side of the slanting surfaces of the plunger is
forced against the cross arm and keeps the lever in a
fixed position unless it is forced over. When the dog on
the slide has forced the lever over by striking against the
dog on the rod and the slide has been returned to its
original position at an increased feed, the blank is turned
that part of a revolution required to obtain a certain
number of teeth. The automatic dividing mechanism is
shown in fig. 350.
A wormwheel c is mounted on an intermediate shaft
284 Milling Machines
which makes a complete revolution each time for one division
of the gear. For this purpose a fast pulley is mounted on
the worm shaft next a loose pulley ; on the fast pulley is a
belt 3/4 inch wide. This belt would drive the wormshaft and
wormwheel if it were not that the pawl e prevents the
worm wheel from rotating ; before the worm wheel can
rotate, or in other words, before the blank can be moved
one tooth further on, the pawl must first be released, and
this is effected by the cutter-slide.
The dog a strikes against the adjustable dog b on the
upper rod carrying it with it a certain length; by means
of a lever the pawl is
lifted which, releasing
the notched disc, pre-
vents the rotation of
the worm wheel; at the
same time, the rod
draws the belt from the
loose to the fast pulley,
which causes the blank
to partly rotate by means
of the gear wheels in the
front of the bed.
Fig. 351. Simultaneously with
Roughing and finishing cutters working
si multaneously . the gear wheels, the
pawldisc turns and when
this has completed a full revolution, the lever which
holds up the pawl falls and thereby the pawl falls in the
notch and the rotary movement of the gear wheel is thus
strictly limited; at the same time the belt is shifted over
to the loose pulley.
By changing the ratio of the change gears the blank
can be turned such part of a revolution as there are teeth
to be milled.
The teeth are milled from the full material. If, as formerly,
the teeth were cast, then, (1) the cost of milling the teeth
would be higher ; (2) the turning of the rim would be dearer ;
(3) after having cut a few teeth, the cutter would be dull
 and Milling Practice. . 285
owing to its having to cut through the hard crust. For
coarse pitched teeth however too much metal would have
to be cut away to permit of this being done in one cut, so
that the cutter would have to do it in two cuts ; to avoid
this, a preliminary cutter is placed by the side of the cutter
which roughs out the tooth space (fig. 351), with the result
that the finishing cutter has to cut away considerably less
metal so that by this means even teeth of fairly coarse pitch
can be milled in one operation.
Although this type of machine works fully automatically
and turns out first-class work, it still has one great objec-
tion, viz: — for each pitch and for each size of gear wheel
another cutter is required, which necessitates keeping a
large stock of cutters on hand.
The custom has been universally adopted of using a set
of cutters, (consisting of either a set of eight or fifteen),
for gears of 12 teeth and upwards to the rack. For gears
requiring accurary, the set of 15 is used ; should perfect
accuracy not be absolutely requisite, the set of 8 will be
found to be sufficient. Should a cutter be desired with
which an absolutely true tooth can be cut, it must be specially
made to the exact circular and liniar pitch, since it is evident
that a cutter which will cut a true tooth on a gear with
35 teeth could not possibly cut a true tooth on a gear with
41 teeth. Cutters in sets of 8 or 15 are on the market; if,
however, a cutter is required for a certain definite number
of teeth, it must be specially made.
The cutters of the set of 8 are used consecutively as
follows: —
No. 8 for gears with 12—13 teeth
„ 7 „ „ „ 13—16
„ 6 „ „ „ 17-20

„ 5 „ „ „ 21 25 ' „
„ 4 „ „ „ 26-34 „
„ 3 „ „ „ 35-54 „
„ 2 „ „ 55-134 „
1 135— rack.
286 Milling Machines

The set of 15 are employed af follows:—

No. 8 for gears with 12 teeth
„ 7* „ „ „ 13
»'»
7 M »
14
** »

n 6i „ „ „ 15-16 „
„ 6 „ „ 17-18 „
* 5£ „ „ „ 19—20
» 5 „ „ 21-22 „
„ 4J- „ „ „ 23-25 „
w 4 „ „ „ 26-29 „
„ 3J „ „ „ 30-34
» 3 „ „ 35-41 „
» 2J „ „ „ 42—54
9 A g n „ OO I «7 „

„ H » » » 80-134 „
» 1 . « 134— rack.

(^). GEAR HOBBING MACHINES.

The type of gear cutting machine previously described
has this great advantage over the bobbing machine that it
permits of the cutting of epicycloidal and other forms of
teeth, whereas the hobbing machine only allows of the
milling of evolute gears.
One of the first requisites for a smooth running gear wheel
is that the arch of the teeth should be perfectly accurate.
The epicycloidal form of tooth is fast going out of use
owing to the cost of production being too high. For
the milling of accurate teeth, it is a matter of the utmost
importance that the cutter used for the purpose should also
be perfectly true; but it is not sufficient that the cutter
should have an accurate form, the relative position of the
cutter must also be perfectly accurate as regards the centre
of the gear. Even then it is not certain that an accurate
gear wheel will be cut. The cutter must further be accurately
adjusted on the milling machine relative to the position of
the blank. Very primitive means are usually adopted for
the cutter adjustment and the position of the blank, the
 287
and Milling Practice.

adjustment of the cutter being generally guided by the eye

alone. It goes without saying that it is impossible to cut
an accurate gear in such a manner.
The milling of gears according to the hobbing process
is accomplished under a totally different principle to that of
the milling of the teeth one after the other with a gear
cutter on a machine as shown in fig. 352.
The form and size of evolute-shaped racks are precisely the
same for every circular pitch of gear whether large or small

Fig. 352.
Gear hobbing machine. Position of gear blank on the machine horizontal. ;

provided the pitch of teeth is the same; the form of the

tooth being a sy metrical trapezium, the sloping sides of
which are at an angle of 30 degrees to one another.
In fig. 353 a is shown a rack, b being a gear of an arbitrary
diameter and number of teeth. If a is moved slowly in the
direction of the arrow 1, whilst b is revolved on its axis in
the direction of arrow 2 in such a way that the circular
pitch line 4-4 rolls upon the linear pitch line 3-3, the exact
involute form of the imaginary gear will be obtained when
all the metal between the teeth of the rack and the imaginary
288 Milling Machines
gear has been removed by the rack teeth ; strictly speaking,
it must be imagined that the teeth of the rack are some-
what deeper, the line of depth of the teeth of the gear
somewhat filled up and vice-versa, so as to be equivalent
to V« of tne linear pitch (see fig. 353).
It is in along this principle
that the gear hobbing machine
works. In place of the rack which
has no cutting capacity, a hobber
works with relieved teeth as per
fig. 354, the profile of its thread
having the perfect form of the
Fig. 353.
rack tooth but modified at adden- The principle of the bobbing
dum and the whole depth of line
in the manner indicated above. system.

When cutting, the relative position of hob and blank is

determined by the following conditions, (see figs. 355 — 357).
1. The pitch line of the hob is a tangent of the circular
pitch line of the gear to be milled (see fig. 353).
2. The axis of the hob forms such an angle with the
axis of the gear to be milled that the thread of the hob runs
parallel to the axis of the gear wheel, (fig. 356).
3. The pitch line of the hob
touches the circular pitch line of the
gear approximately in the middle
of the face of the hob. Perfect ac-
curary in this respect is not neces-
sary. During the cutting process,
the hob and gear rotate in fixed
Fig. 354.
Gear hobber.
ratio in such a way that during
one complete revolution of the gear,
the hob makes as many revolutions
as there are teeth to be milled. It must now be imagined
that the hob is not in the position shown in fig. 355 but
somewhat lower, in the position indicated by the arrow 1,
so that a straight line b-b drawn through the centre a of
the hob to the axis of the gear will bisect the latter. I > y
the rotation of the hob other hob teeth come constant!}' in
 and Milling Practice. 289

the toothspaces and consequently more cutting profiles pass

along this line. These teeth, which are similar in form, are
in another position to the preceeding ones in the direction
of the pitch line of the hob.
The distance traversed by one tooth of the hob during
one revolution is equal to the pitch. It would thus appear
as if the cutter profile moved over the tangent with the
circular pitch line of the gear, whereas the latter rotates
with a speed in accordance
with the diameter and the bl
number of teeth. It is evident
that in this manner the tooth- b
form in the plane b-b is ob-
tained in precisely the same
way as that shown in the
imaginary process in fig. 353
for the exact involute form
of tooth. The hob, however,
does not cut the tooth flank
in an unbroken line since
its teeth only cut when one
of them passes over the sur-
face. The flank of the tooth
is consequently not formed
by one single unbroken curve,
but consists rather of a large
number of straight surfaces Figs. 355—357.
Relative position of hob and blank
forming together the evolute during process of milling.
flank of the tooth and the
greater the number of teeth, i. e. grooves the hob has, the
more the total number of these small surfaces will approach
the perfect evolute line. For this reason it is advisable to
have as many grooves in the hob as possible. However,
the surfaces composing the flanks of the teeth are so small
that even with a hob with a small number of grooves, they
are scarcely perceptible.
For gear cutting according to this principle, two types of
machines, differing widely one from the other, are employed. 19
290 Milling Machines
In the first type, shown in fig. 352, the axis of the blank
is vertical, in the other, shown in fig. 358, horizontal. In
their general construction they also differ greatly from one
another, though both work on the same principle.
The manner in which the machine illustrated in fig. 352
works is as follow: —
By means of bevel gears the cone pulley drives a ver-
tical shaft in the interior of the vertical column, which shaft
is provided with a keyway from which a bevel gear
mounted on the sliding head is driven, the spindle being
driven by another bevel gear which meshes that just referred
to through a second set of bevel and spur gears. The
spindle, the train of gears and the bevel gear that meshes
the gear on the vertical spindle can, together with the
swivelling part of the sliding head, be swiveled vertically
in a complete circle, so that the spindle can be set at any
angle in the vertical plane.
The change gears by means of which the table speed is
determined are driven by the cone pulley shaft. The hori-
zontal splined shaft at left hand side of the bed is driven,
by means of a train of gears and carries a worm meshing a
worm wheel almost as large as the diameter of the table to
which it is connected. The consequent result is, that there
is a fixed ratio between the table and hob speed which
can be varied by the change gears.
The feed of the slide along the vertical column is derived
from the horizontal shaft along the bed. A worm on the
shaft meshes a worm wheel which in its turn drives a
sprocket wheel by a train of gears which by a chain drives
a sprocket wheel on top of the column ; the worm of the
shaft on which this sprocket wheels is mounted drives a
worm wheel which is provided with a square thread and
turns the vertical screw-spindle which moves to the slide
up and down.
The worm on top of the vertical column can be disengaged
either automatically or by hand at any desired point, whilst
by two bevel gears which drive the worm wheel, the slide
on the vertical column can be moved up and down by hand.
 and Milling Practice. 291
For gauging the exact depth of cut, a large dial with
micrometer division is fixed on the feed screw of the table,
so as to adjust the position of the table accurately.
As the form of the teeth of a rack* are, given a certain
pitch, the same for all gears, all gears of the same pitch can
be cut with the same hob, and, since at the present day all
gears have a pitch which contains the value TT, only a com-
paratively small number of hobs are required.
In addition to spur gears, worm wheels can also be cut
on these machines.
In the latter case, the slide is clamped on the column,
the cutter arbor is level (since the teeth of the worm wheel
are at precisely the same inclination as the thread on the
hob), and the axis of the hob is adjusted exactly over the
middle of the width of face of the worm wheel. From the
same spindle which drives the vertical feed of the slide on
the column, a chain drives a sprocket wheel in front of the
bed keyed on a worm shaft meshing a worm wheel mounted
on the table feed screw, the gear being fed horizontally to
the hob. In other respects the manner of working is the
same as for spur gears.
Not only spur and worm wheels but also spiral gears
can be cut in this manner. The manufacture of spiral
gears differs from that of spur gears in that the feed of
the hob is no longer parallel to the axis of the blank
but is in a spiral line over the face of the blank. The
hob is the same as that used for cutting spur gears and
worm wheels.
Certain practical difficulties stand in the way of getting
the hob to follow a spiral line directly, but this can,
however, be obtained indirectly as the result of the feed
parallel with the axis and an increase of speed of the hob
or gear during the revolution.
A spiral line is thus obtained by increasing the number
of revolutions of the hob required for traversing the width
of face for a certain number of teeth by for instance, one
revolution, the number of revolutions of the blank remaining
the same. The result of this additional revolution of the
292 Milling Machines
hob combined with the vertical feed is the spiral line of the
teeth of the spiral gear to be manufactured.
The manner of working in the case of spiral gears is
as follows: —
If a hob be employed with a single thread of 8/4 inch
pitch, the feed screw of the slide having a pitch of 8/ie inch
and a gear is to be cut with 3/4 inch face and 30 teeth at
an inclination of 45 degrees, then in the first place, a
train of . gears must be mounted which will cause the
blank to complete one revolution against 30 revolutions of
the hob.
In order to impart to the slide and hob a movement in a
straight line of 3/4 inch, the feed screw which has a pitch
of 3/,6 inch, must complete four turns. At the same time,
however, the hob must describe a spiral line of 45 degrees
over the face of the blank. To obtain this, the four revolutions
of the feed screw cause a compound movement of the hob
by means of a train of gears in such a manner that the
hob performs just one more revolution during these four
turns than is necessary for the given number of teeth. This
additional revolution is completed during the time that the
hob gets a vertical feed of 3/4 inch. The result of this com-
pound movement is a spiral line with an inclination of
45 degrees.
In the foregoing example it has been taken for granted for
the sake of simplicity that the number of revolutions of the
hob as opposed to the number of revolutions of the blank
requires to be increased by exactly one revolution.
It goes without saying that this will be only the case
with an inclination of the teeth of 45 degrees, other angles
requiring more or less increase of the hob speed according
to a larger or smaller inclination of the teeth.
The same result can also be obtained by reducing the
number of revolutions of the blank during the time that the
slide is traversing a distance equal to the width of face of
the tooth by one or more or a fraction of a revolution, so
that the position of the hob to the blank being altered,
spiral lines are obtained.
 293
and Milling Practice.
In this manner spiral gears with varying lead can be cut
with one and the same hob according as the hob is forced
to an increase of speed of one or more revolutions or the
blank speed is slackened in the same manner.

Fig. 358.
Automatic gear hobbing machine. Position of gear blank vertical.

In either case, however, the axis of the arbor on which,

the hob is mounted must be set at such an angle that the
direction of the hob thread corresponds with the slope of
the teeth of the gear.
294 Milling Machines
Fig. 358 illustrates another type of gear bobbing machine.
The slide on the vertical column is only vertically adjust-
able and cannot swivel. The blanks are mounted in a vertical
'

Fig. 359. Hobbing machine with attachment for cutting internal gears.

position on an arbor carried on this slide and supported on

a stay on the additional column. The hub is carried horizon-
tally and rotates in the carriage on the bed which it traverses
automatically. For the rest, what has already been said
 and Milling Practice. 295
with reference to the machine shown in fig. 352, applies
equally as well to this machine, thus rendering any further
description superfluous.
Reinecker, who has put on the market a gear hobbing
machine very similar to that illustrated in fig. 349, supplies
an attachment to his machine for the cutting of internal
gears as per fig. 359; from the nature of the construction,
this attachment does not permit of so much material being
cut away in one cut as is the case with an ordinary gear
wheel with teeth on the peripheral.
Preliminary cutting is therefore necessary in the case of
wrought iron, cast steel and suchlike tough materials as also
for an anyway coarse pitch. This preliminary cutting can,
however, be carried out at the same time, that is to say, a
cutter which will cut out a large part of the tooth space
can be mounted by the side of the gear cutter which cuts
the true space of the teeth, so that the latter has to cut away
but little metal. In this manner, internal coarse pitched gears
can also be cut. If however, a perfectly accurate gear is
desired, it is necessary to go over all the teeth with the
finishing cutter once again, taking a very light cut.
Reinecker further makes a specialty of machines for
cutting worm wheels and worms. With a hob as shown
in fig. 354 worm wheels may be cut and, provided the pitch
is not too coarse, they may be considered fairly accurate,
(i. e. for all practical purposes), though the manner in which
worm wheels are cut with a hob in such a way conceals a
rather serious fault, which becomes so apparent in the case
of worm wheels with a coarse pitch that it is no longer
possible to cut such coarse pitched worm wheels with a hob
of this kind.
The question is that the hob will only mesh in the worm
wheel accurately when the pitch line of the hob tangents
with the circular pitch line of the worm wheel. The diameter
at the whole depth circle of gears is considerably smaller
than at the addendum circle or outside diameter. The
distance from axis of hob to axis of worm wheel with hob
in accurate mesh is consequently smaller than with hob and
296 Milling Machines

worm wheel touching their outside diameters. The worm

wheel however, is fed to the hob diametrically. The ad-
dendum line of the hob which is intended to rotate in the
whole depth line of the worm wheel, starts cutting on the
outside diameter. It is only when there is a fixed ratio
between the number of revolutions of the hob and of the
worm wheel blank, that a worm wheel with the desired
number of teeth is obtainable. If the rotary movement of
the worm wheel was only caused by motion of the threads
of the hob, a totally different result would be obtained.
This can easily be proved.

Fig. 360. Worm wheel hobs.

Given that a worm wheel with 50 teeth, 5 pitch, is to

be cut.
The diameter of the pitch circle is thus 50 : 5 = 10 inch,
the circular pitch being - - X ^ = • 6285 inch.
50
Diameter of addendum circle being —52
5 = 10.4 inch.
The outside circumference is thus 10,4 X ~ inches.
Dividing the circular pitch on the outside circumference
(which is the case if the hob rolls freely along the outside
10 4
circumference), - - = 52 teeth mill be obtained instead of 50.
 297
and Milling Practice.
It is thus obvious that when commencing cutting on a
worm wheel with a hob as illustrated in fig. 354, in addition
to rolling upon each other the speed of the blank must also

Fig. 361. Worm wheel bobbing machine.

be increased ' /
0 A.rf /— per tooth. In commencing cutting, the
ou
free rolling of hob and worm wheel blank upon each other
is thus out of the question. The more the pitch line of the
298 Milling Machines
hob approaches the pitch circle of the worm wheel blank
by a diminution of the distance from its centres, the more
freely the hob will roll, but the hob will only be perfectly
in mesh when the pitch line and pitch circle actually coincide,
i. e. when the worm wheel is finished, so that any error
that has been made in the form of the teeth is irreparable.

Worm and worm wheel, jg Pitch. Worm wheel with 30 teeth.

Diameter of pitch circle 30 : -J--J = 48 inches.

The foregoing example would be still more striking if a

much coarser circular pitch were taken for the same pitch
circle, whilst above a certain limit of ratio, between the
circular pitch, the pitch circle and width of face, the cutting
of a worm wheel with a hob as illustrated in fig. 354 would
be an impossibility. Worm wheels cut in this way. should
have but little bearing on their toothflanks and are useless
in cases where there is great pressure on the teeth.
 and Milling Practice. 299

The only true method of manufacturing worm wheels is

to set the hob at once at the exact distance from the centre
of the blank and feed it into the blank sideways.
Fig. 360 shows three of such hobs. The two outer ones
with right and left-hand single thread have a pitch of
21/* inches and a diameter of 12 inches, the centre one with
right-hand single thread has a pitch of 5 inches and a
diameter of 12 inches.

Fig. 363. Worm milling machine.

Fig. 361 illustrates a Reinecker worm wheel hobbing

machine. At the commencement of the cutting operation
the distance between the centre of the hob and the worm
wheel blank is accurately adjusted, the hob being fed in
with its small diameter on the blank and travelling com-
pletely through the worm wheel. In this way an accurately
cut worm wheel is obtained.
The large dimensions to which worm wheels are manufac-
tured at the present day are clearly shown in fig. 362 which
'300 Milling Machines
depicts a 30-toothed worm wheel of 10/ie pitch which was
cut on one of Reinecker's machines in 26 hours.
Reinecker also builds automatic milling machines for milling
worms of similar dimensions, as shown in fig. 363.
The carriage travels over the box-shaped bed along
prisma bearings. The spindle rotates in housings in the
sniveling head which can be set at any desired angle.
The dividing head spindle is bored over its entire length
so that not only worms provided with a bore but also
those which form part of a shaft can be milled on the
machine. The feed of the carriage and workpiece is
derived from change gears at the side of the box-shaped
bed, the ratio between them being determined by the pitch
of the worm.
The machine is driven by a five step cone pulley, motion
being imparted to the carriage by worm and worm wheel.

(/). THE ,, WARREN"

GENERATING
AUTOMATIC
MACHINE.
BEVEL GEAR

Bevel gears cannot be accurately cut on the universal

milling machine. If such be attempted through lack of a
suitable machine, the accurary of the bevel gear will have
to be sacrificed to the desire to get a gear with cut teeth
to such an extent that a gear wheel with accurately
cast teeth would even be preferable to such a gear with
cut teeth.
For a 'long time the only means of obtaining a bevel gear
with accurately machined teeth was by planing.
With the machine illustrated in fig. 364, which is con-
structed according to the Warren system, it is now possible
to cut the teeth of bevel gears fully automatically and to
turn out a perfectly accurate form of teeth on the milling
machine. The system along which this machine works is
as follows:—
Each of the wheels of a set of bevel gears can roll over a
crown gear wheel in which the teeth lie flat in the circum-
 and Milling Practice. 301

ference of a circle. The flanks of the teeth of a flat gear,

however, approach a straight line to such an extent owing

Fig. 364. Warren's bevel gear generating milling machine.

to the evolute form of the teeth, that in practice a cutter

with straight flanks can be employed without any fear of
committing any appreciable fault.
302 Milling Machines
Supposing that a flat crown gear, the flanks of the teeth
of which, as well as those of the rack, are straight lines,
has been formed as a cutting tool, then the possibility is
opened up that if this crown gear with cutting teeth
rolls over another bevel gear wheel, a perfect bevel gear
will result.
In Warren's machine, two cutters form two flanks of the
teeth of an imaginary flat crown gear whilst all movements
of the individual parts of the machine are arranged so as

Fig. 365. Adjusting the rocker head according to diameter of bevel blank.

to obtain the same results as if a flat crown gear rolled

over the bevel gear blank cutting away the superfluous metal.
A rocking motion is imparted to the cutter, the total
movement of which corresponds to the rolling of the flat
crown gear over the bevel gear; the cutters revolve on
their own axis, having, at the same time, an automatic up
and down feed, the blank being turned over one tooth at
the end of the return of the cutters.
The rotary motion is transmitted from the two-step cone
pulley (fig. 364), to the two cutters by means of the gears 2,
 and Milling Practice. 303
the universal jointed telescopic shaft 3 and a set of spiral
gears in the box 5.
In contradiction to the usual practice on milling machines,
the two cutters do not cut against the feed, but the direction
of the rotary movement and that of the feed is the same
so as to force the bevel gear blank by the pressure of the
cut constantly against the shoulder of the arbor on which
it is mounted, thus ensuring a perfectly accurate position.
The rocking motion of the cutters is imparted by the
shear 6 and the link 7, (figs. 365, 367 and 368), the latter
being attached to stud 8 of the large flange 9, from whence
a rocking motion is given to the rocker head. The shear
6 acquires its movement from cone pulley 1, gear wheels 2,
belt pulleys 10 and 11 and the gear wheels 12, (fig. 367).
The length of stroke of the link 7. as also the rocking
of the head, can be changed in accordance with the teeth
to be milled by adjusting the point of contact of the link
on the shear. The adjustment is accomplished by means
of the adjusting screw 13.
The to and fro motion of the cutters representing a part
of the flat crown gear, is transmitted to the workpiece in
fixed ratio by the tooth segments 14 and 15, (fig. 367).
The angle of the bevel gear blank with the imaginary flat
crown gear wheel consequently depends upon the ratio of
the pitch circle of the flat gear and that of the bevel gear
blank. The segments 14 and 15 are interchangeable. For
each different set of bevel gears, two new segments are
necessary.
In a larger size of machine these segments have been
dispensed with. The rocking motion is then obtained by an
adjustable shear which allows a ratio between the two bevel
gears of 1 : 1 to 1 : 6.
Segment 15 is attached to arm 16 which swivels .the index
plate 17 and with it the spindle on which it is mounted,
by means of a pawl which meshes the index plate.
The feed motion is transmitted by the three-stepcone pulleys
18 and 19 by the same shaft as that driven by gear 12
which imparts motion to the shear 6. The gears 20 and 21
304 Milling Machines
transmit motion to clutch 22, (fig. 364). If the lever 23 has
engaged the feed, (see fig. 364), the clutch 22 carries with
it gear wheel 24, transmitting motion by the gears which
run in the gear box 25 to shaft 26. This shaft is carried
in the hollow main spindle. Spiral gears, carried in the
rocking head 4, not visible in the illustrations, further transmit
the feed motion from shaft 26 to the feed screws 27, which
finally transmit feed motion to .the cutter slides. If the roll

Fig. 366. Lateral adjustment of cutters.

of lever 23 is on the right-hand side of the pin 28 imme-

diately beneath it, and which is forced by a spring, the
return clutch 29 is engaged, clutch 22 for the down feed
being disengaged.
The return clutch is driven by the bevel gears 30 mounted
on a shaft running transversely through the column and driven
by the bevel gears in the gear box 31, (fig. 367). The
return feed is further transmitted by clutch 29, (fig. 364),
and the gears in gear box 25 to shaft 26, through the spiral
gears in the cutter slides 4 to the feed screws 27 of the
 305
and Milling Practice.
cutter slides, and returns the latter with increased feed to
the top.
The feed of the cutter slides is engaged and disengaged
by pins 32 and 33, (fig. 364) on the drum 34, (which is
connected with wheel 35 by means of differential gears),
the levers 36 and 23 and pin 28.
The down feed of the slides can be adjusted according
to the width of face of the teeth of the bevel gear blank

Fig.
Adjustment of the cutters to the exact angle of the tooth.

by adjusting the adjustable pin 32 in the groove of the

drum 34.
The movement of the bevel gear blank one tooth further
on takes place at the termination of the return stroke of
the cutter slides. Shaft 37, (fig. 364), imparts motion to
spindle 38 by means of a driving chain, which spindle
makes approximately a half turn to and fro each time
that the feed motion of the cutter slides reverses. At
the right hand end of spindle 38 is a connecting flap 39,
(fig. 365). During the down feed motion this flap moves
20
306 Milling Machines
slowly downwards ; on its return, it reverses quickly with
lock 40 against pin 41. Pin 41 rocks with arm 16 and
the gear blank. In this way, when the connecting flap 39
is at the highest point, pin 41 will slide off along the
slanting surfaces of lock 40 and withdraw the pawl from
the index plate 17. The index plate 17 and the blank
remain stationary, arm 16 with the pawl rotating and turning
the blank one tooth further on.

Fig. 368. The machine ready to work.

The adjustment of the machine.

The cutters require to be accurately adjusted in three
ways. Fig. 365 shows the adjustment according to the
diameter. In the place of segment 15, (fig. 364), is set the
caliper 48, by means of which the cutters are so adjusted
that their circumferences traverse the centre of the imag-
inary flat gear wheel.
Fig. 366 shows the lateral adjustment of the cutters.
The inside " a " of the cutter must also traverse the same
point. Fig. 367 further shows the divided scale 42 with
 and Milling Practice. 307
micrometer adjustment which serves for the adjustment of
the slides at the proper angle. _/
The workpiece is first adjusted at the angle (a + ^)» then
set against the cutters by screw 43, (fig. 364), in such a way
that the sides of the teeth converge to the apex of the
cone, being finally adjusted at its exact position at the correct
angle (a — £1). These adjustments are rendered possible
by the use of the divided scale 44, (fig. 367), and micro-
meter adjustment.
The bevel gears shown on the machine in figs. 367 and
368 are first stocked on a universal milling machine. For
this machine, as in the case of the bevel gear planing machine,
the preliminary cutting of grooves is a necessity.

(g). VERTICAL MILLING MACHINES.

The many good qualities of the vertical milling machine

for machine manufacture in general cannot be easily over-
estimated. Ifthe universal milling machine is an exception-
ally valuable tool for machine manufacture in general, the
vertical miller takes a still higher place, though it is a tool
that is not used as generally as it deserves to be.
Large factories have learned to appreciate this type of
machine at its true value but in a greater number of average
size factories, this machine is conspicuous by its absence.
In reply to the query " what can be accomplished on a
vertical miller?", Herbert answers:—
Surfacing
Edge milling
Circular „
Keyway cutting
Cam
Under
Profiling
T-slot _
Recessing
Routing
Die sinking
Cotter hole milling.
308 Milling Machines
From this it can be said that a vertical milling machine
is par excellence a machine for general work. Indeed, we
should strongly advise every manufacturer to begin with the
adoption of a vertical miller. In chapter XIII dealing with
work on the milling machine, the diversity of the work
which can be carried out on the vertical miller is considered
in detail since this chapter will deal with the machine ex-
clusively from the constructive
point of view. The leading
manufacturers of vertical milling
machines,' such as Brown and
Sharpe, Herbert, Cin-
cinnati Milling Ma-
chine Co. Reinecker,
Loewe, etc. build these
machines for general
milling work in three
sizes, viz : No. 1, 2 and
3, differing but slightly
from one another in
their chief dimensions,
their construction be-
ing wellnigh perfect.
Fig. 369 is an No.
tration of the illus-3

Brown and Sharpe ver-

Fig. 369. tical milling machine.
Brown and Sharpe single pulley vertical The leading thoughts
milling machine.
embodied in this
machine are :— single pulley drive ; all drives transmitted from
the main drive by gearing; the handling of the machine
within easy reach of the operator.
The chief dimensions of this machine are: —
Longitudinal feed of the table 34".
Transverse „ „ „ „ 13J".
Vertical „ „ knee 15".
Vertical „ „ the spindle head 8".
all feeds being fully automatic.
 and Milling Practice. 309

Fig. 370 gives a sectional view of this machine. The

drive of the whole of the machine is derived from the main
shaft C. The vertical main spindle derives its motion from
shaft C through gearing. Eight rates of speed are imparted
to shaft E by a train
of gears inside in the
column through the
bevel gears near B,
whilst by means of a
clutch, the upper or
lower verti-
cal bevel
gear can be
madetomesh
the horizon-

Fig. 370.
Sectional view of Brown and Sharpe vertical milling machine.

tal bevel gear and thus the spindle E can impart the eight
speeds either to the right or to the left.
Drive is further transmitted from spindle E and the main
spindle by spur gears, the main spindle being driven by
F, G and H on the pinion on the spindle, (quick speed),
or by F, G, pinion H on the large spur gear on the spindle,
310 Milling Machines
(slow speed), so that in all, with a constant speed of the
pulley, 2 X 8 = 16 rates of speed can be imparted to the
spindle in either direction simply by shifting three levers.
The machine is provided with variable feed mechanism
giving 16 positive feeds driven by a Renold's chain from
the shaft C, the feed being thus independent of the spindle
speed.
From the lower gear case on one side of the column, feed
motion is imparted to the telescopic feed shaft, from whence
the longitudinal and transverse feed of the table and the
vertical feed of the knee are derived and further feed motion
is transmitted to the spindle head and, if one is provided,
for the rotary motion of the circular table. A total of 5
automatic feeds can thus be obtained, each of which has
16 rates of feeds.
The main spindle speed. The belt driving the machine
runs on the pulley D, on the shaft C. The machine can thus
be driven direct from the line shafting, the pulley being
provided with a friction device which can be handled by a
vertical lever in front of the column. The machine is thus
started and stopped by this lever.
The speed changing mechanism which is shown separately
in fig. 370, is very simple.
An idle wheel fig. 370 between the long pinion on C
with the cone gear above it can be made to mesh in one
of the four gears of this cone thus imparting 4 speeds to
the shaft on which the cone gear is mounted, the number
being doubled when either the gear wheel or the pinion of
the topmost shaft is meshed in the cone gear by means of X.
This mechanism resembles to a great extent that for the
feed change, the only difference between them being the
location of the levers. The position of the levers can be
clearly seen on the front of the gear box shown in fig. 371
on top on the left hand side. An index plate gives the
number of revolutions for each position of the levers. The
lever for reversing the motion is the one to the extreme
left on the front.
The eight rates of speed of the vertical shaft E can, as
 and Milling Practice. 311

has already been said, be doubled by means of the gearing

in the gear box on top of the column by shifting the lever
located on the column just above the hand wheel for the
adjustment of the spindle head.
The feed mechanism is driven by chain and sprocket
wheel on the horizontal shaft B (fig. 372).
This gear box is shown in the right-hand upper corner
in fig. 371. On the shaft B are mounted the gear wheel
C and pinion D ; by shifting the lever which can be seen

Fig. 371. Feed and speed gear boxes.

on the gear box in fig. 371, the gear can be placed in

the central position so that the feed mechanism is dis-
engaged, either C or D being in mesh with the corresponding
gears on shaft E. Two rates of speed can thus be impar-
ted to shaft E. The middle portion of this shaft is formed
as a pinion. An idle wheel meshing in this pinion, not
visible in the illustration, can be moved laterally so as
to mesh in one of the four gears of the cone on shaft F,
to which shaft 2X^ = 8 rates of speed can consequently
be imparted. The lever G to the right of the gear box,
enables the different distances required for the difference in
312 Milling Machines
diameter of the wheels to be obtained, whilst the knob
which can be seen just under the index plate in fig. 371,
shifts the idle wheel opposite one of the gear wheels on shaft F.
The eight rates speeds of shaft F are again doubled by
shifting the double wheel H on shaft J so that either the
largest wheel of the cone on F meshes the pinion on J or
vice versa by means of the upper of the two lower levers
to be seen on the gear box in fig. 371.
For each speed of the main spindle, 16 speeds can thus be
imparted to shaft J which finally drives the telescopic shaft.
The automatic
feed is consequently
driven by the teles-
copic shaft to be
seen in fig. 369 to
the right hand side
of the column be-
tween the two feed
gear boxes. By
moving the lever to
be seen in front of
the knee gear box
the motion of this
shaft can be revers-
Fig. 372. Feed gear box. ed. This gear box
is separately de-
picted in the right-hand lower corner of fig. 371. By
means of gearing, the motion is conducted from this gear
box to the feed screw which gives the longitudinal move-
ment to the table or to the mechanism for the transverse
movement of the cross piece and the vertical feed of the
knee. The two latter motions are engaged by levers
and clutches inside the gear boxes for the transverse and
vertical feeds shown in the centre of fig. 371. This box is
to be seen on the right-hand side of the knee in fig. 371.
The automatic right and left-hand longitudinal feed of the
table is engaged by the lever immediately in front of the table.
By means of the large hand wheel in front of the knee,
 and Milling Practice. 313

the table can be moved either slowly or quickly by hand,

while this handwheel, if desired, can be disengaged entirely
by means of a knob in the centre of this hand wheel. All
the hand wheels can be disconnected so as to run loose on
their studs ; the hand wheels are provided with dials graduated
to read to thousandths of an inch.
The automatic vertical feed of the spindle head is driven
by the same mechanism as that for the other feed motions.

Fig. 373. The vertical feed mechanism of the spindle head.

On the left-hand side of fig. 372, a gear wheel is to be

seen on shaft J just behind the fork. By means of a lever,
gear L on shaft F can be made to mesh K and as L is
mounted on the hub of the sprocket wheel M, the latter is
consequently set in motion. From this wheel a chain runs
over two loose sprocket wheels inside the column to a
sprocket wheel N, to be seen in the left-hand lower part in
fig. 371 as also in fig. 373. A lever O locks this wheel N
with the worm shaft to which the hand wheel P is keyed.
314 Milling Machines
The clutch is tripped by the feed tripping dogs at the side
of thesidespindle
the headhead.
of this whichA can be adjusted
worm alongwheel
on the hand ~]~slots at
shaft
for the slow hand movement of the spindle head meshes
the worm wheel Q mounted on shaft R. Q can be engaged
and dropped by the lever S. If Q is dropped, the spindle
head can be raised and lowered quickly by the hand wheel T,
whilst, by means of the hand wheel P, the head can be raised
and lowered slowly to permit of accurate adjustment.
The pinion G at the extremity of R meshes a rack at the
back of the spindle head. This pinion also meshes gear U
mounted on the hub of the wheel V. A steel cable is fixed
to V and is guided by pulley W inside the column, a

Fig. 374. The circular table.

counterweight being attached to the end. The counter-

weight is encased to prevent its swinging (fig, 370).
Such a vertical milling machine as is here described is not
suited for general work unless provided with a circular table.
For at least 50 °/o of general shop work this circular table
is certainly in use. Fig. 374 shows the circular table mounted
on the square one. The automatic rotary movement is derived
from the shaft driving the feed screw which provides the
longitudinal movement of the table. For this purpose the
connection between lead screw and this shaft is broken, so
that only the circular table rotates, the square one remaining
stationary. For the longitudinal movement of the table by
hand, a square is provided at the end of the lead screw
for a crank handle.
 and Milling Practice. 315
The circular table feed is engaged, dropped and reversed
by a lever at the right-hand side of the circular table. The
dogs forferencefeed
of the tripping
table. are located in a "fslot on the circum-
A feature worthy of note in this machine is the manner
in which the different mechanisms are located, the speed
mechanism, that for the feed, for reversing etc. being housed
in separate boxes. This is a great advantage not only from
the maker's point of view but also in the actual handling
of the machine. Should one of the parts of the mechanism
require repair, the particular box can be taken out the column
so that all parts can be easily got at. This is only possible
if each mechanism is wholly independent of the other.
It formerly cost much trouble and loss of time to dismount
machines with the result that minor parts were damaged,
whereas the whole machine can now be quickly dismounted
without injury to the smaller parts by taking out the gear
boxes.
The Brown and Sharpe machine described has a vertical
sliding head in addition to a vertically adjustable knee. In
the smaller type machines this is the rule but in the larger
types it is not so easy to construct machines with a verti-
cally adjustable knee guided by bearings along the column
surfaces so that the table is then only horizontally adjustable
in both directions and travels over a bearing forming part
of the column, the spindle head being vertically adjustable
along the column.

Recently the Cincinnati Machine Tool Company has put

on the market a vertical High Duty milling machine of very
modern and up-to-date construction, especially as regards
its single pulley drive which is similar to that used on the
Brown & Sharpe milling machines, which is designed to take
the heaviest cuts at the quickest feeds the work is capable
.of withstanding. Really, under certain conditions this
machine has more power than a cutter of the very best
quality is able to absorb or the toughest material demand.
Fig. 375 shows the general form of this milling machine.
316 Milling Machines
It will be seen that there is not such a great difference in
its construction to that of the universal single pulley milling
machine illustrated and described on pages 242 — 250, the
main difference being that the head" is vertical ihsTe'aa of
horizontal. It is, therefore, unnecessary to give a detailed
description of the drive, the feed mechanism and construction
of the table, since this has already been given in the pages

Fig. 375. Cincinnati Vertical High Dutv milling machine.

referred to above. The sliding head spindle and spindle

drive are illustrated in fig. 376. The drive is direct from
the main driving gearing, through corresponding mitre gears.
The gear on the spindle is so located as to bring the drive
as close to the lower bearing as possible, thus reducing the
possibility of torsional pressure. The spindle has bearings
of the same size and is of the same length as the spindle
of the universal milling machine described on pages 242 — 250.
From this it will be seen that the designer has introduced
 317
and Milling Practice.

quite a new principle, viz: — the construction of a vertical

milling machine on entirely the same lines as the universal
milling machine with the exception of the head being in a
different position, i. e. vertical instead of horizontal. The
spindle bearings are both carried in the sliding head (fig. 377),
and are, therefore, always at the maximum distance apart
for every position of the head, thus differing considerably

Fig. 376. Spindle and driving gears.

from the Brown & Sharpe construction, sectional view of

which is given in fig. 370, where the distance is variable,
the minimum distance being when the sliding head is at the
highest point and the maximum distance when the head is
down. The vertical sliding head shown in fig. 377 has a
long bearing surface with provision for taking up wear by
means of a tapered jib. An adjustment is also provided for
correcting the vertical alignment of the spindle. In case of
repetition work requiring heavy cuts, the jib screws may be
318 Milling Machines
tightened so as to fit the sliding head tightly to the main
body, thus holding it in an absolutely fast position. The
sliding head may be slowly adjusted vertically by a hand
wheel situated at the front of the head which is brought
into engagement by means of a positive clutch operated by
the handle at the end of the main shaft. This slow movement
is provided with a micrometer dial. A turnstile is provided
at the side of the head for quick adjustment at the rate of

441-A

Fig. 377. The sliding head.

<i inches per turn. The end stop at the side of the head
is also fitted with micrometer adjustment.

The machines described above are adapted for all the

different kinds of milling work necessary in shop practice.
Moreover, a large number of vertical millers are used as
special machines, amongst which profiling machines occupy
a leading place.
Many vertical milling machines for general milling work
are also arranged for profile milling. As a general rule the
 and Milling Practice. 319

larger types of vertical milling machines for general milling

work, are at the same time arranged for profile milling,
but not the smaller sizes.
Fig. 378 shows a vertical milling machine manufactured
by Herbert, having a longitudinal table feed of 62 inches
and a transverse feed of 38 inches, so that it is a machine
of comparatively large dimensions, the sliding head being
vertically adjustable over a 'length of 19 inches, whilst the
machine is also arranged
for profile milling.
The machine is driven
by a four-step cone pulley.
From this cone pulley the
drive is transmitted to the
main spindle by a belt
running on a pulley
mounted on the
same shaft as the
cone pulley and
from thence by
way of two guide
pulleys to the pul-
ley which drives
the main spindle.
This pulley runs
on a sleeve in-
dependent ofthe Fig. 378. A Herbert vertical milling machine.
main spindle,
which prevents any belt pull on the latter, the pulley driving,
the spindle by means of a clutch which permits of the
spindle being started and stopped independently of the belt
drive. The spindle is bored through its entire length, the
cutters being held in place by a draw bolt. This spindle
has 16 rates of speed. The spindle head with the spindle
is vertically adjustable, while the driving pulley remains in
place and the main spindle runs free through its sleeve.
At one side of the column is a steady bracket for carrying
the lower end of the arbor for heavy milling, thus affording
320 Milling Machines
the arbor a support on the underside. This bracket can be
adjusted vertically in two positions so as to permit of its
being used with the circular as well as with the main table.
When not in use, this bracket can be swiveled back out of
the way of the table.
For profile work a profiling roller can be attached to the
bracket. The profiling roller
can be accurately adjusted by
means of a screw so that the
roller can be placed correctly
for putting on the cut. The
roller and the arbor support
are entirely independent so
that both can be used at the
same time.

The Garvin Machine Co.

makes a special profiling ma-
chine as illustrated in fig. 379,
the general lines of which
remind one very much of a
small planer. The table with
the workpiece runs in straight
tracks square on the cross
bridge over which the spindle
slides travel in a horizontal
direction. The drive of this
machine is effected in a special
manner from the countershaft
Fig. 379.
Profile milling machine. without the employment of a
belt. The upper end of the
spindles terminates in a universal joint, (fig. 380). The
machine shown in fig. 379 is a two-spindle profiling machine
so that the workpiece can be roughed out by one spindle
and finished with the other without resetting or requiring
any change of cutters.
The table and cross slide are moved by rack and pinion.
The table has automatic longitudinal feed and is provided
 and Milling Practice. 321
with reverse and automatic trip, The workpiece is mounted
on the table
side by side
with the form.
The former pin
travels along
this form, be-
ing mounted
on the spindle
slide with the Fig; m Universal joint
spindle.
Fig. 381 gives a view of the manner of working, whilst
fig. 382 gives a sectional view of the construction of the spindle
and former pin. The spindle bearings are tapered top and
bottom. Hardened and
ground thrust washers
are placed on both sides
of bottom and under
side of top bearing.
The spindle is shoul-
dered on the lower
box, the end thrust
being taken up by a
steel washer. A hard-
ened steel taper sleeve
runs in the upper be-
aring, and is keyed to
the spindle allowing
freedom for expansion.
Each of the bearings
can be adjusted independently by
lock nuts. In the case of the
lower box, this nut is on the
spindle itself so that its journal
Fig. 381. Profile milling, can be drawn in the tapered box,
whilst for the upper bearing the
nut is on the lower end of the sleeve. The former pin is
mounted in a extended boss in the casting by side of the
21
322 Milling Machines
spindle and can easily be fitted. The slide is balanced by
the long spring inside a tube as shown by the side of the
spindle. The tension of the spring can be altered at will
by means of a screw at the top of the tube.

This profile milling machine is also constructed as an

ordinary vertical
miller and as
TENSION SCREW
STEP I GROUND
TAPER BEARING such, is illustrated
SOLID BRO*;E
in fig. 383.
AND
This type is
CROVND WASHER
TAKE -UP NUT- .
— SPRING TUBS
not a machine
for general mil-
ling work, its use
being limited to
surface milling,
shaft splining and
drilling and the
boring of holes
in .workpieces
machined on this
machine, for
WARDEN
GROUND
AND
WASHER which it is emi-
nently adapted.
eOUO
HARDEN
BRONZE
AND
BOX
The spindle
GROUND WASHER
head is carried
.TAPiH BEARING
on a vertically
•FORMER MM

adjustable cross
Fig. 382. rail whilst the
Sectional view of main spindle of profile milling machine.
spindle itself can
be quickly adjusted vertically by hand over a sufficient length
to permit of the spindle being set to the desired position.
The spindle is balanced whilst the head is moved one inch for
each revolution of the hand wheel in front of it. The spindle
head is moved along the cross rail by feed screw. The
spindle head can also be adjusted in both directions and is
provided with automatic feed trip. The cross slide can be
adjusted vertically by hand and clamped to the housings at
 and Milling Practice. 323

any desired height. As in the case of fig. 379, the spindle

is driven direct from the countershaft by a telescopic

Fig. 383. Garvin vertical spindle milling machine.

shaft without belt transmission. Motion is transmitted from'

the telescopic shaft to the spindle through two sets of spur
gears, each with a different ratio, so that for each speed of
324 Milling Machines
the telescopic shaft, two rates of speed can be imparted
to the spindle. Since three speeds can be imparted to the
former, the spindle has six rates of speed. In the larger
sizes, the machines are provided with back gear which allows
of twelve rates of speed being imparted to the spindle.
The feed is driven from the countershaft by a single pulley
through a feed gear box giving ten rates of feed which can
be changed instantantly by shifting levers. The gearing runs
in an oil bath in the

gear
Fig.box.
384 shows a very
different type of vertical
milling machine. This
machine, manufactured
by Brown and Sharpe,
consists of a box shaped
bed on which a saddle
and a square table travel
in both longitudinal and
transverse directions. At
the rear is a round
column vertically adjust-
able by hand by means
of a hand wheel in its
housing. Motion is im-
Fig. 3b4. parted to the main spin-
Brown and Sharpe vertical spindle
dle from the main drive
milling machine.
by a vertical shaft and
gearing inside the bed
and column. The table has longitudinal feed in the saddle
and the latter transverse feed on the bed driven from a
feed gear box of the same construction as that shown in
fig. 369 with feed tripping mechanism whilst the spindle
bearings are the same as those shown in the sectional
view in fig. 370.
Fig. 385 gives a sectional view over the spindle bearing
of a Hessenmuller vertical milling machine. The bronze
lower box in the spindle head, tapered on the outside,
 325
and Milling Practice.
cylindrical on the inside, is
split over its entire length, the
top and bottom being- threaded
for adjustment after wear. In
the top nut of the lower box
are washers for taking up the
end thrust. A flat ring is fixed
on the spindle and runs be-
tween two hardened steel
washers which can be adjusted
by nut and locknut. The box
is provided with felt lubri-
cation. The spindle has
a conical bore and thre-
aded nose to receive cut-
ters and cutter arbors
which are clamped by a
differential nut.
Fig. 386 gives a sec-
tional view of the spindle
bearing of a Reinecker vertical
milling machine. The spindle
journal is tapered, the bronze
box cylindrical on the outside
Fig. 383.
Hessenmiiller spindle bearing.

being fixed in proper position

by top and bottom locknuts.
(h). SUNDRY MACHINES.
Besides vertical milling machines
with two spindles, machines are also
built with two horizontal spindles.
Fig. 387 shows one of the smaller
machines of this type. These ma-
Fig. 386. chines are exclusively used for the
Reinecker spindle bearing. simultaneous milling of two parallel
326 Milling Machines
surfaces. The machine shown in fig. 387 is extensively
used for milling hexagonals and squares of plugs, taps, etc.
as also for nuts and bolts. For the last mentioned purposes
especially this machine has of late come more and more into
use for general shop work.
For this purpose a divider is fixed on the vertical arbor
by which the
workpiece can
be swiveled
180°, 90°, 60°
and 45° so that
squares, hex-
agons and oc-
tagons can be
milled. Both
spindles rotate
at the same
speed
double andedge
the
cutter fig. 21
is used on this
machine for
milling brass
work. Both
headstocks
can be adjust-
edhorizontally
by means of
micrometer
Fig. 387. Two-spindle horizontal milling machine.

adjustment
but whilst at work remain in a fixed position. The left
hand headstock is moreover vertically adjustable over a
limited distance so as to permit of milling both shoulders
equally with two cutters of different diameter. Should this
vertical adjustment be lacking, it is necessary to use two
cutters of precisely the same diameter if it be desired to
mill two shoulders equally.
The table run's square to the spindles, is vertically adjustable
 and Milling Practice. 327

by handvvheel at the right-hand side of the column whilst

the table has
handfeed, the
larger sizes in
addition having
power feed. The
dimensions of the
table are 14 X 7
inches, the larger
size having a
table 48 X 10
inches. The
larger size is,
however, no
longer employed
for milling small
brass pieces as
described above
but for the paral-
lel milling of
castings such as
are so frequently
to be met with in
general shop
work.
The still larger
sizes of this type
of milling ma-
chines are of the
low built type
shown in fig. 388.
On these ma-
chines the ordi-
nary cutters are
no longer used
but only face mills
with inserted
tooth as illustrated in fig. 10. They are used exclusively
328 Milling Machines
for milling large castings whilst very often only one cutter
is used, as, for example, in the sectional milling of flywheels,
pulleys, gear cases, etc. The main spindles are driven from
a three-step cone pulley through a set of bevel gears by
worm and worm wheel, which latter is fitted direct on the
main spindle. The
table has power feed
square on the main
spindles.
A small two-spin-
dle milling machine
is illustrated in fig.
389. In this machine
the cutters are not
face to face to each
other but contrary.
The cutters make
400 revolutions per
minute, double edge
cutters see fig. 21
being used on this
machine. The ma-
chine is specially
constructed for cut-
ting small slots and
keyways in automo-
bile engine valves,
etc.
The cutting is
entirely automatic,
Fig. 389. Two-spindle keyway cutting -machine.
that is to say, the
table travels auto-
matical y toand fro, the reversal of movement being automatic,
and the table travel can be limited at any desired point
by means of stops at the ends whilst at every reversal of
the table the work is fed against the cutter for taking a
fresh cut.
The type of machine shown in figf. 390 is also employed
 and Milling Practice. 329

as a slot drilling and keyway cutting machine. The table

is vertically adjustable by hand and has a transverse move-
ment on the knee, though during the operation it is
clamped to the
column. The
spindle head has
longitudinal mo-
vement over the
cross rail both
automatically
and by hand in
either direction,
the reversal be-
ing also auto-
matic whilst the
reversal can be
made at any de-
sired point by
adjustable stops.
The spindle head
is vertically ad-
justable whilst at
every reversal
the cutter is fed
into the material
for a fresh cut.

A special ver-
tical milling ma-
chine is shown
in fig. 391. This
machine is used
for rounding off
the Side faces Of Fig. 390. Keyway cutting machine.
spur gear teeth
which is necessary whenever two spur gears have to be
put in mesh sideways, as in the gear boxes of automobiles,
machine tools, etc. The diminutive cutter that runs vertically,
330 Milling Machines

makes 2700 revolutions per minute, describing a semi-circle

around each tooth. The machine works fully automatically.
The gear of which the teeth have to be rounded off, is

Fig. 891. Milling machine for rounding off the teeth of spur gears.

mounted on an arbor which is fixed between the centers

of the two heads on the table. The table is vertically ad-
justable by hand as is also the main spindle, though only
 and Milling Practice. 331
over an limited length. Parallel to the arbor on which the
gear wheel to be milled is fixed, is a second arbor car-
rying a gear wheel which meshes the wheel to be milled
and by which the gear wheel to be milled is turned during
the operation.
When the machine has been properly adjusted and the
cutter set at the exact depth and position as regards

Fig. 392. Automatic twist drill milling machine.

the teeth to be rounded off, the cutter is fed automatically

round the tooth, the gear wheel being turned one tooth
further on as soon as the preceding one is finished, so that
the machine works fully automatically. It is not absolutely
necessary that the rounding-off of the tooth should be a perfect
semi-circle as, in order to facilitate the meshing of the teeth,
they are usually somewhat more pointed.
Fig. 392 illustrates a twist drill milling machine built by
Reinecker. The machine consists of two main parts standing
332 Milling Machines

square one to the other:— the two cutter heads and the head
in which the twist drill blank is fixed and which is fed into
the former. The twro cutter heads are driven separately
and are adjustable longitudinally to the table. The heads
in which the arbors rotate can be placed at any desired
angle in the vertical ptene. Each of the cutters mills one
of the two flutes, both being thus milled simultaneously,
which is imperative since, if the flutes were milled separately,
it would put too great side strain on the blank, with the
consequent result, that the drill would not be straight.
During the operation only the two cutters rotate, both
heads remaining stationary. The drill blank is fixed in the
lead screw head square on the cutter heads.
Whilst operating, the lead screw travels longitudinally
square on the cutter heads automatically whilst, at the same
time, a slow rotating movement is imparted to the lead
screw by change gears to be seen at the right-hand side of
the lead screw head. By changing the ratio of the change
gears, any desired lead can be obtained.
This manner of working is only applicable for twist drills
with the same thickness of core over the whole length of
the flutes.
The machine is, however, so constructed that drills can
be made with a core increasing in thickness towards the
end or with the same thickness of core up to a certain
length after which the thickness is increased. In this case,
the two cutter heads separate automatically and very slowly
over a limited length from the centre outwards.
The flutes of drills up to 1 inch are deepened out com-
pletely in one cut, above 1 inch a second cut is necessary
with a view to the metal to be cut away, the first cut for
roughing, the second finishing. During the finishing cut,
the outside surfaces of the drill are relieved at the same time.
Factories devoting themselves exclusively to the manufac-
ture of twist drills, some of which turn out some 20,000,000
twist drills and more per annum, have constructed their own
special machines for this work, which although very simple
in construction, work entirely automatically and very quickly.
 and Milling Practice. 333
On these machines, some hundreds of which are in use in
one factory, drills varying from */64 inch— 5 inch are made.
As, however, the manufacture of twist drills is the speci-
alty of such factories, they are unwilling that the construction
of their machines should be published.

(k). COMBINED HORIZONTAL AND VERTICAL SPINDLE

MILLING MACHINES.

Combined horizontal and vertical spindle milling machines

are to be met with in all the different types. Universal
milling machines, vertical milling machines as well as
piano-millers are built as combined machines, that is to
say, one machine combines two or more types, as for
instance, the horizontal milling machine is also constructed
to work as vertical spindle milling machine, the piano-miller
working either as vertical or rotary miller or both together.
These combined machines have been met with among
the various types already described, inter alia, the Brown
and Sharpe and Herbert vertical spindle milling machines
which are also built as rotary millers, the Ingersoll milling
machines which are built as vertical spindle- and piano-millers.
By combined machines we do not mean those which
can be changed into another type by the temporary addition
of a separate attachment, but rather those which unite the
essential features of both types and which cannot be regarded
either as vertical, horizontal or rotary milling machines and
which owing to their special construction can only be con-
sidered as combined machines.
Fig. 393 illustrates a machine by Bariquand et Marre,
represented in the illustration as a vertical miller.
The vertical spindle is driven from the cone pulley by a
train of spur and mitre gears, and, fitted up as the
machine is illustrated,, fulfills all the functions of a vertical
spindle milling machine. The spindle head can be
swiveled in a complete circle; the two bevel gears will
still remain in mesh so that angular milling can be
done. The head has only to be swiveled a half circle,
334 Milling Mad tines
whilst a cutter arbor or cutter is to be placed in the horizontal
main spindle which projects from the front of the column
in which it is housed, the arbor being supported by the
overhanging centre to be seen on top which comes in line
with the horizontal main spindle when swiveled 180°, and
the machine is converted into a horizontal spindle miller.
In order to pre-
vent the vertical
spindle running
idle when milling
horizontally, the
small spur gear
at the rear of the
column can be
thrown out.

Fig. 394 shows

such a machine
built by Hure.
Fig. 397 shows
a sectional view
of the spindle
head, from which
it can be clearly
seen how the
spindle is driven
both horizontally
and vertically or
Fig. 898. Combined horizontal and vertical spindle
milling machine of French make. at any angle.
The spindle 11
to which the mitre wheel 5 is keyed, is driven from the
cone pullry. This mitre wheel is always in mesh with
the mitre wheel 6 in the swivel head 1 and 2 fastened to
the column at 3 by ~|~ bolts, and can be swiveled along
this surface in a complete circle, (see fig. 397). The head
is divided, the two halfs 1 and 2 being attached to one
another at an angle of 45° also by "f bolts, i. e. 1 against
2, the half head 1 which carries the gear wheels and the
 and Milling Practice. 335

spindle being, as at 3, swivable in a complete circle. When

set for horizontal milling, the position of the head is as shown
in fig. 395 and 396,
the drive being
accomplished as
shown in the sec-
tional view.
The three mitre
gears really act as
two sets of gears,
since 6 is the wheel
driven by 5 as well
as the driving '
wheel of 7 and for Fig. 394. Combined milling machine working
as a horizontal machine.
this reason pro-
vided with a double set of teeth. Wheel 5 thus drives 6
and 6 drives 7, whilst 7 is mounted on the spindle 4 carried
in two conical bearings.
When swiveled over the surface 3, wheel 6 will travel over
gear 5 and remain in mesh, since wheel 5 runs parallel to
this surface. If, however, 1 be turned along 2, then the
centre on which it turns will be the axis of wheel 6, wheel 7
will thus travel over
wheel 6 and still
remain in mesh. In
whichever relative
position the two halfs
are placed, the three
mitre wheels will still
mesh one another.
If the half head is
swiveled 180°, the main
Fig. 395. Combined milling machine spindle will have as-
as a vertical miller. sumed every angle
between horizontal and
vertical. Seeing that the whole head can again be swiveled
in the vertical plane at any angle from horizontal to vertical,
it is possible to fix the main spindle as well at any angle.
 336 Machines

Supposing that a half globe be attached to plane 3, the

axis of the main spindle can be set at every radius from
the centre of this globe to the circumference.
Figs. 394 and 395 show the horizontal and vertical
position of the spindle, fig. 396 the spindle at an angle.
Both of the machines described here are of French make
but cannot be regarded as examples of modern milling
machine construction. In general, this type of machine is
not employed in larger factories were horizontal as well as
vertical machines are used, but chiefly in workshops where
there is but a
limited amount
of milling work
and where from
time to time the
need arises for
a horizontal as
well as a ver-
tical miller.
The increasing
development of
milling machines
is bringing about
a reformation
Fig. 896. Combined milling mai-hme as a vertical miller
working at an angle. even here and
although the
opinion has been expressed that the combined horizontal and
vertical milling machine might be regarded as an out-of-date
type, the Ingersoll Milling Machine Co. have brought out a
combined horizontal and vertical milling machine of so up-to-
date style and of such correctness of construction that it fully
comes up to the present day position of milling machines
and can consequently take its rightful place with the various
other types. Fig. 398 gives a general view of this machine.
The general features of the column-and-knee type milling
machine can be clearly recognized in this machine. The
vertical milling attachment which almost every maker of
column-and-knee type machines supplies separately, is de-
 and Milling Practice. 337

finitely embodied in this machine. The reason for the

introduction of the vertical milling attachment on the
horizontal milling machine was: (1) to permit of carrying
out milling work that could only rationally be done with a
vertical spindle when no vertical milling machine was at hand,
Q

(2) to machine workpieces

which require to be treated
by a horizontal as well
Fig. 397. as by a vertical spindle
Sectional view of the on one machine without
head of combined
milling machine.
the necessity of resetting
the workpiece. Mounting
and later on dismounting
a vertical attachment on a horizontal milling machine entails,
however, a certain interruption in the regular course of work.
In factories where either one or both these factors make
themselves felt, the machine illustrated in fig. 398 is of ex-
ceptional importance and will certainly win a place for itself.
22
338 Milling Machines
It will be seen from fig. 398 that all parts underneath
the horizontal main spindle correspond entirely with the
construction of a column-and-knee type machine. The

Fig. 398. Ingersoll combined milling machine.

column is extended above the horizontal spindle to permit

of the housing of the vertical spindle. In order to obtain
the maximum transverse motion of the table, the column
 and Milling Practice. 339
above the horizontal spindle is built as strongly as possible,
the knee, which is vertically adjustable over the column,
being very long and supported at the outer end by braces.
The machine is driven by a single pulley, all further motions
being transmitted by gearing, whilst the feed motion is derived
from a shaft running at such a speed that the feed motion
is independent of the cutting speed.
Longitudinal, transverse and vertical power feeds are
provided, all of them reversible and with automatic stops.
The outer end of the main spindle is supported as in the
column and knee type milling machine, whilst, though not
shown in place in the illustration, bracings for connecting
the outer support with the knee can be introduced. This
machine is therefore, a tool which is in no way whatever
inferior to the best constructed horizontal milling machine,
whilst it combines within itself, the horizontal as well as
the vertical miller.
Fig. 399 gives a sectional view of this machine. The
driving shaft B is driven by the pulley A of large diameter
and width which is keyed to shaft B. This shaft carries
the sprocket C which drives the feed as also a double
pinion which can be shifted over the shaft along a keyway
so as to engage one of the two corresponding gears on
shaft D. The double pinion is shifted by a lever on the
outside of the column as shown in fig. 398. Two changes
of speed can thus be imparted to shaft D.
From the shaft D motion is transmitted to shaft F by
a bevel gearing, from which shaft it is further imparted to
the vertical main spindle by spur gears.
The pinion E on shaft D meshes a gear on shaft J from
whence motion is imparted to the horizontal main spindle.
The horizontal and vertical spindles H H are of the same
diameter, the driving mechanism for both being equally
powerful.
Both spindles are carried in a sleeve W provided with a
keyway and clutch teeth. These clutch teeth engage corre-
sponding clutch teeth on the hubs of the gear wheels X and
Y which run idle on W. The gears X and Y are driven
340 Milling Machines
by the corresponding pinions on shaft J for the horizontal
and on shaft F for the vertical spindle. By shifting the
clutches to the central position, both the horizontal and
vertical spindles are stopped,
whilst by engaging the clut-
ches with either X or Y, two
speed are obtained for each

Fig. 399. Vertical section of the Ingersoll combined milling machine.

speed of shaft B. The sleeve W is shifted by the levers shown

in fig. 398, one at the back of the column in line with the
horizontal spindle, the other projecting from an opening in
 and Milling Practice. 341
the vertical spindle housing. Four spindle speeds can thus
be obtained for each of the spindles, with driving pulley A
running at constant speed. With a two-speed countershaft,
eight spindle speeds are thus obtainable for each spindle.
The front housing of the spindles is contained in a sleeve K
which can be adjusted axially by means of a pinion which
meshes rack teeth cut in the sleeve K. This axial adjust-
ment of the spindles is necessary to secure their correct
position when working simultaneously (see fig. 401). The
front housing of the horizontal and the lower housing of the
vertical spindle consist of two tapered journals contained in
sleeve K. The quills K are 12 inches long and have a
lateral adjustment of 6 inches.
As previously mentioned, the feed is driven from a sprocket
wheel C on shaft B so that the feed motions are wellnigh inde-
pendent ofthe spindle speeds, being only increased or retarded
once by the two speeds of the countershaft. The chain from
the sprocket C drives the sprocket M in the gear box at rear
of the base (figs. 398 and 399). This box contains a quick
change gear mechanism. By shifting the lever O, eight feed
changes are provided and this number is doubled by the
handle N which imparts two speeds to a gearing that can
transmit 8 speeds, giving 16 feeds in all. In order to provide
a safety mechanism to prevent damage of certain parts of
the machine, should anything happen, the sprocket M is not
keyed directly to the shaft which it drives. Instead of this,
the bore of this wheel is double tapered and supported by
two taper cones pressed together by a spring. One of these
cones has a long heel which is keyed direct to the shaft.
The compression of these cones in the sprocket bore pro-
duces an adjustable frictional driving device which gives
way in case of undue strain, though there is still sufficient
friction to transmit the heaviest feeds required on the machine.
From the gear box comes a shaft which imparts motion
to the vertical shaft V through a train of mitre gears.
The splined shaft U passes through a gear box attached
to the knee and containing a clucth and bevel gear reversing
mechanism operated by the fork P. The central bevel gear of
342 Milling Machines
this mechanism is connected by spur gears with the worm R
which drives the worm wheel on the horizontal shaft S
driving the various feed motions. The gears connecting
the central bevel gear with the worm R, can be inter-

Fig. 400. Ingersoll combined milling machine as a horizontal miller.

changed as they are placed in the removable guard as

shown in fig. 398. This permits of the feeds being doubled
once more.
The gearing to be seen at the end of the table connects
the splined shaft S with the table feed screw and drives
 343
and Milling Practice.
the longitudinal feed of the table. At the front of the table
is the usual slot in which are the adjustable dogs for the
automatic feed stop. The lever V changes the feed gearing at
the front of the knee which transmits the automatic transverse
and vertical feeds. The ratio of the transverse feed is the
same as that of
the longitudinal
feed, that of the
vertical feed be-
ing in the ratio
of 2: 1 of the for-
mer movements.
The table of
this machine has
a working sur-
face of 48 X 18
inches with a feed
of 56X16 inches.
The saddle gives
a bearing to the
table of 60 inches.
The knee is 36
inches long, the
bearing surface
along the column
28 inches, the end
being supported
by the bracings
T. The vertical
adjustment is 18
inches. The Fig. 401.
Milling with horizontal and vertical spindles simultaneously
spindles have an on an Ingersoll combined milling machine.
axial adjustment
of 6 inches. The greatest distance between the centre
of the table and the column is 24 inches, the least dis-
tance being 8 inches. The greatest distance from the
top of the table to the face of the vertical spindle is 26
inches, the least distance being 2 inches. The greatest
344 Milling Machines
distance from the top of the table to the centre of the
horizontal spindle is 16 inches, the least distance being zero.
A circular table with a diameter of 16 inches and pro-
vided with automatic feed and stops can be mounted on
the main table.
Fig. 400 shows the machine working as a horizontal miller,

Fig. 402. Combined horizontal vertical and circular milling machine.

the vertical spindle being disengaged.

In fig. 401 both spindles are at work. When so employed
the machine has the same capacity as a horizontal and a
vertical machine separately.

Fig. 402 shows a combined milling machine which is a

 and Milling Practice. 345
horizontal and at the same time, vertical and circular milling
machine of most up-to-date construction and adapted for
milling work of great variety.
The square main table, which has a working surface of
48 X 14 inches has longitudinal automatic feed whilst it can
be adjusted transversely by hand over the box shaped bed.
A horizontal spindle head traverses the vertical main
column, in which head the horizontal main spindle is housed,
whilst a cross-rail forming one piece with this head reaches
over the table, the end being supported by an additional
column. This cross-rail carries two vertical spindles heads
both spindles are driven by a worm and worm wheel.
This same cross-rail is further provided with outer bearing
for the horizontal spindle.
A circular table of 24 inches diameter can be mounted on
the main table, provided with automatic rotary feed, thus
permitting all rotary milling work coming within the limits
of the dimensions of the machine. This machine may be
regarded as one of the most useful and handiest of all
combined milling machines.
At the present day the horizontal boring and milling-
machine occupies a leading place among the combined
milling machines.
For machining heavy machine parts, for face milling,
boring etc.,, this type of machine has been universally
adopted in general machine construction.
Fig. 403 shows such a machine as constructed by the
Fosdick Machine Tool Co.
A square table, which can only be adjusted in one
direction by hand, is square on the transverse bed, during
the milling operation occupying a fixed position, being mounted
on the box-shaped bed. On the transverse bed is a vertical
column which is adjustable in both directions either by hand
or automatically, whilst in addition to automatic feed motion,
it has also quick movement over the bed.
A sliding head with automatic and hand feed is mounted
on the vertical column. This head carries a spindle bored
throughout its entire length and running in bronze bearings.
 Milling Machines and Milling Practice. 347
This spindle has a threaded nose which permits of a chuck,
large cutter or face cutter being mounted for heavy milling
work. This spindle can rotate either to the right or left.
A splined boring and milling arbor of 4 inches in diameter
can be adjusted longitudinally in the outer spindle, the outer
spindle being provided with a key, so that the inside spindle
rotates with the outside, though it can be longitudinally
adjusted in the latter either by power or by hand in both
directions, having also fine adjustment by hand for accurate
setting and quick movement for the to and fro motion of
this spindle. The end of the spindle is bored to receive a
Morse taper N°. 5 so that drills, cutters and face millers
without a threaded bore can be mounted. With 10 different
rates of speed, the spindle can make from 4 to 260 revo-
lutions per minute.
Whilst being machined, the work occupies a fixed position
on the machine but the spindle can be set at any position
as regards the workpiece, either vertically, horizontally or
in front, having power feed in either of these directions.
 CHAPTER X.
Attachments for the Universal Milling Machine.
A number of attachments are supplied with the universal
milling machine which allow of the carrying out of a variety
of operations for which the machine was not originally con-
structed, perhaps, not so rationally and accurately as on a

Fig. 404. Vertical spindle milling attachment.

machine specially constructed for the purpose but still, in the

absence of such a machine, these attachments which replace
it may be used and will certainly prove very serviceable.
The various attachments which will now be described,
 349
Milling Machines and Milling Practice.
must be regarded, notwithstanding their great usefulness,
simply as accessories and nothing more.
Viewed from this standpoint, they can certainly prove of
great service, but to think that by adding such attachments,
a universal milling machine can really be changed into a
vertical, a circular, a rack milling machine or a slotting
machine, is to
make a mistake, \Q Q \
as practice will
prove that the
results obtained
as well as the
handling are not
so satisfactory by
far as those ob-
tained with a
machine speci-
ally constructed
for one or other
of the purposes
mentioned above.
One of the at
tachments most
used is the ver-
tical spindle mil-
ling attachment,
by means of Fig. 405.
which a vertically Section of vertical spindle
rotating cutter milling attachment.
can be used on
a horizontal milling machine.
Fig. 404 illustrates a vertical milling attachment whilst
fig. 405 gives a sectional view of the construction of such
an apparatus.
The attachment is mounted on the machine partly by
bolting it to the column and partly by clamping it to the
overhanging arm above the horizontal main spindle.
In fig. 405, which differs somewhat in construction from
350 Milling Machines
the attachment shown in fig. 404, the part A is bolted to
the column. The front of this piece is provided with a
circular "fslot c, in which the attachment, carried by the
support E, can be swiveled in a vertical plane through 360
degrees, thus permitting of the attachment being set at
any desired angle.
A shaft, clamped in the horizontal main spindle, drives
the vertical spindle by bevel gearing when it rotates.

Fig. 406. Circular table on horizontal milling machine.

The journal G runs in a bronze taper bearing, adjustable

by the nut a. The top bearing, which is tapered on the
outside and cylindrical internally, is split throughout its entire
length, being adjustable by the nut b, thus narrowing the
internal diameter.
The taper bore in the vertical spindle is the same as in the
horizontal main spindle so that the same cutters and arbors can
be used. The vertical spindle is bored throughout its entire
length, and in this bore is enclosed the draw bolt H by
which the cutters and arbors, which are provided with a
 and Milling Practice. 351

5/s inch threaded hole at the top, can be drawn in or

pushed out. The spindle nose is threaded so as to permit
of mounting face millers.

A circular table is an almost indispensible adjunt to the

vertical milling attachment as its use permits of rotary
milling being
performed on a
horizontal
milling machine.
Such a circular
table is illustrated

Fig. 407.
Attachment for milling wide angle spirals on a universal milling machine.

in fig. 406 and is mounted on the main table of the machine.

The telescopic shaft which transmits the feed motion to the
main table, is changed and attached to this circular milling
table so that the latter can be made to rotate automatically
and by hand, whilst it has the same number of feeds as
can be imparted to the main table.
The vertical spindle milling attachment mounted on the
352 Milling Machines
machine in fig. 406 is of a different construction to either
of those shown in figs. 404 or 405. Such attachments are
manufactured in a variety of constructions.

For milling spiral gears and wide angle spirals which do

not permit of being cut on the universal milling machine,
a spiral milling attachment, a sectional view of which is given
in fig. 407, can be mounted on the machine.
Spirals of any angle can be milled with this attachment,
right as well as left-
_ handed, as also racks,
~ ~U }\ which must be mounted
lengthwise on the table,
the arbor thus rotating
parallel to instead of
square on the main
spindle.
The casting A of
this attachment is bolt-
ed to the column, being
further clamped to the
overhanging arm.
Shaft B which rotates
with the horizontal
Fig> 408. main spindle, drives the
Universal milling attachment. vertical Spindle C by a

bevel gearing, the end

of spindle C being formed as a spiral wheel which meshes
another spiral wheel mounted on the horizontal shaft a.
The ratio between these spiral wheels is 2:1, so that the
horizontal main spindle makes twice as many revolutions as
the horizontal spindle of the attachment, which gives a far
greater belt pull. The end thrust of the vertical as well as
of the horizontal spindle is taken up by a ball bearing.

A similar attachment, unsuited however for heavy milling

work, but more generally adopted than that shown in fig. 407,
is illustrated in fig. 408. This attachment is equally well
 and Milling Practice. 353

suited for vertical milling as for milling wide angle spirals

and racks and is applicable to a large variety of work.
The vertical spindle of this attachment can be set at any
angle in the vertical plane so that even slanting sides can
be milled ; if the vertical spindle be swiveled 90 degrees
from the vertical position, a horizontal cutting spindle will
result, though square to the horizontal main spindle. As
previously mentioned, spiral gears and
spirals with a greater angle than 45
degrees can be
milled with the hori-
zontal spindle of
this attachment, and
seeing that this spin-
dle can be turned to
any angle in the
horizontal plane, a
large number of
different positions
can be obtained so
that by using either
a shell end mill or
an end mill, a great
variety of milling
work which would
otherwise be very
difficult ot perform Fig. 409.
on a universal High speed milling attachment.

milling machine, can easily be carried out.

Whenever a cutter of exceptionally small diameter or

a small drill is used on a universal milling machine, the
main spindle of the machine, even at its highest speed,
rotates far too slowly. For this reason the majority of
manufacturers of universal milling machines supply an
attachment which enables a small cutter or drill to rotate
at a very high speed.
Fig. 409 shows such an attachment and the increase
23 of
354 Milling Machines
speed obtainable can easily be seen. From the cone pulley
increased speed is imparted to a
horizontal shaft above the over-
hanging arm, from whence mo-
tion is transmitted at an increased
rate to the small pulley mounted
in front of the main spindle of
the machine by means of a larger
pulley. The small pulley runs
on a bronze stud which fits in the
main spindle, and has a conical
bore which enables the small cutter
to be fitted. In this manner the
small cutter can be made to rotate
at from 1500 to 1800 revolutions
Fig. 410. per minute.
A simpler attachment for the
High speed milling attachment.
same purpose is that shown in
fig. 410. This attachment is bolted to the column, the high
speed spindle being driven by gearing. The same number

Fig. 411. Spiral and worm wheel nobbing attachment.

 and Milling Practice. 355

of speeds at which the main spindle can rotate can also be

imparted at an increased
ratio to the high speed
spindle.

An attachment for the

nobbing of worm wheels
is shown in fig. 411. It
is used in connection
with a plain dividing
head. A hob is fitted
in the main spindle. The
attachment is clamped
to the overhanging arm
and driven by a gear
that is attached to the
main spindle nose. Mo-
tion is transmitted to Fig. 412. Slotting attachment.
the telescopic shaft by
gearing The telescopic shaft in [its turn
causes the spindle of the dividing head
which drives the worm wheel blank, to
rotate through the worm and worm wheel
of the head.
The consequence is that there is a fixed
ratio between the number of revolutions
of the hob and the worm wheel blank,
the number of teeth of the latter being
dependent on this ratio. By changing
the gears between the driving shaft and
the bevel gearing, all worm wheels up to
50 teeth, all even numbers between .50
and 100 and many odd numbers between
100 and 360 can be cut.
Fig. 413.
Sectional view of
slotting attachment. Fig. 412 shows an attachment by
means of which the rotary movement of
the main spindle is changed into a vertical up and down
356 Milling Machines
motion, thus converting the milling machine into a small
slotting machine. This attachment is unsuited for ordinary
slotting work, but is used for tool
making of all kinds, such as box
tools, templates etc.
Fig. 413 gives a sectional view
of this attachment. It is clamped
to the overhanging arm A above
the spindle and bolted to the column
by a bolt in the circular slot. The
attachment can thus be swiveled
10 degrees from the vertical on
either side of thecentre of arm A. Fig. 414.
Slotting tools.
A crank disc is fitted in the hori-
zontal main spindle, which is partly shown at D. In this
disc is a dovetailed slot in which is placed the crankpin a
by means of which the stroke is adjusted. This crankpin
moves the crank G and
the slide F up and down.
The tools used with this
attachment differ in form
from the ordinary slotting
tools. A set of tools for
use with this attachment

£ ^PJRff is shown in fig. 414.

Fig. 415 shows a similar
attachment with this dif-
ference, however, that the
tool can be swiveled in
a complete circle and can
thus be set in any desired

positon.
For milling a number
-tting attachment
of pieces of similar shape
simultaneously, a triple index centre head, i. e. one provided
with a number of centres, can be mounted on the table of
the milling machine instead of the usual dividing head.
 357
and Milling Practice.

Fig. 416 illustrates such an attachment. With this attach-

ment three workpieces can be taken between the centres
and milled simultaneously, all of which turn at the same
time by moving"
the crank handle
of the dividing
head. This at-
tachment can be
used advantage-
ously for a num-
ber of operations, Fig. 416. Triple index centres.
as for instance,
for milling quadrants or hexagons on spindles, for cutting
small pinions which form one whole with the shaft and
must consequently be milled tooth for tooth, which would
otherwise take up considerable time in grooving taps etc.

Fig. 417 shows a special attachment for milling racks on

the universal milling machine. The attachment is fixed to
the column, one or two racks being put in a special jig.
In connection with this attachment, a quadrant is mounted
on the table feed screw for the exact adjustment of the
table necessary for rack teeth cutting. This quadrant,

Fig. 417. Attachment for rack milling.

358 Milling Machines
tfig. 418), is provided with a disc in which are two notches
in which a pawl presses.
A spur gear is mounted on the table feed screw that
meshes another spur gear fixed to the notched disc and the
ratio of these two gears can be determined in such a manner
that the disc must make exactly one half or a complete
turn for the table motion equal to the pitch of the rack.
The disc has only two notches. If the disc has only to
make half a revolution when turning the crank handle
on the table feed screw, the pawl is drawn out by hand
from the notch into which it has been pressed by a spring

Fig. 418. Dividing attachment for rack milling.

and when the disc is turned half a revolution, it engages

the next notch. In order to prevent mistakes when the
disc has to make a complete revolution, one of the notches
is filled up.

Fig. 419 shows a tailstock that is used for supporting

the outer end of taper work when the angle is large or
the work long. The centre of this tailstock can not only
be placed considerably higher than the centre of the dividing
head but, and this is the chief advantage of this attachment,
the centre can be placed at an angle suitable for the
workpiece, thus preventing any side strain on the centre.
The angle at which the workpiece is placed can be seen
 and Milling Practice. 359

from the dividing head, whilst the swivel block of the tail-
stock is also graduated in degrees which permits of both
being placed at the same angle.

Fig. 420 shows an attachment supplied by the Cincinnati

Machine Tool Co. by means of which spur gears of large
diameter can be milled on the universal milling machine.
The ordinary manner of working on the milling machine
is that the cutter mills either on top or side of the work-
piece. In the case of spur gears, it mills above the work-
piece. When such is the case, however, no spur gears can

Fig. 419. Universal high tailstock.

be milled which have a diameter larger than the maximum

distance between the top of the table and the centre of the main
spindle of the milling machine, from which must be deducted
half the diameter of the cutter and a certain amount of play.
As a matter of fact, however, no spur gears can be milled
when their diameter exceeds double the height of centres of
the universal dividing head. For the No. 1 Cincinnati milling
machine this is 10 inches and for the No. 4 14 inches.
With the attachment shown in fig. 420, spur gears can be
milled on the No. 1 machine up to 20 inches and on the
No. 4 machine up to 26 inches in diameter, thus, practically
twice the former diameters. The attachment consists of two
360 Milling Machines

Fig. 420. Undercutting attachment.

raising blocks on which the dividing head and tailstock are

mounted, the arbor being carried in a special outer support.
The spur gear blank is supported imme-
diately above the cut by an adjustable
stud in the raising block under the tail-

Fig. 421. Cam milling attachment.

 and Milling Practice. 361
stock, which takes the strain due to the thrust of the cutter and
thus relieves the tailstock and prevents any buckling of the
spur gear. It will be clearly seen from the illustration that
the cutter now works under the workpiece.

Fig. 421 shows an attachment for milling cams and other

objects of irre-
gular shape not
only on the cir-
cumference but
also on their flat
surfaces. By
means of the
weight shown on
the table that is
attached to a steel
wire which is
fixed to the hook
in the slide of this
attachment, the
slide is pushed
against the for-
mer, the shape of
which it conse-
quently follows.

Gear wheels
can be cut on the
universal milling Fig. 422.
machine but Full automatic milling of gear wheels on a universal
milling machine.
semi-automatic-
ally, that is to say, for each tooth space the table must be
returned by hand ; the dividing head spindle must be turned
by hand one tooth farther on, after which the machine can
recommence its work automatically until the tooth space is
cut, when the machine must again be attended to.
On this account, when cutting gear wheels the machine
requires almost uninterrupted attention. There are, as de-
362 Milling Machines
scribed before, various gear cutting machines on the market
which work fully automatically, but in so many shops the
purchase of a special gear milling machine would not pay,
A very ingenious attachment manufactured by Loewe, by
which the universal milling machine is transformed into an
fully automatic gear cutting
machine, deserves attention^
The attachment can be used
on any universal milling ma-
chine, works in combination
with the universal dividing
head, and is equally suited for
milling either spur
^^^^ or bevel gears. Fig.
422 shows the at-
tachment cutting
spur gears, fig. 423,
an angle cutter.
The external form
of this attachment
is a closed gear box
(figs. 424 and 425),
mounted on the end
of the table, at the
rear of the dividing
head which is now
placed more to the
centre of the table.
Fig. 423. The change gears
Full automatic cutting of an angle cutter on the
universal milling machine. otherwise employed
for spiral millingand
which connect the dividing head and the feed screw, are
now used for the automatic travel of the table and its quick
return, the change gears on the dividing head being used
for the automatic dividing motion of the latter.
The manner in which the attachment works is shown in
figs. 424—425, and is as follows: —
The drive takes place by means of a pulley a. Shaft b has
 363
and Milling Practice.
motion imparted to it by a worm and worm wheel. By means
of gearing a right or left-hand motion is imparted by shaft b
to shaft c after engaging the clutch d either on the right
or left hand. Shaft b also causes shaft f to rotate to the
right by gearing. By change gears mounted on the stud e
of shaft c motion is brought to the table g of shaft /con-
trolling the dividing motion. The dividing motion thus
depends on the movement of the table, the latter acting on

Attachment for milling gear wheels automatically on the horizontal milling machine.

the dividing head by the lever h which is bound to the

draw-rod in front of the table, for the reverse movement
(see figs. 422 and 423). The speed of the return, stroke which
is now entirely automatic, is increased eightfold. Fig. 429
shows the mechanism of the attachment with the cover
removed.
Pulley a is driven by a belt running either from the
countershaft, in which case it runs over the guide pulleys
shown in fig. 430, or by an electromotor which can be attached
underneath the table of the milling machine (figs. 431 and
364 Milling Machines

432), though this can only be done when the table is suffic-
iently strong. The stops to be seen on the horizontal rod
in figs. 422 and 423 serve to limit the automatic longitudinal

.1 ' I '_ ; r " ;. . j []

Figs. 426-429.
Sectional views of the attachment for milling; gear wheels automatically
on the horizontal milling mad.

travel of the table as they come in contact during the travel

of the table with one of the stops on the saddle.
This rod is connected to the lever // (fig. 429), which is
connected with the reversing lever k by screw i. By shifting
 and Milling Practice. 365

the screw i to /, the to and fro motion can be reversed.

The automatic dividing after the return of the table is
accomplished in such a manner that the shaft f on which
the driving gear is mounted, completes exactly one revolution
for each division. This must be taken into account when
calculating the gear wheels for a certain number of divisions
in addition to the ratio of gearing on the dividing head.

Fig. 430. Belt guide apparatus.

Universal milling machines provided with this attachment are

metamorphosed into fully automatic gear cutting machines,
whilst bevel gears and angle cutters can also be cut since
the dividing head can be placed either vertically or horizontally
or at any intermediate angle.

In addition to the attachments for general use just men-

tioned, a number of more special attachments are supplied
366 Milling Machines and Milling Praclice.
with the universal milling machine with the sole object of
making this type of milling machine really and truly universal.
As has already been said, the value of these attachments
must not be estimated higher than it really is; in certain

Figs. 431 and 432. Electric drive of attachment shown in fig. 422 — 423.

cases they are of excellent service, being really invaluable,

for which reason the universal milling machine cannot yet
be regarded as suited for every purpose, since each special
kind of work can be much better performed on a machine
specially constructed for the purpose.
 CHAPTER XL

Clamps and Clampings Devices.

Clamping devices may be divided into. two main groups:—

1. General clamping- devices.
2. Special clamping devices.
A workpiece to be machined on the milling machine must
be firmly fixed to the machine for that purpose. The
manner in which this shall be accomplished depends entirely
on the dimensions and form of the workpiece.
If a certain kind of work has to be turned out in large
quantities or the same class of work is constantly recurring,

Fig. 433. Plain parallel vise.

it pays to make special clamping devices specially adapted

for pinching such workpieces as quickly and expeditiously
.as possible in accordance with their shape.
But milling work is not always repetition work so that it
is necessary to have certain appliances at hand for clamping
work of diverse form and dimensions to the machine.
One of the appliances most generally in use is the parallel
-vise, which at the' present time almost invariably forms part
•of the equipment of the machine.
Such a parallel vise is illustrated in fig. 433. The vise
itself has a baseplate by which it can be easily attached
368 Milling Machines
to the table, the workpiece being held between the jaws.
A possible difficulty in connection herewith is that when
the vise is set in a central position on the table, the crank-
handle for turning the screw which moves the moveable
jaw, cannot make a complete turn.

Fig. 434. Fig. 435.

Extension piece. Parallel vise with extension piece.

For a single occasion this is not so serious, though

when used continuously it will cause considerable loss of
time. Fig. 434 shows an accessory which can also be
mounted on the table. One end of the horizontal arbor
is formed as a socket and fits the square part of the screw
of the parallel vise, the crankhandle fits on the other end
which now projects beyond the table, (fig. 435), and can
thus make a complete turn.

Fig. 486. Swivel vise.

The vise shown in fig. 433, is what is called a plain vise,

in contradiction to that shown in fig. 436, the base of
which is clamped to the table and whilst this part remains
fixed, the upper part can, with the workpiece, be swiveled
to any desired angle in the horizontal plane so that it
is possible to mill surfaces which are not parallel to the
 369
and Milling Practice.
sides of the workpiece, as shown, for instance, in fig. 438.
The vise shown in fig. 436 can only swivel in the horizontal
plane. Fig. 437 shows a vise that can also swivel in the
vertical plane and although not in a complete circle, still
from horizontal to vertical, i. e. 90 degrees, so that the
workpiece can be set at any position within the limits of
this space. Only moderate size
workpieces can be clamped in these
vises. Fig. 439 shows a vise of
considerably
heavier construc-
tion, also of the
swivel type.
The vises illu-
strated above
have the great
disadvantage
that they can
only clamp work-
pieces with equi-
distant sides so
Fig. 437. Universal vise. that TOUgh pieces
which do not
comply sufficiently with this condition, cannot be clamped
harmly enough to allow of the surfaces being accurately
tooled. A vise is illustrated in fig. 440 which has one fast
jaw whilst the other can be swiveled and as it can be set
at any desired position, workpieces of
very irregular shape can easily be clamped.
It should be noted that in the case of
the vises illustrated in figs. 439 and 440,
the loose jaw is not threaded but the
workpiece is pinched by the pressure
of a bolt. Besides the internal thread Fig. 438.
in the loose jaw is quickly worn out,
when the screw is bended the jaw can only be moved
with difficulty unless the jaw is permitted to follow the
swinging motion of the screw by giving it play in
24
370
Milling Machines

Fig. 439. Swivel vise.

the vise but then the workpiece is not clamped accurately,

since when clamping, the loose jaw is lifted and carries
the workpiece with it so that when pinched, it is not in a
true position. For this reason vises are to be preferred in
which the jaw pinches the workpiece by means of an inde-
pendent pressure bolt which has no fixed connection with
the loose jaw.
Fig. 441 shows a vise, the loose jaw of which can be
swiveled in any position and which pinches the workpiece
because the bolt on the back of the jaw is placed at an
angle with regard to the surface over which the jaw moves

Fig. 440. Quick setting vise with swiveling jaw.

 and Milling Practice. 371

Fig. 441. Vise with independent jaw.

so that the latter is drawn towards the fixed jaw by fastening

the bolt.
This vise offers still another advantage in that the jaw
can be completely reversed so that by a combination of
two vises, workpieces can be clamped which are of con-
siderably greater length than could be placed between the
jaws of one vise as shown in fig. 442.
Next to the vise as general clamping device comes the
angle plate, as illustrated in fig. 443, for objects which have
to be clamped to a vertical surface, the use of which is gener-
ally known. For workpieces which require to be set at an
angle or have to be placed in various positions in a vertical
plane without resetting, the angle plates as shown in fig. 444

]\
\ \
\\\\\\\\\\\^x\\\\\\\\\\\\\\\\\\\\\\\\
Fig. 442. Combination of two vises shown in fig. 441.
372 Milling Machines
and 445 are used, the vertical surface of which can be set at
an angle.
Fig. 446 shows a very <-- _
simple vise for use when
milling key ways in shafts.
With this vise the upper
portion of the shaft is
quite free.
Those parts, which on
account of their
shape or dimensions,
cannot be clamped
in a vise, must
either be clamped
to the table direct
by means of bolts Fig. 443. Angle plate.

and plates or clamp-

ed in jigs specially made for the purpose.
The simplest case of all is when the workpiece has a
number of projecting parts which are lower than the surface
to be milled so
that it can be
bolted to the
milling table by
clamping plates
and bolts, (fig.
447).

If, however, the

. form of the work-
piece is such that
clamping with
, plates would
cover a portion
Fig. 444. Swivable angle plat
of the surface
to be machined, another method of clamping must be chosen.
This is effected as shown in fig. 448 and 449, but clamping
in this way cannot by any means be regarded as at all
atisfactory. The workpiece is insufficiently pressed on the
 and Milling Practice. 373

milling table so that there is no certainty that perfect parallel

surfaced pieces will be
obtained whilst there is
also a possibility of its
working loose during the
tooling process.
The manner of clamping
illustrated in fig. 450 is
better adapted to
press the work-
piece down pro-
perly although it
is, however, also
primitive since
such a combina-
tion of clamping
strips is only re-
ally suitable for Fig. 445. Swivable angle plate.
one particular
piece of work, as other strips would have to be selected
for work which varies in width,
and as the operator is in such
cases accustomed to look for

Fig. 446. Shafts vise.

374 Milling Machines
strips at hand, the exact proportions usually leave much
to be desired.
The Ingham clamp shown in fig. 451 is a decided impro-

Fig. 447. Clamping plates.

vement on the last-named manner of clamping. The stud

on which the jaw swivels is at an uneven distance from the
four sides so that this clamping device is suited for workpieces

Fig. 448 and 449. Clamping strips.

of various height or width. An equally serviceable clamp

to that shown in fig. 451 is the Newark combination clamp,
(fig. 452), which clamps the workpiece very firmly.

Fig. 450. Clamping strips.

Small and very thin workpieces, the whole upper surfaces of

which have to be machined, can only be clamped with the
 and Milling Practice. 375

greatest difficulty either in a vise or by means of clamping

Fig. 451. The Ingham clamp.

strips. In such cases, magnetic chucks similar to the one

shown in fig. 453, have to be employed. Such workpieces as

Fig. 452. The Newark combination clamps.

a rule require to have very little of the material taken off.

The work is, therefore, usually done with an end mill.

Fig. 45.3. Magnetic chuck.

In addition to all these clamping devices which are of a

more general character, a large number of special devices
376 Milling Machines and Milling Practice.
and jigs are employed for clamping workpieces on the milling
machine, which cannot even be reviewed generally as they
are usually constructed according to the form of the work-
piece and the special nature of the work to be performed.
A clamping device not belonging to the general category
of vices and, at the same time, adapted for various classes
of work, is deserving of special notice.
It so frequently happens, especially with the vertical
milling machine, that work, having a bore, has to be milled
either wholly or partially in a circular form, as for instance,
the heads of connecting rods, levers, cranks etc. In such

Fig. 454—455. Cone mandrel.

cases of bossing, the ends the workpiece must rotate on the

centre of the bore.
Figs. 454 — 455 show a cone mandrel which, when mounted
on the circular milling table, clamps the workpiece quickly,
firmly and truly, whilst, when once the centre of the spindle
of this clamping device has been set accurately in the
centre of the milling table, the workpiece is bossed per-
fectly true.
 CHAPTER XII.

The Power absorbtion of the milling machine.

It will certainly not have escaped the notice of the reader

that as far as possible theoretical considerations have been
avoided. This has chiefly been done to prevent the purpose
of the present work, viz: — the popularising of the milling
machine and the promotion of milling practice, from being
lost sight of.
This consideration is the reason why in the following
chapters in which the practical part of milling comes even
more to the front than in those which have preceeded,
theoretical considerations as to the power absorbtion of the
milling machine have been left on one side. This compels the
author to pass over a considerable quantity of work which
he has carried out in this direction. As the result of in-
numerable practical tests, he has endeavoured to build up
a formula by means of which it would be possible to attain
certain theoretical results which should coincide with the
results obtained in practical work, even if only approximately.
It was not only that the tests made and the tables composed
therefrom scarcely ever permitted of such a condensation of
the tables as would allow of the formulation of certain fixed
data, but every time he thought he had found the right track
and applied the data obtained to practical work, practice
proved that they were entirely fallacious.
It is, of course, true that a certain power absorbtion can
be determined theoretically and that the results so obtained
will not show a greater divergence than from £ — 2 H.P.
but since practical experience shows that the difference
378 Milling Machines

works out at from 100 — 150 °/o, it cannot be said that the
expression „ fallacious" is at all too strong.
The mechanism of the milling machine absorbes a certain
amount of power for its own movements; this absorption
of power is dependent on the dimensions and type of the
machine, so that it cannot possibly be determined absolutely.
The power absorbed by the milling machine depends on :—
The dimensions of the surface to be milled.
The depth of cut.
The cutter speed.
The ratio of feed and cutter speed.
The kind of material.
The tendency of the material.
The quality of the cutter.
The construction of the cutter.
The condition of the cutterteeth every moment of the
milling process.
These are factors which not only differ at every moment,
but which in their various combinations give rise to such
divergencies, that the laying down of any regular formula
is wholly and entirely out of the question.
In his work wFraiser und deren Rolle bei dem derzeitigen
Stande des Maschinenbaues" Professor von Knabbe has
gone exhaustively into the theory of this subject as a result
of his own experiments and those of Ernest Hartig and
Prof. Hart, but, when he proceeds to tabularize, even as a
result of partially presumptive data, we see at once that
for seven different cases he arrives at the result that the
H.P. required to cut away 1 Kg. of material per hour
is respectively . 13, .03, .11, . 07 and . 03, differences thus
of . 03 and .13, or 400 %, and further, that the material
cut away in Kg. per H.P. per hour amounted for these
seven cases to 7.7, 28.7, 8.71, 14, 7.64, 13.3 and 35.4,
differences again of 7.7 and 35.4 Kg. or about 450%.
We ourselves do not wish to risk laying down even
general data relative to the power absorbtion of milling
machines, especially when we consider that the term „ milling
machine" embraces everything from the small hand milling
 and Milling Practice. 379
machine for turning oujt small brass work in large quantities
to the gigantic machine tool illustrated in fig. 314, but not-
withstanding the small amount of satisfaction which the follow-
ing conclusion affords, shall confine ourselves to the maxim :
wThe power absorbtion of the milling machine is entirely
dependent on the factors mentioned above."
The question of power absorbtion is furthermore not of
primary importance as regards the use of the milling machine,
indeed, we doubt very much whether in general machine
construction, a manufacturer has ever seriously considered
the question of power absorbtion in connection with the
question as to the general type of machine tool he will adopt
for his particular needs.
It may generally be accepted that as regards efficiency,
the milling machine is not inferior either to the drilling or
slotting machine, though, in this respect it certainly is behind
the planer and the lathe.
Under these circumstances it is impossible for us to agree
with the conclusion drawn by Prof, von Knabbe in the
work referred to above when he asserts that the H.P.
required to cut away 1 Kg, of material per hour amounts
to . 32 for the planing machine as against . 11 for the
milling machine, i. e. approximately I/B of that needed for
the planer, and are entirely opposed to its adoption as a
general rule ; it depends entirely on the question as to
whether the work done was exceptionally favourable or
unfavourable to one or other of the two types of machines,
as also to the construction of the tools on which the tests
were made. Nothing spoils such a question more than
exaggeration and disappointed expectations, and we cannot
believe that any industrial concern would find their expec-
tations realised should they decide upon the general adoption
of the milling machine simply and solely for the sake of
reducing the power absorbed ; no,, on the contrary, the
true economy of the milling machine is to be seen in the
time occupied in carrying out the work and other advan-
tages connected with the use of the milling machine.
380 Milling Machines
Tests have been made by Mr. DeLeeuw of the Cincinnati
Machine Tool Co. on horizontal milling machines similar to
those illustrated in fig. 198 for the purpose of determining
the power absorbtion required to cut away a given quantity
of material on milling 'machines of diverse construction in
order to find out to what extent the construction of the
machine effects its power absorbtion, as also to determine the
influence exerted on the power absorbtion required for cutting
away a certain quantity of material by diverse feeds and
speeds and depth of the cut. In principle, it is entirely
erroneous to begin exclusively by calculating the power
which can be transmitted by the driving belt. It is indeed
true that the belt must be capable of transmitting the
power which the machine can absorb, but of what use is
it if the belt can transmit a high power if the other parts
of the machine are not in proportion ? Or, of what use is
it if the belt can transmit high power, a greater part of
which is wasted in the machine itself? The only question
for the user is: — "What power can be transmitted to the
cutting tool, which is, after all, the only point at which the
power absorbed can be turned. into useful results"?
In the whole of Mr. DeLeeuw's tests the metal to be cut
was of the following specifications : —
Combined carbon 16%
Silicon 008%
Manganese 51%
Phosphorus 086%
Sulphur 041%
Tensile strength per square inch . . . 523781bs.
Limit of elasticity 30313
Elongation per cent of length . . . .50%
Per cent reduction of area 54%
The test blocks used were 18 inches long, 5J inches wide
and 5J inches thick. The ends were milled to provide means
for holding the block on the table of the milling machine.
In all tests a spiral cutter with nicked teeth was used,
3| inches in diameter, 6 inches face and for a 1^ inches
arbor. The cutter was made of high speed steel.
 and Milling Practice. 381
The machines were driven by an electric motor, belted
to the machine. The power consumed was ascertained by
the reading of ammeter and voltmeter, and the amount of
metal removed by measuring width and depth of cut and
the amount of feed per minute. The feed on all the
machines used was obtained by direct gear transmission so
that the proportion of the gears could thus be accurately
determined.
These tests showed considerable differences in the effi-
ciency of the machines, that is, there was a considerable
difference in proportion between the horsepower developed
by the motor and the quantity of material cut away. The
tests also showed that the efficiency of the milling machines
was relatively low as compared to the lathe. This latter
might have been expected considering the nature of the
cutting tool. As has already been said, the main problem
in a machine shop is not to save power, but to get the
greatest possible output. If, on account of the cutting tool
employed, the milling machine is really behind other tools
as regards efficiency, this cannot be regarded as detrimental
to this type of machine, since its other advantages far out-
weigh this deficiency in practical work.
The fact that one machine is so much more efficient than
another of the same type is however of considerable impor-
tance, seeing that in proportion to the power absorbed, the
output of one machine is so much more than that of another
of the same size.
It shows that the less efficient milling machines: —
1. Use a needlessly large amount of power.
2. Have less capacity than they might have for removing
metal.
3. Use a large amount of power constantly for the
purpose of breaking down the machine.
It must thus be . the aim of the designer to produce a
machine of the highest possible efficiency as a power transr
mitter so as to ensure the loss of as little power as possible
between the source of power, i. e. the driving belt and the
cutting tool which turns the power used into practical results.
382 Milling Machines

It goes without saying that everything cannot be sacri-

ficed to the attainment of this object but must be combined
with all the other good features which favourably affect
the rational application of the machine.
The tests were of three kinds, viz: —
1. To determine the amount of metal removed per H.P.
per unit of time (efficiency).
2. Tests determining the efficiency of the feed mechanism.
3. Tests determining the efficiency of the driving me-
chanism.
A serie of tests was made with a depth of cut of J/i6 inch:
then with a depth of */8 inch, 3/i 6 inch, V* inch anc* 3/» inch
so as to determine the efficiency by a gradually increasing
depth of cut. These tests were repeated four times so as
to prevent the possibility of any error being made. The
cutter was sharpened each time before starting a complete
series of tests, and not resharpened during test.
For each depth of cut a number of different feeds were
used for the purpose of finding out what influence the rate
of feed exerted on the efficiency. In all cases the even
feeds were used starting with the second, (next to the
lowest) and increasing thus: 2nd, 4th, 6th, 8th, 10th etc., up
to the highest feed. It was of course impossible to go
through the entire series with the deeper cuts, as the belt
could not transmit the power required but slipped. This
slippage of the belt was at all times the end of the test
for that depth except where the entire scale of feeds could
be used up to the highest feed. The test during which
the belt commenced to slip, was not used in plotting curves.
The tests showed that the ammeter readings gradually
increased from the first to the fourth series. This was
probably due to the gradual dulling of the cutter.
In plotting the curves, the test readings were first cor-
rected:— the power readings given by the volt and am-
meter by means of the efficiency chart of the motor; the
amount of metal for loss of speed of the machine (% of
belt slippage). The curve as plotted is the curve of the
average value of the powers. Where the curve shows an
 and Milling Practice. 383

amount of metal removed of, say 5£ cub. in. per minute,

this amount may be due to a depth of cut of Vie inch and
a feed of 16 inches or to a depth of cut of y and a feed
of 8", or perhaps a depth of cut of */s inch and a feed of
8 inches.
The amount of power required to remove a given amount
of metal varied with the speed, depth of cut and feed per
minute and seems to have a tendency to the minimum
when the section of the chip removed per tooth approaches
most nearly a perfect square. The diagrams given in figs.
456 — 457 show curves giving the relation existing between

10

0.10

Fig. 456. Fig. 457.

Cutting speed 12 ft. per minute. Cutting speed 32 ft. per minute.
Work of 1 H.P. min. measured in cubic inches of metal removed, feed increasing.

power required and metal removed under different condi-

tions of speed, feed and depth of cut. They are partially
derived from the tests described and partly from tests made
for the special purpose of ascertaining these relations. The
fact that the power required changes with these conditions
of feed, speed and depth of cut made it impossible to plot
a single curve giving relation between power and metal
removed. Besides, the same speeds and feeds obtainable on
one machine were not obtainable on another, even the per-
centage of belt slip varied with the different machines.
For these reasons averages have been plotted.
384 Milling Machines
Power required for feed mechanism.
Various tests have shown that a considerable amount of
power is required for the feed drive of the milling machine,
amounting even to 40 °/0 of the total power applied. The
feed mechanism of a N°. 4 Cincinnati milling machine can
amount to as much as 3^ H.P. If, in that case, the feed is
20 inches per min. (the highest feed found on a modern milling
machine), then the pressure against the cutter must be :—
3jX 33000 X 12

provided there are no losses in transmission. Further, it is not

likely that the greatest amount of horse power is required

2 A 40 *

•a s 0 35
£ S /<+
^— -
^
& • .
/ ,^— -
1. a /

"o 0 20 /

'
0.00 &*

nsa
U n te

0.10
4 5 6 7 8 9 10 11 13 15

Feed in inches per minute.

o.o*>
Fig. 458. X^
Cutting speed 45 ft. per minute, feed increasing.
Work of 1 H.P. minute measured in cub. inches of metal removed.

for the feed at its maximum number of inches per minute.

It is more probable that the maximum of feed power is
used for 10 inches feed or less per minute, in which case
the pressure would be in the neighbourhood of 140.000 Ibs.
A machine using 6 H.P. at the cutter would thus require
a total of 11| H.P. supposing that 2 H.P. is lost in the
driving mechanism with the 3} H.P. lost in the feed
mechanism.
Assuming the cutting speed to be 40 ft., the pressure at
the circumference of the cutter must be :—
6 X 40
33.000 = 4950 Ibs.
 385
and Milling Practice.
and this must also be the approximate pressure against the
table screw instead of 140.000 Ibs. Of course all these
figures are assumed but they illustrate the computations
which led up to the second series of tests relative to the
amount of power required for the feed mechanism.
In order to determine the efficience of the feed mechanism,
the total amount of power used was measured as well as
the amount of work done by the table. As the amount of
power required varied considerably, the idea of using an
individual motor for the feed alone was abandoned since it
would be impossible to obtain an efficiency chart covering
the whole range of powers used by the motor. The neces-
0.50

456789
Feed in inches per minute.
10
Fig. 459. Fig. 460.
Cutting speed 67 ft. per minute. Cutting speed 150 ft. per min.
Work of 1 H.P. min. measured in cub. inches of metal removed, feed increasing.

sity thus arose of giving the motor a fairly constant load

by artificial means. For this purpose the square box shown
in fig. 462 was mounted on the spindle arbor; it had a
paddle inside and a number of obstructions which made the
required resistance for the water in the box. By increasing
the amount of water in the box and by giving the paddle
various speeds, any load could be produced and this load
was constant. The box was kept from rotating by resting
against the overarm of the machine. The artificial load of
the motor was adjusted until it came within the efficiency,
curve of the motor. The part of the apparatus used for
measuring the work done by the table consisted of a
dynamometer, graduated up to 8000 Ibs. 25
386 Milling Machines
One end of this dynamometer was attached to the table
of the milling machine whilst a chain at the other end of
the instrument was wrapped around a drum which was
mounted on a brake of the Weston type. The brake itself
was used only as a safety device, being set at sufficient
pressure for the test but slipping before there was any
danger of wrecking the machine.
It had been originally intended to set the brake for a
certain pressure and to have the table feed under this
pressure for some length of time but it was found that the
brake was too jerky in its action. The mode of working
0.60

•* ' 10 20 30 40 50 60 70 80 SW 100 110 120 130 HO 150

Cutting speed in Feet per minute.
Fig. 461.
Cutting speed 15 ft per minute speed increasing.
Work of 1 H.P. Minute measured in Cubic Inches of Metal removed.

was therefore changed and the test was carried out as

follows : — All even feeds were taken, beginning with the
second lowest and going up to the highest. For each feed
the following pressures were selected :— 1000, 2000, 3000,
4500 and 6000 Ibs. The entire series was repeated once
if nothing happened to spoil the test If something hap-
pened to disturb the proceedings and to cause doubts as to
the correctness of the results obtained, the entire result of
the test was dropped and no curve was plotted until two
complete series of tests had been made without interruption.
A sensitive ammeter reading ^ amperes was used. With
 387
and Milling Practice.

a given feed, an entire series of pressures was gone through,

after which the amount of feed was changed for the new
series, etc. Before taking a series of readings, the feed
mechanism was disconnected to get the reading of the dead
load. Another reading of the dead load was taken after
«ach series of readings was completed. During the tests
special attention was paid to the rotary speeds of the
machines and the readings of the dynamometer and ammeter.
Fig. 463 shows the curve of average values plotted from

Fig. 462.

the readings, from which it appears that the efficiency of

the feed mechanism is not 20%, which goes to show how
necessary it is that efforts should be made to bring about
-an improvement by improving the construction of the me-
chanism. The great importance of a higher efficiency in
the feed gearing cannot be over-estimated. It may seem
that 20% efficiency is still so low that it makes little differ-,
ence whether this figure is somewhat higher or lower. It
may seem at a first glance that it is of little importance to
the user whether 80% or 90% of the feed power is lost in
388 Milling Machines
transmission. But a more careful look at this problem
shows the importance of high efficiency very clearly. If
3 H.P. out of 10 are used for feed on a machine of which
the feed efficiency is 10%, then 0.3 H.P. is actually used
for this feed. If 10 H.P. is used for the entire machine,
that is, for feed and drive, then 7 H.P. is left for the
spindle drive alone and therefore the amount used for the
feed is 3/7 of the amount used for the spindle drive.
With a machine having a feed efficiency of 20°/o, or
twice as much, the amount of power used for the feed will
be 3 1 4 of the amount of power used for the spindle drive

6 7 8 9 10 11 12 13 14 1* 16 IV 13 1
Feed in Inches per minute.

Fig. 463.
Feed efficiency curve.

alone or 3/i? of the total amount used for the machine. If

again this amount is 10 H.P. then the amount used for
the feed will be 1.76 H.P. as against 3 H.P. in the first
machine, and the amount left for the spindle drive will be
8.24 as against 7 H.P. in the first machine, giving an
increased spindle power of 18°/o available for cutting. Of
the 3 H.P. used by the first machine for the feed, only
2.7 H.P. are employed to wear down the feed mechanism,
whilst of the 1.76 H.P. used for feed in the second machine,
20°/o or 0.352 H.P. is usefully employed, whereas the
remainder or 1.41 H.P. is used destructively. It will be
seen, therefore, that the power used to break down the
 389
and Milling Practice.

machine is almost twice as great in the first machine as

it is in the second.
Efficiency of Driving Mechanism.
The third series of tests were taken to determine the effi-
ciency ofthe machine drive. These tests were carried as per
fig. 464 on a combination of two N°. 4 Cincinnati milling
machines connected by a stout shaft. The feed works were
removed, as were also knee, saddle and table, so that nothing
remained but the bare frames and driving works. One of

Fig. 464. Apparatus for testing the efficiency of a milling machine.

the machines was driven by a motor while the other drove

a generator. The current thus generated was dissipated in
a water rheostat, by means of which the amount of current
could be closely regulated. There was a set of electric
instruments both for motor and generator, so that all readings
could be taken simultaneously. Both machines were driven
by belts, the amount of slip being carefully checked. If
the generator volt meter showed considerable drop and the
tachometer showed about the proper speed at the first driving
shaft of the first machine (motor machine), then the belt on
390 Milling Machines
the generator must have slipped. If, however, the tachometer
showed a drop, then the belt from the motor to the first
machine must have slipped. During the tests the same
transmission was used on both machines.
Various tests were taken at different loads, viz: — 125,
100, 80 and 70 amperes. Each set of tests was carried out
over a number of speeds, namely, the lowest, third, fifth,
etc. up to the highest but one. After the necessary cor-
rections for slip, efficiency of motor dynamo, etc., the ef-
ficiency of the two machines was plotted as per diagram
fig. 465, which shows that same varied from 67 to 79.7%.

100 Amperes

GO

10 2U 3040 50 100 150 200 250

300
Spindle speeds in R. P. M.
Fig. 465.
Efficiency curves of a No. 4 Cincinnati high speed miller.

It cannot be gainsaid that workpieces which are suitable

for the milling machine can be tooled much quicker and
with a far better finish on this machine than on either the
planer, slotting machine or lathe. The output of the milling
machine to that of the same work on the lathe, the slotting
machine or planer depends entirely on the nature of the work.
The milling machine has taken over a greater part of the
work of the planing machine, is doing more and more of
the work previously done on the lathe whilst practically
the whole of the work done on the slotting machine can
be done much quicker and better on the milling machine.
The milling machine, however, is not adopted for cutting
 and Milling Practice. 391
keyways in bores but since there are now special machines
on the market for this class of work, the slotting machine
can really be regarded as an abandoned type of machine,
the necessity for which no longer exists.
Although the milling machine can supersede the planer
in a large number of cases, still it often happens that the
planer can do the work equally as well and perhaps better,
so that in comparing milling and planing work it is especi-
ally a question as to which type of machine is better adapted
for each special kind of work. Only a comparatively small
amount of lathe work can be carried out on the milling
machine, at any rate when output and quality have to
be considered.
To attain the best results from the milling machine it is
a matter of the greatest importance that the workpiece
should be mounted properly on the machine and the most
profitable manner of working be chosen.
In the following chapter an attempt will be made to give
further particulars in connection therewith by means of
examples derived from practical work.
 CHAPTER XIII.

Milling Operations.

Workpieces widely divergent in form can be machined on

the milling machine.
The following examples will serve to give an idea not only
of the manner in which various workpieces are clamped to
the milling machine but also of the manner of working and

Fig. 466. Surface milling.

the kind of cutters employed in different cases.

Fig. 466 shows the milling of rectangular pieces of cast
iron. As it is here more a question of cutting away a large
quantity of material than of obtaining a true surface, a
cutter with inserted teeth is used. The workpieces, four in
number, are clamped in a jig, a plate at the front taking
 Milling Machines and Milling Practice. 393

up the end pressure. The removal of 1/8 inch of metal

from these workpieces, 81/* inches wide over a length of
32 inches occupied 4 minutes.
Fig. 467 shows the milling of the surfaces of castings.
The width of the workpieces is 8J/2 inches and with a feed
of 16 inches per minute a cut of 3/32 inch is taken. To
prevent too great an axial pressure on the spindle, a pressure
which in the case of such heavy milling work would be
likely to prove detrimental, a right and a left-handed spiral

Fig. 467. Surface milling.

cutter are combined, which effectually prevents undue end

pressure. Two workpieces pinched in a special vise, are
milled simultaneously.
In this case as well as in that illustrated in fig. 466, the
arbor is supported on either side of the cutter.
The workpiece in fig. 468 is of such form that it can be
bolted to a base plate, which ki its turn is clamped to the
table. The workpiece which is flat at the top but has a
groove running through the centre, is milled on all sides
simultaneously except, of course, on the underside. To
accomplish this, a combination gang of cutters is mounted
394 Milling Machines

Fig. 468. Milling composite surfaces.

on the arbor. Two shell cutters with right and left-hand

spiral teeth are mounted on the arbor for machining the upper
surface with a slotting cutter between them, the whole being
enclosed by a pair of face cutters with inserted teeth for
milling the sides. These castings are 101/* inches wide.

Fig. 469. Simultaneous milling of two workpieces.

 395
and Milling Practice.
In fig. 469 a combination of cutters is shown milling
two. workpieces at the same time, which are clamped in a
special vise. :5/i6 inch stock is removed all over, a semi-
circular slot being milled in the centre and the sides finished
at the same setting. The face cutter mills the two sides of
the workpieces, an equal gang of cutters being placed at
the right and left-hand sides. The left-hand side of the
face cutter thus belongs to the left-hand gang of cutters
and the right-hand side to the right-hand gang.

Fig. 470. Milling the top of a milling table.

The two workpieces were milled in 18 minutes, that is 9

minutes each, including time required for clamping. The
actual cutting time was 4 minutes, a planer with two heads
working at 18 meters cutting speed per minute, took 36
minutes to finish one, — just 4 times the milling time.
Fig. 470 shows the complete milling at one cut of the
top of a milling table. The combination cutter consists of
no fewer than 13 separate cutters. The two outside cutters
each have a diameter of 7 Va inches and mill the sides. The
6 small shell cutters, which mill the surface of the table,
396 Milling Machines
have a diameter of 3 Va inches. The two cutters for the oil
grooves and the 3 for the "]" slots have a diameter of 51/*
inches. The dotted lines on the workpiece show the metal
to be removed. The table which is 9 inches wide and
35 V* inches long, is milled in 25 minutes including chucking.
In this case also the cutters are carried closely between the
bearings. The table is clamped by a special clamping

Fig. 471. Rack milling.

device. As the underside of the table has already been

machined, this clamping device allows of the grooves being
milled in the table in precisely the correct place, not only
as regards the upper surface but, at the same time, with
regard to its bearings.
Racks are usually cut tooth by tooth by a gear cutter.
In fig. 471, however, all the rack teeth of a drill sleeve are
cut simultaneously. The cutter consequently consists of just
 397
and Milling Practice.
as many teeth as the
rack. The racks are
16 pitch, the length
of the rack being 8
inches. The teeth are
milled at one cut, the
rack being completed
in one minute.
Fig. 472 shows three
face cutters milling-
three grooves simulta-
neously in a number
of workpieces. The
workpieces are chuck-
ed in a jig in which
these pieces, otherwise
so difficult to chuck
accurately, fit perfectly
Fig. 472.
whilst the projections Simultaneous milling of more than one
workpiece.

are also clamped by plates.

In fig. 473 the entire frame of
a 8 H.P. gas engine^ is to be
seen on the
milling ma-
chine and
with a com-
bined cutter
consisting

of five dif-
ferent cut- .
ters, the
whole of the
fitting sur-
faces for the
covers are
milled
Fig. 473. Milling a gas engine. simultaneously.
398 Milling Machines
In all the examples given so far, the cutters have been
mounted on an arbor and were consequently provided with
a bore and with but one exception, cut on the contour, thus
acting principally as shell cutters.
In all the examples the table had automatic longitudinal
motion and with the exception of the workpiece shown in
fig. 47 3, where
the form of the
workpiece
rendered this
impossible, the
spindle was

Fig. 474. Undercutting "j"-slots.

carried close up to the cutters by bushings on the over-

hanging arm and the bracings which, in their turn, rested
on the knee, thus ensuring a rigid connection between the
arm and the knee.
In fig. 474 on the other hand, the cutter which is pro-
vided with a taper shank is placed in the conical bore of
the spindle, into which it is pressed by a nut.
The workpiece has to be provided with a fslot. For
 and Milling Practice. 399
this purpose a groove is first milled over the entire length
by a slotting cutter, the width of the groove being equiv-
alent to the narrowest part of the "fslot ; after this groove
has been milled the workpiece is turned 90° and clamped
in the position shown in the illustration. The workpiece is
not held by any special clamping device but by means of
bolts. To accomplish this, one end of the clamping plates
rests on the workpiece, the other end on a support of equal
height If that part of the workpiece on which the clamping
plates rest has been machined, it is advisable to put a piece
of cardboard between the clamping plates and the work-
piece. In cases such as that shown in fig. 474, it is also
desirable to put a piece of paper between the table and the
workpiece ; this serves two purposes, firstly, to increase the
friction between the two superincumbent parts, thus holding
the workpiece more firmly, and secondly, to prevent any
damage to table and workpiece.
In the case of workpieces such as those under considera-
tion, careful attention should be given to a detail which
is of importance in connection with good workmanship
and accurate work, viz : — the supporting piece at the other
end of the clamping plates. Owing to lack of proper
appliances, the most terrible bungling frequently results.
A really good support is a piece of hard wood of the same
height as the workpiece plus the thickness of the cardboard
placed between the clamping plates and workpiece. The
exact height is a matter of importance and can better be
a trifle too high than too low, the exact height of the
workpiece plus the thickness of the cardboard is, however,
the most desirable. If the support is higher, the sharp edge
of the clamping plate will press on the workpiece leaving a
mark; as soon, however, as the clamping plate lies somewhat
slanting or only bears on the edge of the surface, it is
liable to damage the edge of the workpiece which has often
been previously finished. It is still worse if the support is
too low, as the clamping plate will then only bear on the
outside edge of the workpiece which it will not only injure
but since pressure is only exerted on one side, the underside
400 Milling Machines
is not clamped fast on the table, the clamping is not firm
and therefore, not true.
If the workman were given the opportunity of obtaining
supporting blocks of the exact height required, he would,
in the majority of cases, feel sufficiently interested in his
work to take care to do so, but most times the workman
has neither the time nor the opportunity for this. In such
a case he gets together all the supporting blocks on hand
and tries to make the best of a bad job by sometimes using
two or three blocks of different height, which are either too
high, or too low, with the
inevitable result that the work-
piece is damaged and the work,
when done is inaccurate.
On looking at fig. 474, it will
be observed that no wooden
blocks are used but a proper
supporting block as shown in
fig. 475. Within certain limits,
this supporting block can be
adjusted to the exact height
required, whilst the head
swivels in any direction on a
ball bearing so that it forms a
Fig. 475. Supporting block. suitable support even for
slanting workpieces.
The cutter used in fig. 474 works principally on the
contour, the front is also provided with teeth but these are
only to secure an accurate surface of the ~]~slot and conse-
quently remove very little metal.
The cutting tool in fig. 476, in this case a face cutter,
is mounted directly on the spindle. A vertically adjustable
supporting block is also used here as a support for the clamp-
ing plate. The form of the workpiece lends itself better for
resting on the flat of the side and not vertically. The surface
to be milled is, however, longer than wide ; in the position
in which it is now placed the diameter of the face cutter
exceeds the width of the surface to be milled, the long side
 and Milling Practice. 401

being in the length. By this means the whole of the surface

is milled at one operation by the longitudinal motion of the
table. In suchlike milling work it is necessary that there
is sufficient depth of cut for the cutter, as otherwise the
teeth will traverse the hard surface of the casting and very
soon become dull. It is also worthy of note that the cutter
is placed as near to the main bearing as possible to prevent
vibration.
Fig. 477 illustrates the milling of spiral teeth in a tool

Fig. 476. Milling with face cutter.

steel blank which has a diameter of 4 inches and is to be

provided with 24 teeth at an angle of 14 degrees.
The dividing head has a single-threaded worm and a
worm wheel with 40 teeth.
On referring to the table on page 115, it will be seen
that for 24 divisions, dividing circle 39 can be taken and
on this a full turn and 26 holes must be moved over.
The required division can be calculated without recourse
to the tables, as follows :—
g .v 40 _ 2 26
t =~24 Z 3 = "39"'
26
402 Milling Machines

The angle at which the table must be set, viz :— 14°,

is known.
Upon reference to table XVI on pages 148 and 149, it will be
found that if the teeth of a cutter of 4 inches diameter are
at an angle of 14 degrees the spiral lead will be 50 inches;
granted that the feed screw of the table is as usual lk inch
pitch, the ratio of the change gears will thus be:-
50. 5X 10 30X50
2X5 15X20

=
10

Fig. 477. Milling spiral teeth.

since as the wormwheel has 40 teeth and is single-threaded,

the constant c (see page 146) = 10.
Should it be desired to calculate the change gears instead
of taking them from the tables, then according to figs.
193—195, the angle A and a are known since /_ A = 90°,
/ B = 90° -- 14° = 76° and a = circumference of the cutter-
blank ; b the spiral lead which it is necessary to know in
order to calculate the ratio between the spiral lead and the
pitch of the lead screw of the table from which the change gears
are calculated, is according to page 141 equal to a . tg A.
a = 4 X 3.14 = 12.56 I rt#.^ = 12.56X4.011 = 5
= tg. 76° = 4.011 I or co 50 inches.
 403
and Milling Practice.
The table is thus set at an angle of 14 degrees. Next, the
index plate on which the division 39 appears, is mounted.
The segment is so adjusted that the two legs cover 27 holes.
Then the change gears are mounted in such a manner that
15 and 20 are the driving gears and 30 and 50 those driven,
since only when the table has travelled 50 inches may the
cutterblank have
completed one
full turn ; when
the cutter has
been mounted
on the arbor, the
cutterblank is
placed in such a
manner that the
line c a of the
blank passes
through the cen-
tre o, (see fig.
107). The table
is then set to the
requisite height.
According to
table III, page 64,
the depth of the
tooth of a cutter
of 4 inches diam-
eter is V2 inch.
The grooves are Fig. 478. Milling hexagons.
first cut to a
depth of 3/s inch, after which the work is gone over with
a depth of cut of ljs inch.
Figs. 478 and 479 illustrate an attachment on the milling
machine for milling the hexagon heads of bolts and nuts.
Six bolts are placed in the vertical plane of a vertical revolving
head. Four side cutters are mounted on the arbor at an
equal distance from one another. As the feed is vertical,
the braces between the knee and overhanging arm cannot
404 Milling Machines
be used, but short bracings are attached to the knee to
carry the arbor. The attachment is placed under the cutters
in such a manner that their contours traverse the bolt
heads whilst the table is fed vertically.
When the cutters have traversed the bolt heads, the table
is lowered, the revolving head in which the bolts are chucked
is turned J/«th of a revolution and the traverse of the cutters
is repeated. After having been traversed six times, the
six bolt heads are finished,
so that it can be reck-
oned that for each traverse
1 bolt head is completely
milled on all six sides.
As a matter of fact, for
the first three traverses
eight sides are milled
simultaneously, four sides
being milled during the
last three traverses.
In figs. 480 and 481 two
attachments are mounted
on the milling machine
as described on pages
'•-- 352 and 357, figs. 408 and
417, by means of which
the cutter rotates parallel
Fig. 479. Milling hexagons. to the spindle.
Fig. 480 shows the
cutting of pawlteeth, the length of blank exceeding the
transverse movement of the table; not only would it be
impossible to carry out this work without resetting, but
if the rack were reset and reversed, then other cutters
would have to be employed which would mean a con-
siderable loss of time and interruption to the work. In
order to prevent this, the workpiece is placed lengthwise
on the table and the attachment mounted on the milling
machine causes the spindle of the attachment to rotate
square on the main spindle.
 and Milling Practice. 405
The attachment shown in fig. 481 serves the same pur-
pose as that illustrated in fig. 480 but is more universal.
The spindle of the attachment in fig. 480 can only rotate
square on the main spindle, whilst that in fig. 481 can
rotate at any angle. The principal object of this is to permit
the milling of wide-angle spirals, which would necessitate
placing the table at too wide an angle if the cutter were
mounted on the spindle. With this attachment, however,
the table can retain
its position square
on the spindle whilst
the cutter can be
set to the desired
angle for the spiral
line to be cut.

Fig. 480. Milling the teeth of a pawl.

For cutting spirals, the feed screw motion of the table

is usually transmitted to the dividing head spindle by the
change gears. For a pitch as in fig. 481, however, the
table motion will be very small in comparison to the rotary
motion of the dividing head spindle.
The spindle of the attachment is set at such an angle-
that the centre line is square on the spiral line.
Fig. 482 illustrates a vertical milling attachment on a
horizontal milling machine as described on pages 348 and
406 Milling Machines
349, figs. 404 and 405. A face cutter of 8 inches diameter
mills thin plates perfectly true. It is desirable for two reasons
to mill workpieces such as those shown on the machine in
fig. 482 with a face cutter instead of an shell mill. In the
first place, the chucking of similar thin plates is not easy.
No clamping plates can be placed on the top face as this
must be machined all
over. The workpiece
must consequently be
clamped at the sides
but then there is very
little to keep the work-

Fig. 481. Cutting 3 pitch steel gears.

piece accurately on the table surface, the more so as the

sides of the plate cannot be clamped firmly in order to
prevent their twisting.
With shell mill cutting, the teeth try to lift the workpiece,
whereas the face cutter on the contrary exercises but a slight
pressure on the workpiece in a longitudinal direction which
is counteracted by clamping plates taking the end thrust,
whereas the cutter presses the workpiece to the table surface.
 407
and Milling Practice.
Furthermore, it is scarcely possible to mill a thin plate
with a width such as that in fig. 482 perfectly true with
a shell mill ; with a face cutter on the other hand, the
teeth cut the metal away on the working side whilst the teeth
on the other side pass over the work again and thus finish
the surface.
Fig. 483 shows
the manner of
working with the
attachment illus-
trated and de-
scribed on page
356, fig. 415,
which converts

Fig. 482. Surface milling with face cutter.

the milling machine into a slotting machine since the

motion of the tool is up and down. Square holes are
being slotted in the workpiece shown in fig. 483. Holes
are drilled in the four corners in which the slotter begins
to work. The tool can be turned to an angle of 90°
whilst owing to the longitudinal and transverse movement
of the table, accurate square holes can be slotted. Steel
408
Milling Machines

Fig. 483. Slotting on the milling machine.

dies of irregular shape are principally slotted in this manner.

teresting
A few in-
examples
of milling
work on the
vertical
milling ma-
chine are

given
fig. in
484 and
those
following,

from which
it will be
Fig. 484. Surface milling <>n a vrrtir.il milling machine. Seen tor
 409
and Milling Practice.

what a great va-

riety of work the
vertical miller is
adapted. The
machine part in
fig. 484 has four
surfaces to be
tooled, all of
which must be
parallel and equi-
distant from one
another. These
surfaces are to
be milled with Fig. 485.
an end mill. Circular milling on the vertical milling machine.

When one of the surfaces is finished the vertical adjust-

ment of the workpiece is read from the graduated collar on
the spindle and the exact dis-
tance can then be determined
without the employment of any
other measuring. The project-
ing part of the workpiece which
is liable to spring during the
operation of milling, is pre-
vented from so doing by the
supporting block shown in
fig. 475.
Fig. 485 illustrates circular
milling for which the vertical
milling machine is eminently
adapted. In general machine
construction a very large num-
ber of workpieces are met with
having both in and external
circular parts followed by -a
tangent line so that such parts
Fig. 486. Milling a "f-slot. cannot be machined on the
lathe. Consider for example the various parts in connection
410 Milling Machines

with the building of steam engines, such as slide valve rods,

connecting rods,
eccentric half
rings, levers,
cranks etc.
The circular
table placed on
the main table of
the milling ma-
chine, has a bore
in the centre,
recessed on the
underside ; a bolt
with round head
fitting the hole
is placed in the
Fig. 487. Milling with an end mill.
table, the pro-
jecting part be-
ing turned to a diameter that just fits the bore of the
workpiece.
After the workpiece has been fastened with ~ a nut, an

rotary mo-
tion is im-
parted to the
table and the
workpiece is
milled to :the•

required ameter.di-The

rotary move-
ment is trip-
ped at the
point where
the circular
Fig. 488. form changes
The end mill on the vertical milling machine.
into a straight
line. When the workpieces have holes larger than the
 411
and Milling Practice.

bore in the table, cones are employed (see figs. 454 — 455)
which permit of the workpiece being mounted centrally.
Fig. 486 shows the
milling of a slot in a cast
iron ring. Without the
vertical milling machine,

Fig. 489. The face mill on the vertical milling machine.

suchlike work would have to be drilled, after which it would

have to be slotted or filed by hand. With the end mill, the
vertical milling machine does the work better and quicker.
412 Milling Machines
Fig. 487 is an example of the use of the end mill for
milling recesses in a casting. A great variety of similar
workpieces can be machined in this way, which could
otherwise not be done accurately.
Fig. 488 is a good example of what a diversity of sur-
faces can be milled on a workpiece by means of the end
mill and face cutter without resetting the workpiece. The
same cutter has machined the two surfaces of the hubs of

Fig. 490. Face milling on a Cincinnati vertical high duty milling machine.

this workpiece, the two sides of the fork, has milled the
vertical surface at the same time and could, if necessary,
also mill various horizontal surfaces.
Fig. 489 gives an example of heavy surface milling
work on the vertical milling machine. The workpiece, the
underside of which is of irregular form, rests on flat pieces
and is securely chucked by four vises which in turn are
clamped to the table with ordinary clamping plates. The
mill is a face cutter of 12 inches diameter. The cutting
 and Milling Practice. 413

speed 75 ft. per minute, the depth of cut 5/a2 inch,Jthe

width of the workpiece 11 inches, and the feed 71/* inch
per minute.
Fig. 490 is an example of heavy cutting with the vertical
high duty milling machine illustrated on page 316. The
workpiece is 20 point carbon steel. A 12 inches cutter is
taking cuts while running at 17 revolutions per minute,
which gives a surface speed of 44 inches per minute, 10 H.P.
being absorbed in the cut which is 6 inches wide and J/4
inch deep, the feed being 6 . 7 inches per minute. This
means that 10 cub. inches of steel are removed per minute,
or 1 cub. inch per nett H.P. minute.
 CHAPTER XIV.

The Backing off Lathe.

If, after the mechanical treatment on the lathe, the cutter-

blank is provided with teeth on the milling machine, and
has become a cutting tool, the backed off cutter cannot be
finished on the milling machine, but the back of the tooth,
must be machined on the backing off lathe.
The backed off cutter is at the present time so extensively
used on the milling machine, (at least 95 percent of the
formed cutters are backed off), that the backing off lathe
can be regarded as being inseparably connected with the
milling machine.
Tools for the manufacture of backed off cutters may be
divided into two classes : —
1. The backing off lathe.
2. Backing off attachments.
The backing off of the teeth of cutters may also be
accomplished in two ways : —
1. A rotary motion is imparted to the cutterblank whilst
the cutting tool at the same time moves at intervals in a
straight line towards the centre of the blank, the result
being that a logarithm atical spiral is formed.
2. The workpiece has not only a rotary movement on its
centre line but at the same time, revolves eccentrically, so
that although not a true logarithmatical spiral, still one
which is near enough to accuracy is obtained.
The backing off lathe works in accordance with the first
principle; the backing off attachment usually according to
the second.
 Milling Machines and Milling Practice. 415
The backing off lathe is a machine tool differing only in
some special points from the ordinary lathe and can conse-
quently be used without alteration as an ordinary lathe and
in factories where it cannot be fully occupied with the
backing off of cutters, it is indeed often used as such,
whilst the backing off attachment which is mounted on the
ordinary lathe, is so constructed that during the rotation
of the workpiece it moves towards the cutting tool.
As long as the width of the cutter is not too large, the
cutting tool is given the negative form of the cutter and
is fed in square on the centre of the cutter. To what
extent this can be done, depends considerably on the bore
of the cutter,- that is to say, the diameter of the arbor on
which the cutter is mounted since the arbor must be of
sufficient strength to withstand the pressure of the cutting
tool on the workpiece.
Formed cutters composed of two widely different profiles
are manufactured in sections. If, however, the width of the
cutter is too great, the feed of the cutting tool square on
the centre of the cutter is no longer possible, the tool must
traverse the width of the cutter in a longitudinal direction
and be fed in a little more each time after the cut has been
completed, as in the case of ordinary lathe work.
If the body of the cutter is either cylindrical or taper,
this can be accomplished without any special attachment ; if,
however, the cutter has a profile form, it will be absolutely
necessary to conduct the tool by a guide.
Still another case is possible, viz: — when the backed off
tooth also forms a spiral line, in which case the backing
off movement of the rest must be increased or decreased
according as the spiral is right or left handed and in such
a ratio that after the carriage has traversed the length
of one spiral lead, the increase or decrease shall also
amount to one complete revolution. This increase or decrease
of the backing off motion is obtained by an arrangement
on the lathe by means of a set of differential gear wheels
driven by the lead screw, which effects the increase or
diminution in fixed proportion to the travel of the carriage.
416 Milling Machines
When the cutter to be backed off is a hob, the increase
or diminution must be very high.
For the manufacture of formed backed off cutters with
spiral teeth a fully equipped backing off lathe will be re-
quired, the backing off attachment being more used for the
simpler cases.
As the backing off consists in a jerking motion, both the
lathe spindle and the rest must be exceptionally rigid.

Fig. 491. Backing off lathe.

Bearings of ample dimensions for the main spindle, broad

bearing surfaces for the carriage and rest are absolutely in-
dispensible for the attainment of a good cutter, though much
also depends on the skill of the workman.
The arbor on which the workpiece is mounted must be
kept as strong as possible and be of tool steel; the arbor
must fit the cutter precisely, being keywayed, the cutter
being thrust against an edge of the arbor by a nut.
Just where the dog is mounted on the arbor there must
 417
and Milling Practice.
be a flat for the bolt in order that the dog may not move
over the arbor but will maintain an invariable position with
regard to the lathe spindle. This is obtained by the use
of a dog with a bent tail which will mesh in a notch of
the catch plate.
Fig. 491 illustrates a backing off lathe. There is a high
ratio of back gearing viz: — 1 : 16. The backing off motion
of the rest is obtained by means of a separate shaft housed
in the centre of the bed. The carriage is moved longitu-
dinally by means of the lead screw.
Cutters up to a diameter of 10 inches can be backed off
on this machine, threads with pitches from 1lm to 10 inches

Fig. 492. Sectional view of backing off lathe.

can be cut and backed off, cutters from 2 to 40 teeth with

straight, right or left hand spiral teeth with a lead of from
4 to 400 inches can be machined. Such a coarse pitch,
which can only be required for the backing off of hobs for
cutting worm wheels, is obtained by transmitting the motion
of the lead screw not from the lathe spindle but from the
cone pulley direct. With double back gear, the lead screw
will then rotate sixteen times as fast as when driven from
the lathe spindle since the cone pulley runs sixteen times
faster than the lathe spindle.
Fig. 492 gives a sectional view of the backing off lathe
shown in fig. 491. To the cone pulley which runs on
the main spindle, is attached the pinion /i for the back
27
418 Milling Machines
gearing next to pinion l} the pinion /> both of which drive
the gear wheels g± and g>>_ placed underneath, which run on
the hollow shaft p2. By means of the key p^ both ^, and
g^ can be connected with the hollow shaft /2 which can
consequently be made to rotate quickly by means of /, or
slowly by means of 4- At the other extremity of the
hollow shaft p\ and keyed to it, is the gear wheel o which
transmits motion to the lead screw. When cutting a very
coarse pitch, the shaft /2 is driven by the gear wheel /,
which is connected to the cone pulley. When running
with back gearing in for one revolution of the lathe spindle,
the shaft p2 which drives the lead screw, makes sixteen
revolutions, so that a
quick longitudinal
motion of the carriage
in proportion to the
lathe spindle speed
is thus rendered P°S-
The pinion s on the
shaft J is driven by the
gear wheel gx through
Fig. 493. Differential gears. a train of intermediate
gears ; the differential
gears for the increase or diminution of the backing off motion
are mounted on this shaft J and consist of the mitre gears
a, blt £2 and c, the worm wheel d and the worm e, all of
which are mounted on the right hand end of J (fig. 493).
The shaft D, the continuation of J, is driven by the
differential gears. At the left hand extremity is the cross
head m on the taps of which and running idle are the two
mitre gears 3, and £2 which mesh in a and c. Except
when backing off spiral shaped teeth, the mitre gear c
does not revolve. The gearing from J to D takes place
as follows : — The mitre gear a meshes 3, and b2. When
rotating, these two mitre gears revolve not only on their
own axis, but since both mesh the mitre gear c connected
to the worm wheel d which meshes the worm e, they must
 419
and Milling Practice.

both revolve over the mitre gear c, carrying the crosshead m

and consequently the shaft D with which it is connected,
with them. The speed ratio between the shaft D and J
is 2 : 1.
When the worm e causes the wormwheel d as also the
mitre gear c to rotate in the same direction as that in which
the mitre gear a rotates, the result is that the mitre gears
bi and 32 run faster, since they are not only driven by the
mitre gear a, but at the same time, they run over it. As
a consequence, the speed at which the shaft D rotates is
increased in the same ratio as the increase of speed of the
gears b± and t>2.
If the wormwheel d which is driven
by the worm e, rotates in the opposite
direction to the mitre gear a, then the
speed at which the shaft J revolves is
reduced in the same ratio as the re-
duction ofthe gears bl and &2.
According as right or left-
hand spiral teeth have to be
backed off, it is by this means —
rendered possible that the
backing off movement shall Fl&- 494>
take place either earlier or later.
How much earlier or later this backing off movement
must take place depends entirely on the lead of the
spiral and can, consequently, be very divergent. In order
to regulate this at will, the wormwheel e is driven by a set
of mitre gears z from the lead screw through change gears,
(fig. 494), the ratio of which is calculated in the usual way.
If one intermediate gear is mounted, so that the lead
screw motion is transmitted in the same direction, the
backing off movement will follow a left-hand spiral; by
mounting a second intermediate gear, the direction of
movement is reversed and a right-hand spiral obtained.
These change gears are placed at the right-hand side of
the bed on the tailstock side (see fig. 491).
Shaft D causes shaft N to revolve by means of change
420 Milling Machines
gears r, (fig. 493), which shaft governs the number of to
and fro movements of the tool. The ratio between these
gears thus depends on the number of cutter teeth.
The shaft N drives the backing off movement, that is, the
to and fro motion of the rest and the lathe tool. A mitre
gear is mounted on this shaft with which it rotates, whilst
a mitre gear with which it meshes, causes the vertical
stud K to rotate. To this stud K is attached the cam F
(fig. 495), which moves the rest to and fro. The stud K
is the axis on which the compound rest can swivel
so that the to and fro movement is obtained in every
position of the rest and thus flat,
slanting and sideway backing off
is possible. On either side of the
feed screw of the rest are the
springs f which force the roller
L which is attached to the rest,
against the cam. As this springs
more or less, the speed at which
the tool is returned can be regu-
lated in accordance with the
width of the previously milled
Fig. 495.
groove.
The cam can also be changed
so that the to and fro movement of the tool can be altered
at will and can vary according to the kind of cutter from
V9-3/8 inch.
When the cam suited to the cutter to be backed off has
been duly mounted, the change gears r must be calculated
and mounted for the number of to and fro motions of the tool.
The gearing from the main spindle to shaft D is such
that by a ratio of the change gears per revolution of the
main spindle and thus also of the cutter to be backed off
10 to and fro movements are obtained, whilst the ratio of
the change gears must be calculated in the same proportion
as the number 10 to the number of teeth of the cutter.
If the cutter has 12 teeth, the ratio will be 10 : 12, so
that the gears 50 : 60 will suit : if the cutter has 8 teeth,
 and Milling Practice. 421

the 10 : 8, i. e. 50 : 40, so that in any case the gear with

50 teeth will be mounted on the shaft N and will thus be
the gear driven.
Given that the constant 10 = a, and the number of teeth
of the cutter to be backed off b, the following formula will
be obtained :—
a gear driven _ 10
b driving gear b '
Example 1. Number of teeth to be backed off 21.
10 10 4X2.5 20X25
b = ~21~ = 6X3.5 == 30X35'
2. Number of teeth to be backed off 15.
10 10 20

b "~ 15~~30*
3. Number of teeth to be backed off 27.
10_10_ 4X2.5 20X25
b =~27~= 6X4.5 30X45"'
„ 4. Number of teeth to be backed off 9.
10 _ 10 _ 50
b ~~ ~~ 9 ="45*
In the case of a cutter with straight teeth the lathe is
then ready for work.
If, however, spiral teeth have to be backed off the change
gears i in fig. 494 take up the backing off motion earlier
or later.
Whether the spiral is right or left handed makes no
difference to the ratio of these gears, as for left hand spirals
only one gear more must be mounted : the number of teeth
on the cutter is also of no consequence as the ratio of these
change gears affects the lead, of the spiral.
Supposing now that a cutter has to be backed off, the
spiral of which has a lead of a 12 inches and that the lead
screw has a pitch of */* inch, then, for the longitudinal
movement of the carriage over the bed for one lead of the
spiral, the lead screw must make 4 X 12 = 48 revolutions*
The shaft D must now have its speed increased accordingly
and if it should make the same number of revolutions as
the main spindle, it should be advanced one complete revo-
422 Milling Machines
lution over a length of 12 inches. As, however, it rotates
ten times as fast as the main spindle, it must be increased
10 revolutions whilst the carriage travels 12 inches.
This increased speed is imparted to the shaft D by means
of the mitre wheel c and the wormwheel d, (fig. 493). The
worm e which drives the wormwheel d must consequently
make 10 revolutions as many times as the wormwheel has
teeth. In the case of the lathe, illustrated in fig. 491, this
wormwheel d has 32 teeth, so that the worm must thus
make 10 X 32 = 320 revolutions for 12 inches travel of
the carriage.
This number 320 is consequently fixed, so that it is simply
a question as to the lead of the spiral when these 320 revolutions
of the worm e have been completed and this depends on
the pitch of the lead secrew and of the spiral lead of the
cutter tooth.
Given the number of revolutions of the worm e, the
constant n, the pitch of the lead screw g = */* inch, the
lead of the spiral = e in inches, the following formula is
then obtained, viz: —
n = 320 = 80

In the case of a 12 e~' 4 lead,

g . inches e' ratio of the change
£ ' ' the
gears will thus be :—
80__ 8X10 40X50
12" 3X4 : 15X20*
Example 1. Lead of spiral 21 inches.
80 = 80= 8X10 40X50
e = ~21~ 3X7 : 15X35'
„ 2. Lead of spiral 33 inches.
80_80_ 8X10 _ 40 X 100
e = =33^= 6X5,5" 30 X 55 '
„ 3. Lead of spiral 40 inches.
80 = 80

4. e =56
Lead of spiral = 40*
inches.
80 80 8 X 10 _ . 40 >
e =~56~ 7X8 35X40'
 and Milling Practice. 423

The two following tables of the number of teeth and

leads of spiral are most frequently met with.
Table XXVI.
Table for change gears r (fig. 493) for the number of teeth.
N°. of teeth = / __ a^c

10 = £X d'
t a b c d t a b c d

20 25 25
2 60 30 50 14 20 40
20 30 16 40
70 — —
3 40 50
20 — — 50 25
4 60
25 — — 50 18 — 30
— 40
5 20
— — 60 — — 30
6 30 50 24 25
20 70
7 70 50 40 28 60. 50
— — 40 30 40 20
8 40 50 32 60 20 25
25
60 30
9 40 60 30 50 36
10 20 30 60 40 60 25
40 50 20
30
12 30 — — 25 50 60 30 50

The foregoing table is drawn up on the presumption that

the lathe runs with back gear in as is most frequently the
case. In the case of cutters with but few teeth, direct drive
can be used, the gearing being accomplished by means of
the gears /i, and fa. (fig. 492), so that the formula is changed
into — -— =

Table XXVII.
Table (lathe running without back gear).

t a b c d t a b c d
25 25 80
2 60 30 40 5 50 80 20
3 40 20 60 25 6 60 20
20
25 25
4 40 80 20 7 80
70
424 Milling Machines

Table XXVIII.

Tables for change gears z, (fig. 494) for leads of spiral

/= lead of spiral in inches _ a X c

80 ~~b~d'

I a b c d / a b c d

6 96 24 80 24 80 40 64
6.66 96 80 — 32
—
24 72 24 90 64
96 40 — — 72
7 28 80 24 48
80 96 40 — —
8 96 32 24 100 56
24 112 40 — —
9 80 24 64 50
10 96 120 48 — —
24 64 32 72
80 32 128 40 — —
12 24 64 64
14 80 28 64 140 32 — — 56
32
28 40 —
16 80 32 56 144 —
48 150 40 72
18 64 80 24 48
20 — — 24 160 32 —80 —
96 64
— — 24 32 — —
24 80 180 32
28 — — 28 192 30 — —
80 72
30 — — 200 32 — — 72
80
64 24 40 56
32 — — 224 32 64
80 32
36 80 24 48 240 24 — —
80 — — 40
72 255 30 — — 72
96
40
— — 280 56
48 80 48 40 30
— — 40 288 40
32
50 64
80 — — 300 48
32 64 72
56 56 60 24
60 64 — — 48 320 24 — — 72
64 80 — — 40 32 96
64 360
70 — — 56 384 40 30 80
80
64 72 80
80 — — 400 28 56 32
72 72

The attachment shown in fig. 496 may render good ser-

vice in repairing shops. This attachment can be mounted
on any lathe bed and since the fact that the lathe is not
perfectly accurrate does not affect the working of this
 and Milling Practice. 425

attachment in the slightest, it can be mounted on a lathe

which can no longer be used for other work.
With this attachment, cutters up to 8 inches in diameter
can be backed off both internally, externally and sideways.
With this attachment, the rest and the tool remain sta-
tionary whilst the. cutter makes a rotary movement not
only on its own axis but also eccentrically the cutter
being turned one tooth farther at the exact point of the

Fig. 496. Backing off attachment.

eccentric motion. The cutter consequently then makes three

movements at the same time.
The attachment is driven by the lathe spindle which
carries with it the tail piece which is provided with a slot
as seen in the left-hand side of the illustration.

An attachment for the backing off of cutters of compa-

ratively small dimensions is shown in fig. 497. It is not
of such solid construction as that shown in fig. 496 and
426 Milling Machines
can consequently only be used as an emergency in small
factories
and work-
1F -
shops. The
principle is
similar to
c 1
that of the
attachment 3 _2 — © —

\
previously -
mentioned
but it can
be mounted
between 1-
c
c o
the centres
of the lathe O'

without Fig. 497. Backing off attachment.

further
trouble. The appliance consists of an eccentrical rotating
spindle provided with a tail piece (fig. 498).
On this spindle fits a sleeve, (fig. 499), one side
of which is turned so as to fit the bore of the
cutter e which at that
part is provided with a
- key so that the cutter
Fig. 498. has to move with the
sleeve and is clamped
by means of the nut d.
A pawl a is attached to this
sleeve and next to it a friction
ring b of the form shown in
fig. 500. This friction ring is
loose on the sleeve but is
clamped by the nut c by means
of fibre washers i. e. so that
the sleeve can only rotate under
friction provided the ring c is Fig. 499.
prevented from rotating with it.
In order to prevent it from revolving with the sleeve,
 and Milling Practice.
427
this ring, (fig. 500), has a slotted tail piece and a pin
which is clamped to some part or other on the carriage

Fig. 500.

of the lathe which prevents its from revolving, (fig. 497).

An eccentric, (figs. 501 and 502), is clamped to the spindle,
behind the sleeve. One half ring of this eccentric is pro-
vided with a tail piece similar to that of the friction ring,
and is kept by the same pin which prevents the friction
ring from rotating. A pawl is attached to the other ring
and this pawl meshes the pawl wheel on the sleeve.

Fig. 501. Fig. 502.

The attachment is rather primitive, since another pawl-

wheel is required for each different number of teeth of the
cutter which has to be backed off whilst the backing off
428 Milling Machines and Milling Practice.
motion derived from the fixed eccentricity of the spindle,
(fig. 498), cannot be altered except by using a spindle with
another eccentricity and the range is also very limited owing
to the diameter of the spindle.
When mounted between the centres and driven by the
lathe as shown in fig. 497, the eccentricity of the spindle
will cause the cutter to make an eccentire motion, though
it will not revolve with it, as the sleeve, is prevented from
rotating by the friction ring. During one revolution of the
spindle, the eccentric, (figs. 501 and 502), completes one
stroke and the pawl moves the cutter one tooth further on.
If the cutter has 20 teeth, then during one eccentric move-
ment of the cutter, the latter is moved ]/2o th, i- e. the pitch
of the tooth.
 CHAPTER XV.

The grinding of cutters.

Formerly cutters were not ground. That was when cutter

and milling machine were still in their infancy. There were
no tools suitable for grinding hardened cutters correctly and
no machines for this work. At present it is difficult to think
of a cutter the cutting edges of the teeth of which are not
ground with the grindingwheel. It was Brown and Sharpe,
who introduced simultaneously with the new type of cutter,
the " innovation " of the grinding of cutters by means of
the grinding wheels which they manufactured, an innovation
which speedily proved to be one of the leading factors in
the further development of the science of milling. The
grinding of the teeth by means of the emery wheel is now
not only an indisputable necessity for a new cutter, but the
emery wheel and the grinding machine are to-day the great
means for keeping the cutter in a perfectly fit state for use.
Milling machine and cutter, grinding machine and emery
wheel, these four are indissolubly connected; if the milling
machine with its cutting tool, the cutter, were deprived of
the services of the grinding machine and the emery wheel,
the former would cease to be of any practical use. This
present chapter will, therefore, treat of the grinding of cutters
as a separate branch of milling practice.

In the metal working industry of the present day, the

grinding machine with the emery wheel fulfills such im-
portant functions that in addition to being regarded as an
auxilliary tool for the milling machine, it has also taken its
430 Milling Machines
place as a machine type. This chapter will, however, deal
exclusively with the cutter grinding machine and then more,
with a view to its use for the grinding of cutters than to
its construction.
The emery wheel, the general name for the artificial
grinding wheel is put on the market under names referring
more especially to the raw material of which it is composed,
such as: — corundum, carborundum, alundum, pyronite, etc.
These raw materials are found as minerals in various
parts of the globe, as for instance, South Germany, Spain,
Dalmatia, Asia Minor and, as far as corborundum is con-
cerned, more especially in the United States, whilst the
island of Naxos supplies emery of an excellent quality, known
as Naxos emery, which is crushed by suitable machinery,
into fine or coarse grain according to the purpose for which
the wheels are to be used. This material is then formed
into wheels of the desired form and size either by chemical
processes or by being mixed with glue. Wheels for every
purpose are manufactured under high pressure from the
raw material mixed with other substances determined upon
in view of the material to be ground after which the size
of the grain and the hardness of the wheel are fixed.
The hardness of the emery wheel and the quality of the
raw material determine the proportion of emery and binding
material as also the pressure to which the wheel must be
subjected during the process of manufacture. In this way
fine and coarse grained, hard and soft emery wheels are
obtained, whilst in general, although this is not a fast rule,
it may be taken for granted that a coarse grained wheel
is hard and a fine grained wheel is soft.
As the fine grain gives a much closer wheel than the
coarse, it would seem that fine grained wheels are the hardest.
According to the means used for binding the wheels, they
are divided into the following classes:—!. Emery wheels
made according to the cold process and bound with magne-
sia-cement. 2.Emery wheels bound with vegetable bond.
3. Emery wheels bound with mineral bond by chemical pro-
cesses, being subjected to great heat in a furnace.
 and Milling Practice. 431

Wheels bound with magnesia-cement easily absorb

moisture, which affects the cement so that such wheels are
absolutely useless for wet grinding.
Wheels bound with vegetable bond such as gum, shellac,
vegetable oils, gelatine, indiarubber, (this latter being termed
the elastic binding), can be used equally as well for dry as
for wet grinding.
The emery and the bond are mixed hot in special machines,
then pressed into shape under high pressure in hydraulic
presses, after which the wheels are burned in a furnace.
The more expensive materials used herefor, chiefly india-
rubber, as well as the cost of the process and the installation
required for their manufacture, make those wheels very
much dearer.
The wheels best suited for grinding fine tools such as
cutters, knives, etc. are those manufactured by the chemical
process and bound with mineral substances. These were
originally put on the market under the name of Norton emery
wheels and are manufactured in the United States. The
principal substances employed in the manufacture of these
wheels are alundum and clay, which after being properly
mixed, are formed under hydraulic pressure and then exposed
to a very great heat. By this method of binding, the wheels
acquire then- porosity which suits them so eminently for the
grinding of cutters, wheras with other kinds of emery wheels
the abrasive is completely covered by the bond, thus giving
insufficient porosity ; in the case of wheels manufactured by
the chemical process with mineral bond, the abrasive becomes
mingled or vitrified, thus forming one complete whole so
that the bond also becomes abrasive. This in conjunction
with the easier formation of new grinding and cutting edges
owing to their porosity explains the far keener grinding
capacity of this class of wheels. Their light weight further
ensures greater safety in use.
In addition to these, wheels composed of minerals artificially
rendered abrasive are also used in the manufacture of grinding
wheels. Amongst these, the carborundum wheels occupy the
leading place. Carborundum is derived by a process of melting
 432 Milling Machines

clay and coke by the heat obtained by electricity, being chiefly

manufactured by the Carborundum Co. of Niagara Falls.
The .enormous heat required for the manufacture of these
wheels renders it only possible to manufacture them where
the power required for generating the necessary electric
current is exceptionally cheap.
This applies not only to carborundum but also to the
various other kinds of wheels placed on the market under
various names. Their hardness depends on the mixture
added to the natural abrasive, since the expensive artificial
material can in general only be regarded as an addition.
Owing to their keener cutting edges and greater hardness,
these wheels may certainly be reckoned among the best.
For general purposes, ordinary emery from the island of
Naxos and the Levant will certainly remain the most
advantageous.
Hard objects such as cutters require a soft stone for
grinding. Owing to the cutting points of the abrasive quickly
becoming dull, they may not be bound too closely.
It is of the utmost importance that during the grinding,
that part of the cutter which is being treated, would not
become too warm.
With many objects which are being ground, the heat
generated is dispersed by a flow of water. Since however,
the workman when resharpening cutters, must have the
whole of the teeth clearly in view when grinding, the use
of a cooling liquid is not possible.
If the cutting edges of a cutter are raised to too high a
temperature whilst being ground, the cutter may be regarded
as spoiled. Too great an increase of temperature of the parts
ground must, therefore, be carefully avoided. In connection
herewith the following should be carefully attended to :—
1. Use a soft, sharp wheel.
2. Let the grinding wheel run at the exact speed, not
too quickly, but above all, not too slowly.
3. Remove but a small quantity of metal at a time.
Point 1. has already been discussed. The softest wheels
are the carborundum, alundum and corundum wheels. In
 and Milling Practice. 433

any case, wheels which are manufactured by the chemical

process should be employed. The above-mentioned kinds of
wheels are the most expensive. Lower price should, how-
ever, be no inducement to use wheels less suited for the
purpose. The small difference in price will not compensate
for the damage caused by soft spots in the cutter tooth as
a result of a local increase of temperature caused by the
inferior cutting of the wheels.
The surface speed of emery wheels varies from 4000 to
6000 ft. per minute and the number of revolutions must be
regulated in accordance with the diameter of the wheel.
In table XXIX the number of revolutions is given for
various diameters and surface speeds.
Table XXIX.
Diameter No. of revolutions for a surface speed
of
per minute of: —
emery wheel. 4000 Ft. 5000 Ft. 6000 Ft.

1 15279 19099 22918

2 7636 9549 11459
3 5093 6366 7639
4 3820 4775 5730
5 3056 3820 4584
6 3820
2546 3183
7 2183 2728 3275
8 2387 2865
1910
10 1910 2292
12 1528
1273 1592 1910
1637
14 1091 1364
16 955 1432
1194
18 849 1061 1273
20 764 955 1146
22 694 868 1042
24 637 796 955
26 586 879
733
30 509 637 764
36 424 531 637
42 546
364 455
48 318 397 477
425
54 283 354
80 255 319 383
28
434 Milling Machines
For the proper carrying out of point 3, the workman must
r have had the
• requisite prac-
?-"'-£
Fig. 503. Hollow sharp edged disc wheel.

chine must be so constructed to take a very grinding ma-

thin cut from
all the teeth in succession.
The shape of the wheels [
varies considerably in Fig. 504. Cylindrical disc wheel.
accordance with the man-
ner of working and the kind of cutter.
Figs. 503—506 illustrate some of
the forms most usually met with.
Those most used are the cylindrical
discs shown in fig. 504 and the cup
wheel as per fig. 505. Both kinds
Fig. 505. Cup wheel. are employed for grinding shell and
end mills of every variety, the discs
shown in figs. 503 and 506 being used for deepening the
tooth spaces and the
grinding of backed off
cutters.
„. PA_ Fig. 506. Sharp edged disc whorl.
Fig. 507 illustrates
the grinding of the teeth of an end mill with a disc wheel ;
fig. 508 shows the same
operation being performed
with a cup wheel, whilst
figs. 509 and 510 illustrate
the grinding of shell and

Fig. 507. Fig. 508.

T<x>th grinding with disc Grinding teeth with a dip wheel.
 and Milling Practice. 435

end mills, the two lastnamed operations being carried out

by means of the cylindrical disc
wheel. Fig. 511 shows the manner
in which an emery wheel as per
figs. 503 and 506 is used for
grinding backed off cutters.
There is a diversity of opinion
as to which kind of wheel is the
most preferable for the grinding of
the ordinary coarse pitched cutter,
the common cylindrical disc as per Fig. 509.
Grinding side teeth with
fig. 504 or the cup wheel as per disc wheel.

fig. 505. The manner of working

differs considerably in each
case. The disc shown in fig.
504 grinds on the circum-
ference, that shown in fig. 505,
on the front. The back of
the tooth when ground with
the cup wheel, shows a grind-
Fig. 510. ing line in a longitudinal direc-
Grinding front teeth with a tion which ensures an accurate
disc wheel.
and very smooth cut. There
is, however, a certain objection con-
nected herewith namely, that the chips
will not break, so that a very long
chip results which fills up the tooth-
space and covering the workpiece with
chips which can only be removed with
difficulty, besides impeding a proper
view of the work.
The emery wheel which works as
per fig. 507, produces a tran verse
grinding line over the tooth edge DeepeningFig.tooth 511.
spaces or
which ensures the chips breaking, grinding backed off cutters. '
whilst the adjustment and grinding are
rendered much easier. The latter manner of working is
far and away the one most generally employed. The only
436 Milling Machines
objection to this method is that in cases where the teeth
are worn or, in the case of fine teeth, the
tooth is not ground flat but concave, as is
shown, greatly exaggerated, in fig. 512. It
is thus advisable always to choose an emery
wheel of as large diameter as possible and
to take care that, when the cutter and emeryJ Concave ground
wheel have been so adjusted that the proper tooth.
clearance is obtained, and the emery wheel
does not foul the sharp edge of the tooth above. This also
applies in the case of fig. 509.

Fig. 513. Fig. 514.

Two directions can be imparted to the emery wheel as

regards the tooth of the cutter. The emery wheel can
rotate towards the cut as per fig. 513, or away from the cut
as per fig. 514. The first-named manner of working has
this advantage that the emery wheel forces the tooth against
the tooth rest, thus keeping the cutter in a fixed position.
The second manner of working is theoretically correct, but
is seldom employed in practice.

As has already been stated, this chapter does not purpurt

to give anything like a detailed description of the con-
 and Milling Practice. 437

struction of the grinding machine as a type of machine

tool, since anything like a complete treatment of the subject
would be at least as extensive as that of the milling machine
itself. We shall, therefore, content ourselves with the con-
sideration ofthe milling cutter grinding machine.

Fig. 515. Milling cutter grinding machine.

The milling cutter grinding machine may be constructed

either plain or more universal, though in general construction
the various makes differ but little.
Fig. 515, illustrates a milling cutter grinding machine. •
A matter of primary importance in a first class grinding
machine is the exact bearing of the main spindle in its
housings, firstly, on account of the great number of revo-
438 Milling Machines

lutions which this spindle has to make, and secondly, so as

to ensure the rotary motion of the emery wheel being
free from vibration. Owing to the great number of revo-
lutions and the consequent speed, a liberal lubrication is
essential if the spindle is to run easy in its bearings ;
if however, such a comparatively thin spindle as that of a
milling cutter grinding machine which has to make such a
great number of revolutions per unit of time, is to run
without vibration, it is imperative that it should be very
closely housed in the bearings.

_
0
^2 is

1
i

f
1

Fig. 516. Sectional view of the main spindle of a milling cutter grinding machine.

Fig. 516 shows the construction of spindle and bearings

of a Norton grinding machine. Spindle 1 runs in cylindrical
bearings and is hardened and ground according to the
Harvey system. The cylindrical bearings 2—2 are of bronze.
Externally these bearings are conical and fit in the conical
bore of the casting. Wear can be taken up by means of
the nuts 4.
The end thrust is taken up by spindle 5 which, in its
turn, can be adjusted by screw 6 and presses against the
pin 8 in the pulley 9. The hub of this pulley runs against
a fibre washer 10. The pressure screw 6 is provided with
 439
and Milling Practice.
a nut, whilst pulley 9 is kept in place by means of an
adjusting screw 11.
In this way longitudinal movement of the spindle is pre-
vented whilst wear can also be taken up. The top of the
bronze bearing has a large opening filled with felt which
absorbes
the oil sup-
plied by the
oil cups.
For inter-
nal grind-
ing, two
different
35-
36
spindles are
used which
rotate in an Fig. 517. Spindle and chuck for internal grinding.
attachment
which can be mounted on the grinding table.
Fig. 517 shows a spindle on which a chuck can be
mounted, the grinding spindle being illustrated in fig. 518.
Spindle 34 runs comparatively slowly and is housed in a
bearing which is tapered to both ways.
The spindle shown in fig. 518 has bearings close to the
pulley, running on the front side in a long, cast iron
bearing. Owing to the limited diameter, abjustable bearings

Fig. 518. Internal grinding spindle.

cannot be used in this case. End thrust is provided by a

hardened steel nut, whilst the pulley encloses the spindle
in a longitudinal direction. This spindle must be able to
make 20.000 revolutions per minute and can only be lubri-
cated with kerosene oil.
Figs. 519 and 520 illustrate the upper part of a Loewe
cutter grinder, arranged in fig. 519 for the grinding of
440 Milling Machines

cutters between the centres, and in fig. 520 for the grinding
of cutters chucked in the holder 5 by means of their shaft
or conical arbor.
The bracket along the column of the machine shown
in fig. 519, is vertically adjustable by the hand- wheel 21
(see fig. 520). The centre in bracket 6 can be accurately
adjusted by means of the adjusting screw in the bracket in
question. The carrier 4 which has a double fork is mounted

Fig. 519. Cutter grinding machine.

on centre 2 in bracket 5. On the opposite side of bracket

5 is the indexing apparatus 7 which can be accurately
adjusted by the screw in 8.
The swiveling head 10 is mounted on the guide. By
this means the cutter can be set in each and every
position as regards its plane of motion against the grinding
wheel. The head itself is held securely by screw 12, the
head being secured to the guide surface by screw 14. Tin-
head which is graduated in degrees, can be accurately
 and Milling Practice. 441

adjusted by screw 11. The crosspiece which can swivel,

is clamped by the hand wheel 20.
In fig. 520, the bracket 5 is to be seen in the swiveling
head 10 instead of the guide 9, In its chuck, cutters with
taper shaft can be placed to permit of end and angular
cutters being ground.

Fig. 520. Cutter grinding machine.

In both illustrations the tooth rests used for placing the

cutter in the proper position, are indicated at 23. Many of
the illustrations previously given show not only these tooth
rests but also the way in which the tooth presses against
the rest. It will be seen that this small part of the cutter-
grinding machine, performs a most important function. It
442 Milling Machines

is employed in a variety of shapes and sizes according to

the form and dimensions of the cutter to be ground.
Adjusting the machine.
The cutter to be ground is mounted between the centres,
or in the swiveling head 10, (fig. 519). The cross slide must
be placed in such a way that for backed off cutters the tooth
face is at a proper angle whilst for grinding common teeth,
that the tooth when ground has the right angle of clearance.
It will be seen from fig. 108 on page 62 that the angle
of clearance may vary between the extreme limits of from
3 to 12 degrees, the smaller angles for hard, the larger for
soft metal. The clearance usually varies from 5 to 7 degrees
for hard and soft metals. In order to obtain the correct
angle, the tooth rest against which the tooth of the cutter
is pushed whilst being ground, must be set at the right
height. To obtain this, the centres between which the
cutter is mounted must be placed a certain distance below
the centre line. When using cup-shaped wheels, this distance
depends on the diameter of the cutter; when using disc
wheels, it depends on the diameter of the grinding wheel.
Tables XXX and XXXI give this distance for cutters
.and grinding wheels of various diameters for angles of
clearance of 5 and 7 degrees.
Table XXX
for setting the tooth rest at the correct height to obtain 5 and 7 degrees
clearance for grinding peripheral teeth with a cup wheel.
'
For a For a For a 5/3» For a
Diam. of
cutter. '/
clearance '/64
clearance
Diam. of
clearance 11 64clearance "/..
4
'64 cutter.

Inches. of 5°.
Inches. Inches.
of 7°. Inches. 3/l« Inches.
Inches.
'/•• +•/»•
6 *
3-4 of 35°. +
'/•4 + of 7°.
9 64 18/(U
*/
% 4
7/
'/a
8
' 64 +
'/•4 '39 + 4 4%
4'4
1364-
'/»-
5/8 '/•• -
' 3, +
"/«« +
8/64-f 4-;2
1

Vie
 19/6/
and Milling Practice. 443 «416
X/
4

7/3
2 8l/
For a For a For a 6*
Diam. of Diam. of "/6
4
For a
clearance clearance clearance clearance
cutter. cutter.
"/s2a3/64
of 5°. Inches.
l7/ 86/
Inches. Inches. of *7°.
Inches.
/•* Inches. 64
Inches.
64

3/3
2 5!/4 of 5°. of 7°. 27/
3/64 9/8 64
+
IVa 7/6
4 55J/2
2

IV*
29/
B/1 64
6
&,64 Vie + 58/4 2l/
6 4 3l/
64
I1/!
28/
9/64 64
!3/4 Vie - */
• 5/3 6J/a
2
Vie
2
2'/4
7
3/32
/64
-
11 /
•Ai 64
6
3/32 +
7!/a
2V2 V8. 7
V* —
23/4

3 8
Vs +
-j- after the number indicates that it is fully the given amount,
n 17 :i 11 n 51 15 barely „ „ » «
Set the centres at the same height as the centre of the emery wheel, then
set the top of the tooth rest below centering gauge the amount given in the
table for each diameter of cutter and clearance (see fig. 521).
Table XXXI
giving the vertical distance below the centre of the emery wheel at which the
l7/
centres must be set between which the cutter is mounted for 5 and 7 degrees 64
'/•
clearance when using disc wheels for grinding peripheral teeth. 9
•/.. /3l2
9/6
4
For a For a For a 13/64 For a
Diam. of Diam. of

emerywheel
clearance clearance 9/81 emerywheel
clearance clearance
5/1 '
6 /
"A «
*
3/3
2 41/*
Inches. of 5°.
Inches. Inches. 11/
of >7°. ''
Inches. Inches.
4!4/2 32
/32 /« % 14/6!
of 5°. + Inches.
2
7A
±
3/16
'£ '/.. of 7°. 23/
64

21/* 3/32 +

2Vi
13/e
«
16/61 +
"A*
23/4 '/
9/64
«
5V*
5
5^/2
1B/6
3 5/32
4
53/4
3>/4
Vs + . 15/6,
8Vi Vs
B/32 3/8 '
33/4 +
6
4
Set the centres at the distance given in the table = A (fig. 521), below
W64
the centre of the emery wheel.
444 Milling Machines

Fig. 521. Adjusting the table to the exact height.

To the equipment of a cutter grinding machine belongs

a centering gauge, i. e. a small block which, when placed
on the table, indicates the exact height of the centres between
which the cutter arbor is placed. This gauge can be seen
on the table in
fig. 521. In the
case of disc
wheels the dis-
tance A of the
tooth rest below
the height of the
centresisas given
in table XXXI
Fig. 522. for a clearance of
Grinding cylindrical cutter with straight teeth.
5 and 7 degrees.
When grinding the periphery of the teeth with a cup
wheel, the centre of the emery wheel is set at the same
height as the arbor centres. The tooth rest is then placed
the distance A below the centres as indicated in table XXXI.
 and Milling Practice. 445

For grinding a cylindrical cutter with straight teeth, the

table travels at
right angles to
the axis of the
main spindle,
(% 522).
When grinding
a conical cutter
with straight
teeth, the table
must traverse a Fig. 523.
Grinding a conical cutter with straight teeth.
line forming an
angle with the axis of the main spindle, the angle being
equal to the an-
gle formed by
the axis of the
cutter with its
side, (fig. 523).
When grinding
a cylindrical cut-
ter with spiral
teeth, the table
Fi 524 must traverse a
Grinding a cylindrical cutter with spiral teeth. line forming an
angle with the
axis of the main spindle, equal to the angle given in table
XVI, pag. 148
and!49,(fig.524).
When grinding
a conical cutter
with spiral teeth,
the table must
traverse a line
forming an angle
with a line square
on the axis of Fig. 525.
the main Spindle Grinding a conical cutter with spiral teeth.
equal to the angle formed by the axis of the cutter and its
446 Milling Machines

Fig. 526. Sharpening a spiral cutter with a disc wheel.

side increased by the angle given in table XVI, pag. 148

and 149 (fig. 525).
In the latter case there is a double
deviation.
The angular travel of the table is not
necessary when grinding spiral mills with
a disc wheel on the peripheral.
The tooth rest by which the cutter is
adjusted to the correct position for grind-
ing, either travels with the cutter or is
attached to a fixed point on the machine.
In the latter case the tooth of the cutter
moves along the tooth rest whether the
tooth rest is attached on a fixed part <>f
Fig 527 t^ie macmne or on the table. The grind-
ibie portion of
ing of cutters with straight teeth can be
performed in both ways, but in grinding
cutters with spiral teeth, it is necessary to attach the tooth
 and Milling Practice. 447
rest to a fixed portion of the machine as the position of
the cutter whilst travelling along the emery wheel will only
traverse a line equal to the spiral line of the tooth in this
way. If at all possible, the tooth rest must be so adjusted
as to bear the tooth which is being ground.
Fig. 526 illustrates the grinding of a cylindrical cutter with
spiral teeth. The cutter is mounted between the centres.
The emery wheel is a disc wheel. When cutting cylindrical

Fig. 528. Sharpening an angular cutter.

cutters with a disc wheel on the peripheral, setting the table

at an angle is not necessary. The tooth rest is set at the
height of the centres, the centres being the distance below
the centre of the emery wheel given in table XXXI. The
stops which limit the table travel are so adjusted that the
tooth rest cannot pass the tooth of the cutter, but only passes
over a portion of it. When the cutter is turned over one
tooth, the flexible part of the rest acts as a spring pawl,
(fig. 527). When grinding, the cutter must be kept against
the tooth rest by hand, which is all the more requisite when
448 Milling Machines
the emery wheel rotates as shown in fig. 514 than when it
rotates in an opposite direction. As has already been stated,
grinding can be done in both ways, that shown in fig. 514
being theoretically correct though a less easy and the
least used.
Fig. 528 shows the grinding of a right hand angular
cutter with straight teeth. The cutter is held on the end of
swiveling head spindle and secured by a bolt through the

Fig. 529. Sharpening side teeth with cup wheel.

spindle. The head is then swiveled to the required angle.

The tooth rest is set at the centre height of the swiveling
head so that the face of the tooth being ground is also at
the same height. The table is dropped the required position
below the centre of the emery wheel which is necessary
according to the diameter of the emery wheel as given in
table XXXI and the cutter is kept against the tooth rest by
hand. The grinding of a left-hand cutter is identical except
that the swiveling head is set to the proper angle on the
other side of zero.
 and Milling Practice. 449
Fig. 529 illustrates the sharpening of the left side teeth
of a side milling cutter with a cup wheel. This gives a
straight clearance and a stronger cutting edge than the
cupped-out clearance obtained by grinding with a disc
wheel, the diameter of which is small enough to get be-
tween the teeth. The cutter is held on the spindle of
the swiveling head and secured by a bolt passing through
the spindle. Through the swiveling head which can also

Fig. 530. Sharpening peripheral teeth with cup wheel.

swivel in the vertical plane, the cutter is brought sufficiently

out of the vertical plane as is necessary to obtain the
desired clearance. The knee is !/2 degree out from the square,
being set at 90!/2 degrees, so that the " down " side of the
emery wheel will touch the work while the " up " side will clear.
The tooth rest is fastened to the swiveling head, its height
being so fixed that the face of the tooth being ground is at
the same height as the centre of the cutter. For sharpening
the right side teeth of a side milling cutter, the setting is
exactly the same, except that the knee is now set at 89!/2 degrees
29
450 Milling Machines

56

Fig. 531. Sharpening peripheral teeth with disc wheel.

Fig. 532. Sharpening a backed off cutter.

 and Milling Practice. 451

so that the " up " side of the emery wheel will touch the
work while the " down " side will clear. When sharpening
these teeth, the table must be raised before commencing
the operation, until the tooth next to the one being ground
clears the top of the emery wheel.
Fig. 530 illustrates sharpening peripheral teeth of a side
milling cutter with a cup wheel. The relative positions of
the emery wheel and cutter are clear from the illustration.
The cutter is now perpendicular in the vertical plane and

Fig. 533. Sharpening a backed off formed cutter.

the centre of the swiveling head is at the same height as

the centre of the emery wheel. The top of the tooth rest
against which the front of the tooth to be ground bears
is now dropped the distance below the centre of the emery
wheel indicated in table XXX to obtain the desired
clearance. The knee is set at 89V2 degrees which brings
the " up " side of the wheel in contact with the work:
Should the emery wheel strike the tooth next to the one
being ground, the table must be raised until this tooth
clears the top of the emery wheel.
452 Milling Machines

Fig. 531 shows the same operation as that in fig. 530,

but being carried out with a disc wheel. The position of
the knee is however, as regards that in fig. 530, set at
90 degrees. The cutter is perpendicular, the tooth rest is
set at the same height as the swiveling head and the centre
of the cutter as much below the centre of the emery wheel
as is given in table XXXI.
The sharpening of a backed off gear cutter is illustrated

Fig. 534. Sharpening a hob.

in fig. 532. For this purpose a gear cutter grinding attach-

ment is clamped to the table which ensures the faces of the
teeth being radial and the same amount being ground off
each tooth. The knee is set at a slight angle to the axis
of the emery wheel which brings only the edge of the
emery wheel in contact with the work.
Fig. 533 illustrates the sharpening of a backed off formed
cutter which is mounted on an arbor and held between
special centres. A disc wheel is used. The table is brought
towards the column of the machine until the face of the
 and Milling Practice. 453
emery wheel is in line with the centres. The tooth rest is
then set to the heel of the tooth.
A similar operation to that shown in fig. 533 is illustrated
in fig. 534. The cutter which is being ground is a hob
with spiral teeth. The hob is sharpered with a disc wheel.
The tooth rest is attached to a fixed point on the machine
so as to impart to the hob to be ground a movement
similar to the spiral line of the teeth ; the hob bears against

Fig. 535. Sharpening the peripheral teeth of an inserted tooth face mill.

a master form of the cutter mounted on the same arbor

but without teeth. The knee is swiveled to the required
angle corresponding to the inclination of the spiral.
The sharpening of an inserted tooth face mill is illustrated
in fig. 535. The mill is mounted on the spindle of the
swiveling head which is clamped by a bolt through the
spindle. The table is square on the spindle. The tooth
rest is attached to the swiveling head, the table being
dropped below the centre of the spindle to obtain the correct
clearance as given in table XXXI.
454 Milling Machines and Milling Practice.
The side of the tooth is subsequently sharpened with a
cup wheel as illustrated in fig. 530. The cutter is brought
out of the perpendicular and inclines to the front so as to
obtain the correct clearance. The knee is set at 891/*
degrees so that the u up " side' of the wheel will touch the
work while the " down " side will clear. The tooth rest is

Fig. 536. Sharpening side teeth of an inserted tooth face mill.

attached to the swiveling head and is set at such a height

that the tooth to be ground is at the same height as the
centre of the cutter.
The greater number of profile cutters used at the present
time are backed off. Backed off cutters are sharpened along
the face of the teeth without regard to the form of the cutter
(see figs. 532 and 533).
 CONTENTS.
Page.

INTRODUCTION 5—6
CHAPTER I.
General review 7 — 11
The milling machine compared with the lathe, planer
and shaper 7
PART I.

The Cutter.
CHAPTER II.
Development of the milling cutter 12 — 16
CHAPTER III.
Denomination of cutters 17 — 33
(a). Classification 17
(b). Group I. Cutters composed of blades ... 19
(c). „ II. End mills 22
(d). „ III. Shell „ 24
(e). , * IV. „ end mills 27
(/). „ V. Formed milling cutters 29
(<£")• » VI. Composed formed milling cutters . 30
CHAPTER IV.
The working methods of the cutter 34—51
(a). The relative position of cutter and workpiece . 34
(b}. The manner in which the cutter works in respect
to the plane of motion 45
(c). The manner in which the cutter works in respect
to the cutting plane 47
456 Contents.

CHAPTER V. Page.

Construction of cutters 52—76

(a). Diameter and number of teeth 52
(b). The tooth and its angle 58
(c). The spiral line of the teeth 65
(d). The backed off cutter 69
(e). The bore of the cutter 73
CHAPTER VI.
Manufacture of cutters 77 — 156
(a). General considerations 77
(b). Milling the teeth 89
(c). Dividing heads 98
(d). Indexing with the index plate 107
(e). Compound indexing 120
(/). Practical directions for milling cutter teeth . . 128
(g). Spiral milling 131
(h). The calculation of the lead from the inclination 137
(/). The hardening of cutters 147
CHAPTER VII.
Speed and feed of cutters 157—175
PART II.

Milling Machines.
CHAPTER VIII.

Construction of milling machines -. 176—250

The column and knee type milling machine.
(a). The main spindle 181
(d). The housing of the main spindle 188
(c). The drive 196
(d). The feeds 201
(e). The supply of cooling liquid to the cutting tool 227
(/). The arbor support
(g). Constant speed drive milling machines. ... 232
 Contents. 457

CHAPTER IX.
Page.

Different types of milling machines 251—347

(a). Piano-millers 251
(b). Rotary milling machines 260
(c). Thread milling machines 272
(d). Gear cutting machines 281
(e). Gear hobbing machines . 286
(/). The " Warren " automatic bevel gear generating
machine . 300
(g). Vertical milling machines . . . . . . . . 307
(//). Sundry machines 325
(z). Combined horizontal and vertical spindle milling
machine . . 333
CHAPTER X.
Attachments for the universal milling machine. 348 — 366
CHAPTER XI.
Clamps and clamping devices 367 — 376
CHAPTER XII.
The power absorption of milling machines . . 377 — 391
CHAPTER XIII.
Milling operations 392 — 413
CHAPTER XIV.
The backing off lathe 414—428
CHAPTER XV.
The grinding of cutters 429 — 454
 INDEX.
All-geared headstocks, 200, 236, 243, Circular milling, 409-
244, 340. Circular milling attachment, 350.
Angle calculation, 138 — 141. Clamping devices, 367 — 376.
Angle cutter sharpening, 447.
Angle drive, 235. „„ plates, 374.
strips, 374.
Angle plates, 372—373. Clearance of cutter teeth, 442—443.
Angular cutters, 28, 128—129. Coarse pitched milling cutters, 17, 27, 18.
Arbors, 187—188. Coarse pitched teeth cutting, 84.
Arbor stays, 231. Combined milling machines, 333—347.
Arbor support, 228—232. Composed formed milling cutters, 31, 32.
Arm. overhanging, 228—229. Compound indexing, 120 — 127, 135 —
Attachments, 348—366.
137.mandril, 376.
Cone
Automatic gear cutting attachments,
361-366. Conical cutter grinding, 445.
Constant speed driven machines, 199,
200—201, 233—250, 316—318.
Back gearing, 196-198, 244, 263. Cup wheels, 434.
Backed off cutters, 30, 69, 83, 49. Cutter diameters, 52 — 58.
Backed off cutter sharpening, 450. Cutter grinding, 429—454.
Backed off cutter teeth, 70. Cutter pitch, 61—68.
Backed off teeth cutting, 32, 85. Cutter speeds, 156—164, 166—175.
Backing off attachments, 425—428. Cutter teeth clearance, 442—443.
Backing off lathe, 414. Cutting angles, 60.
Bevel gear generating machine, 300—307. Cutting angles of cutters, 63.
Bore of cutters, 73, 81. Cutting capacity, 66.
Bracings, 230—252. Cutting feeds, 162—163, 166—175,
Brown and sharpe topers, 184. 383—388.
Cutting speeds, 156-164, 166— 1*75,
383—386.
Calculation of angles, 138 — 141. Cylindrical cutter grinding, 444 — 445.
Calculation of spirals, 137.
Cam milling attachment, 360.
Centering cutter blanks, 81. Depth of backed off teeth, 72.
Change gears for backing off lathe, Depth of cutter teeth, 63.
423, 424. Diameter of cutters, 52 — 58.
 Index. 459

Disc wheels, 434. Gear bobbers, 289, 296.

Dividing heads, 98—147, 357. Gear hobbing, 286—295.
Dividing, 91, 107—127, 357—358. Gear boxes, feed, 208—216, 240, 247—
Double back-gearing, 197—198.
249.
Doable edged milling cutters, 21, 25. Gear cutters, 29, 46, 50, 285, 286.
Double spindle milling machines, 326 — Gear cutting attachments automatic,
328. m 361—366.
Drive of milling machines, 196—200, Gear cutting machines, 281.
235-236, 320— Grinding, cutter, 429 — 454.
Grinding machine main spindle, 438.
Grinding machines, 437 — 454.
Early milling cutters, 15.
Efficiency of feed, 388—389.
„ „ milling machine, 390. Handwheel position, 223.
Electric driven milling machines, 201,
Hardening of cutters, 147 — 156.
235, 258.
Headstocks, 190—200, 263.
Elevating screws, 203—205. Headstocks, all geared, 200, 236, 243,
Emery wheel materials, 430, 431.
244, 340.
Emery wheels, 430—434. Heating furnace, 80.
Emery wheel speeds, 433.
Heating of cutters, 147 — 153.
End mills, 24.
Hexagon milling, 326.
Hexagon milling, 403, 404.
High tailstocks, 359.
Pace milling, 401, 407, 408, 411,412.
High speed milling attachment, 353 — 354.
Feed efficiency, 388—389. Hobbers, worm wheel, 296.
Feed gear boxes, 208—216, 240,
Hobbing, worm wheel, 297—354.
247—249. Hob sharpening, 452.
Feed interlocking, 241. Hollow mills, 25.
Feed mechanisms, 202— 226, 239-241, Horizontal boring and milling machine,
259, 311—313. 346-347.
Feed of cutters, 162—163, 166—175.
Feeds, table, 207, 218—221, 314.
Feeds, cutting, 162—163, 166-175,
383—388. Inclination of cutter teeth, 58.
Feed trip mechanisms, 229—224. Inclination of spiral teeth, 66, 68, 137-
Fine pitched cutters, 82. Ingham clamps, 375.
Inserted tooth cutters, 22.
Fine pitched formed cutters, 94—96.
Fine pitched teeth cutting, 83, 89 — 94. Internal grinding spindle, 439.
Forging of cutters, 79. Internal milling, 280, 294.
Formed milling cutters, 29, 49.
Form of coarse pitched cutter teeth,
26, 86—88.
Keyway cutting machines, 328—329.
Keyways of cutters, 75.
Knee clamping devise, 206.
Gang cutters, 394—397. Knees, 202—207, 234.
460 Index.
Left hand cutters, 67- Ratio of depth and cutter diameter, 64.
Lincoln millers, 253. Relative movements of cutter and work-
Loewe tapers, 183.
piece, 48—51.
Lubricating, 227. Relative positions of cutter and work
piece, 34—35.
Right hand versus left hand spiral
Magnetic chuck, 375. cutters, 69.
Main spindle of grinding machine, 438. Right hand cutters, 67.
Main spindles of milling machines, 185 — Rotary milling, 40, 43, 260, 344. 350,
195, 245, 317—322, 325, 349. 376, 409.
Metric tapers, 182. Rotary milling work, 262.
Micrometer adjustment, 224—225.
Milling arbors, 187, 188.
Milling tables, 218—219, 226. Shaft vise, 373.
Milling work, 392-413. Shell mills, 25.
Morse-tapers, 187—182. Side teeth sharpening, 448, 454.
Single edged milling cutters, 21.
clamps, 375. Single pulley drive, 199—200, 233—250.
Slab-millers, 251—260.
Number of cutter teeth, 52—58.
Sliding heads, 318.
Slotting, 408.

Oil pump, 227. Slotting attachments, 355 — 356.

Slotting cutters, 28.
Overhanging arm, 228 — 229- tools, 356.
Speed of cutters, 156-164, 166—175.
Peripheral tooth sharpening, 448, 450, Speed of emery wheels, 433.
453. Spindle bearings, 189—195, 257, 259,
Pitch of cutters, 61, 68. 325.
Plain index centers, 99—102. Spiral calculation, 137.
Plain vise, 367. Spiral and wormwheel hobbing attach-
ment, 354.
Piano-millers, 251—260.
Position of cutters on the grinding Spirals, 65.
machine, 442—446. Spiral milling, 131 — 137, 402, 406
Power absorbtion of milling machines, Spiral mills, 27.
377-391. Stays, arbor, 231.
Profile milling, 319—322. Steel quality of cutters, 78.
Straddle mills, 29.
Pump, oil, 227.
Supporting blocks, 400-
Surface milling, 34—35, 38— 4!». 45,
Quenching of cutters, 153—156. 392-395.
Surface milling machine, 327.
Surface speed of cutters, 156— I«i4.
Hack milling, 405. 166-175.
Rack milling attachments, 357, 396, 405. Surface speed of emery wheels, 433.
Rake of cutters, 62. Swivable angle plates, 372.
 Index. 461

Swiveling heads, 334—337. Turning of cutters, 81.

Swivel vises, 368—370. Twist drill cutting machine, 331.
Types of cutters, 18—33, 73.

Table feeds, 207, 218-221, 314.

Tables, 58, 61, 64, 65, 68, 72, 75, 76, Under cutting attachment, 360-
115-119, 142—145, 148—149, Universal dividing heads 103 — 127.
162-164, 174—175, 182—184, Universal joint, 321.
423, 424, 433, 442-443. Universal milling attachment, 352.
Tail stocks, high, 359. Universal vise, 369.
Tapers, 181—184.
Teeth ratting, 81—98, 128 — 130.
Teeth depth, 63. Vertical milling machines, 307 — 325.
Teeth grinding, 62. Vertical spindle milling attachments,
Telescopic screws, 203—205. 348—352.
Temperature of cutters, 153. Vises, 367—371, 372, 373.
Tempering of cutters, 80. Vises with swiveling jaws, 370—371.
Thread milling, 272—281.
„ „ cutters, 279.
„ work, 273. Worm milling, 299.
Tooth rest, 446. „ wheel hobbers, 296.
Triple index centers, 357. „ hobbing, 297, 354.
"|"-slot cutting, 46, 398.
 TABLES.
Page.
I. Determining the pitch and number of teeth
of cutters 58
II. Determining teeth angles by a given diameter
of cutter and number of teeth 61
III. Tooth depth 64
IV. Tooth construction 65
V. Lead of spiral teeth by a given diameter of
cutter and angle of teeth 68
VI. Backed off cutters 72
VII. Square key ways of cutters 75
VIII. Semicircular keyways of cutters 76
IX. Indexing on the universal dividing head . . 115
X. „ „ „ „ „ . . 116
XL „ . „ „ „ . . 117
XII. „ „ „ „ „ „ . . 118
XIII. „ „ „ „ „ „ . . 119
XIV. Sine and cosine tables 142 — 143
XV. . „ „ „ 144-145
XVI. Angles for setting the milling table for spiral
milling , . 148 — 149
XVII. Average cutting speeds and feeds for ordinary
tool steel cutters !''»-
XVIII. Average cutting speeds and feeds for high
speed steel cutters 163
XIX. Number of revolutions of universal milling
machines K>4
XX. Speeds and feeds of cutters under a diversity
of working conditions 174 — 175
XXL Morse-tapers 182
 Tables. 463
Page.
XXII. Metric tapers , 182
XXIII. Loewe „ 183
XXIV. „ „ 183
XXV. Brown and Sharpe tapers 184
XXVI. Change gears for backing off lathe . . . 423
XXVII. „ „ „ „ „ . . . 423
XXVIII. „ „ „ „ „ . . . 424
XXIX. Surface speeds and number of revolutions of
emery wheels .."........ 433
XXX. Clearance of cutter teeth 442—443
XXXI. 443
 AUTHORITIES CONSULTED.

VON KNABBE. Fraiser und deren Rolle bei dem der-

zeitigen Stande des Maschinenbaues 1893.
HORNER. Modern milling machines 1906.
JURTHE und MIETSCHKE. Handbuch der Fraserei 1903.
PREGEL. Frase- und Schleifmaschinen 1892.
H0LLE. Die Werkzeugmaschinen 1906.

„ Machinery."
„ American Machinist."
Zeitschrift des Vereines Deutscher Ingenieure.
„ fur Werkzeugmaschinen und Werkzeuge.
Catalogues and private information from the leading
milling machine and milling cutter manufacturers in the
U. S. A., England, Germany and France.
 ADVERTISEMENTS.

KEARNEY & TRECKER

MILWAUKEE, WISM U.S.A.
Manufacturers of the Celebrated High-grade

Milwaukee Milling Machines

As described in the subject matter of this book.

These machines are adapted for every kind of Milling r

whether plain, jobbing or manufacturing, and also for the
highest class of Tool Room work.
For further particulars apply to the Makers, or to the
Sole Agents for the United Kingdom—

C. W. BURTON, GRIFFITHS & CO.

1, 2 & 3 LUDGATE SQUARE, LONDON, E.G.
MANCHESTER-Dyer St., Chester Road. GLASGOW— 19 Waterloo St.
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