PowerPoint to accompany

Technology of Machine Tools

6th Edition

Krar Gill Smid

Helical Milling
Unit 71

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 71-2

Objectives
Calculate the lead and helix angle of a
helical gear
Set up a milling machine to machine a
helix
Make the calculations and setup for
milling a helical gear
 71-3

Helical Milling
Process of milling helical grooves
Flutes in drill, teeth in helical gears, or worm
thread of shaft
Performed on universal milling machine by
gearing dividing head through worm shaft to
lead screw of milling machine
 71-4

Helix
Theoretical line or path generated on a
cylindrical surface by a cutting tool fed
lengthwise at a uniform rate, while cylinder
also rotated at same uniform rate
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 71-5

Spiral
Path generated by point
moving at fixed rate of
advance along surface of a
rotating cone or plane
Example conical spiral
Threads on wood screw
Example plane
Watch springs
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 71-6

Cutting an Inch (Metric) Helix

Must know two of the following:
Lead of helix
Longitudinal distance helix advances axially in one
complete revolution of work
Angle of helix
Formed by intersection of helix with axis of work
Diameter (and circumference) of workpiece
 71-7

Lead of a Helix
Varies with:
Diameter of work
Angle of helix
If surface of cylinder unwound to
produce flat surface, helix would
form hypotenuse of right-angle
triangle, with circumference
forming side
opposite and lead
side adjacent
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 71-8

Steps to Cut a
Helix on a Cylinder
1. Swing table in proper direction to angle of
helix
Ensures that groove of same contour as cutter
produced
2. Work must rotate one turn while table
travels lengthwise the distance equal to
lead
Achieved by installing proper change gears
between worm shaft on dividing head and
milling machine lead screw
 71-9

Determining the Helix Angle

To ensure groove of same
contour as cutter is produced,
the table must be swung to angle
of helix
Tangent of helix
circumfere nce of work

lead of helix
3.1416 x diameter(D )

lead of helix
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 71-10

Example: Inch Measure

To what angle must the milling machine table be
swiveled to cut a helix having a lead of 10.882 in.
on piece of work 2 in. in diameter?

3.1416 x D 3.1416 x 2
Tangent of helix angle
lead of helix 10.882
6.2832
.57739
10.882
Helix angle 30
 71-11

Example: Metric Measure

To what angle must the milling machine table be
swiveled to cut a helix having a lead of 250 mm on
piece of work 40 mm in diameter?
3.1416 x D 3.1416 x 40
Tangent of helix angle
lead of helix 450
0.2792
Helix angle 1536
 71-12

Determining Direction
to Swing Table
After helix angle calculated necessary to
determine direction to swivel table
Hold cylinder on which helix is cut in
horizontal plane with axis running in right-
left direction
Right-hand helix: helix slopes down and to right
Counterclockwise direction
Left-hand helix: helix slopes down and to left
Clockwise direction
 71-13

Calculating Change Gears to

Produce the Required Lead
To cut helix, work must
rotate and move
lengthwise at same
time
Lead: amount work
travels lengthwise
with one revolution
Rotation caused by
gearing worm shaft of
dividing head to lead
screw of machine

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 71-14

Inch Calculations
Dividing head ration is 40:1 and standard milling
machine lead screw has 4 threads per inch (tpi)
Lead screw revolves one turn, dividing head spindle
1/40th revolution
For dividing head spindle to revolve one turn, lead
screw must revolve 40 times
Table would travel 40 x , or 10 in. while work
revolves one turn
Lead of milling machine is 10 in. when lead screw
(4 tpi) connected to dividing head (40:1) with
equal gears
 71-15

Calculation of Change Gears

Lead of helix product of driven gears

Lead of machine (10) product of driver gears

Ratio of gears required to produce lead on

milling machine having lead screw with
4 tpi always equal to fraction having lead of
helix for numerator and 10 for denominator
 71-16

Example: Inch
Calculate change gears required to produce helix having
lead of 25 in. on piece of work. The available change gears
have the following number of teeth:
24, 24, 28, 32, 36, 40, 44, 48, 56, 64, 72, 86, 100
Solution: lead of helix (driven gears) 25
Gear ratio
lead of machine (driver gears) 10
Since 10- and 25-tooth gears not supplied with standard
dividing heads, necessary to multiply 25:10 ration by any
number that will suit change gears available.
25 4 100 (driven gear)
Gear ratio x
10 4 40 (driver gear)
 71-17

Example: Inch
Calculate change gears required to produce helix having
lead of 25 in. on piece of work. The available change gears
have the following number of teeth:
24, 24, 28, 32, 36, 40, 44, 48, 56, 64, 72, 86, 100
Solution: lead of helix (driven gears) 25
Gear ratio
lead of machine (driver gears) 10
Since 10- and 25-tooth gears not supplied with standard
dividing heads, necessary to multiply 25:10 ration by any
number that will suit change gears available.
25 4 100 (driven gear)
Gear ratio x
10 4 40 (driver gear)
 71-18

Metric Calculations
Pitch of lead screw stated in millimeters
Lead screws have 5-mm pitch
Dividing head has ratio of 40:1
Therefore, lead of machine would be 40
times pitch of lead screw
lead of helix (mm) product of driven gears

lead of machine (mm) product of diver gears
 71-19

Example: Inch
Calculate the change gears required to cut a helix having a
lead of 500 mm on a workpiece using a standard set of
gears. The milling machine lead screw has a pitch of 5 mm.
The normal change gears in set are: 24, 24, 28, 32, 36, 40,
44, 48, 56, 64, 72, 86, 100
Driven gears lead of helix 500

driver gears pitch of lead screw x 40 5 x 40
Driven gears 5 20 100
x
driver gears 2 20 40
 71-20

Direction of Spindle Rotation

To cut left-hand helix, the gear on lead
screw and worm gear revolve in same
direction
To cut right-hand helix, spindle must revolve
in opposite direction
Another idler must be inserted but acts merely
as means of change direction or rotation of
dividing head spindle
Direction of spindle rotation for simple
gearing opposite to that for compound
gearing
 71-21

Cutting Short Lead Helices

Disengage dividing head worm and
wormwheel
Connect change gears directly from table
lead screw to dividing head spindle
Permits machining leads to one-fortieth of
leads shown in handbook tables
 71-22

Example:
A plain helical milling cutter to the following
specifications is required
Diameter: 4 in.
Number of teeth: 9
Helix: right-hand
Helix angle: 25
Rake angle: 10 positive radial rake
Angle of flute: 55
Depth of flute: in.
Length: 4 in.
Material: tool steel
 71-23

Procedure For Cutting Short

Lead Helices
Turn blank to sizes indicated
Apply layout die to end
of blank and lay out
Lay out a line on
periphery to indicate
direction of the
right-hand helix
Dimensions of helical milling center
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 71-24

4. Press cutter blank firmly on mandrel

If threaded mandrel used, tighten nut securely
5. Mount dividing head and footstock
6. Calculate indexing for nine divisions
40 4
Indexing 4
9 9
4 turns 8 holes on an 18 hole circle
7. Set sector arms to 8 holes on 18-hole
circle (do not count hole where pin engaged)
 71-25

8. Disengage index plate locking device

9. Calculate lead of helix
3.1416 x D
Lead 3.1416 x D cot helix angle
tan helix angle
1
since cot
tan
3.1416 x 4 x 2.1445
26.949 in.
 71-26

10. Consult any handbook for change gears to

cut lead closest to 26.949 in. (27)
11. If handbook not available, change gears
can be calculated for closest lead 27 in.
12. Change gears for 27 in lead calculated:
Required lead 27 9 3
x
Lead of machine 10 5 2
9 x 8 72 3 x 16 48

5 x 8 40 2 x 16 32
72 x 48 (driven gears)
Change gears
40 x 32 (diver gears)
 71-27

13. Mount change gears, allowing slight

clearance between mating teeth
14. Mount work between centers, with large
end of mandrel against dividing head
15. Swivel table 25 counterclockwise
16. Adjust crossfeed handwheel until table
about 1 in. from face of column
17. Swing table back to zero
18. Mount 55 double-angle cutter so it
revolves toward dividing head and center it
over flute layout
 71-28

19. Rotate blank until flute layout is aligned

with cutter edge

20. Rotate blank until

flute layout is aligned
with cutter edge

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 71-29

21. With work clear of cutter, set depth to .500

in.
22. Rotate table 25 (counterclockwise), and
lock securely (right end in toward column)
23. Carefully cut first tooth space, checking
accuracy of location and depth
24. Index for and cut remaining flutes
25. Remove fluting cutter and mount plain
helical milling cutter
 71-30

26. Rotate work (using index crank) until line at 30

to side of flute parallel to table
May be checked by means of surface gage
Blank may be rotated by indexing an amount equal to
55
90 30 90 57.5 32.5(3230)
2
Indexing for 3230 : 32 x 60 1920
3 0 30
3230 1950
1950 3330 11
3
540 540 18
3 turns 11 holes on the 18 hole circle
 71-31

27. Adjust workpiece under cutter

28. With cutter rotating, raise table until
width of land on workpiece is about
.030 in. wide
29. Cut secondary clearance (30 angle) on
all teeth of workpiece