GIVEN TASKS 8th Dec, 2017 & 17th/24th Jan, 2018

TOPIC: Design Modification and Fabrication of Tailstock for Horizontal Milling Machine.

TASKS ONE:
1. State briefly, what a milling machine is and its principle of operation of operation (not more
than 2 pages)
2. Differentiate between Horizontal-axis milling machine and Vertical-axis milling machine.
3. State the main parts of a Horizontal-axis milling machine and the functions of each
component part. (N/B: Tailstock is one of the main parts)
4. State all the parts of the tailstock and describe how they work.

INTRODUCTION
Milling machine plays a vital role in the manufacturing industries and its importance
cannot be overemphasized. It is capable of doing any milling operation whether it is gear
milling; thread milling, angular milling etc. It is one of the most commonly used processes in
industry and machine shops today for machining parts to precise sizes and shapes.
Milling is the cutting operation that removes metal by feeding the work against a
rotating, cutter having single or multiple cutting edges. Flat or curved surfaces of many shapes
can be machined by milling with good finish and accuracy. A milling machine may also be used
for drilling, slotting, making a circular profile and gear cutting by having suitable attachments.
(EngineeringMyIndia, 2009).

1. DEFINITION:
A milling machine is a machine used to remove metals from a workpiece with the help
of a rotary cutter called milling cutter. It is a machine used to cut the flat, rough and irregular
surfaces of a work piece and this is done or achieved by feeding the workpiece against a rotating
milling cutter. (Mechanical Booster, 2017)
Milling machines are tools designed to machine metal, wood, and other solid
materials. Often automated, milling machines can be positioned in either vertical or
horizontal orientation to carve out materials based on a pre-existing design. These designs
are often Computer Aided Design (CAD) directed, and many milling machines are Computer
Numerical Control (CNC)-operated, although manually and traditionally-automated milling
devices are also common. Milling machines are capable of dynamic movement, both of the
tool and the workpiece, and many milling machines can perform multi-axis machining.
[

PRINCIPLE OF OPERATION:

Milling is the process of machining flat, curved, or irregular surfaces by feeding the
workpiece against a rotating cutter containing a number of cutting edges. The milling
machine consists basically of a motor driven spindle, which mounts and revolves the milling
cutter, and a reciprocating adjustable worktable, which mounts and feeds the workpiece.

The work piece is held on the worktable of the machine. The table movement controls the
feed of workpiece against the rotating cutter (as shown in Fig.1 below). The cutting action of
the many teeth around the milling cutter provides a fast method of machining. The machined
surface may be flat, angular, or curved. The surface may also be milled to any combination of
shapes.
 The workpiece is held on the worktable of the machine. The table movement controls the
feed of workpiece against the rotating cutter. The cutter is mounted on a spindle or arbor and
revolves at high speed. Except for rotation the cutter has no other motion. As the workpiece
advances, the cutter teeth remove the metal from the surface of workpiece and the desired
shape is produced.

Fig. 1: A Horizontal Milling Machine (Source: EngineeringMyIndia, 2018)

The direction of the cutting motion (as shown in Fig. 1a and 1b above) has a direct effect on the
workpiece being machined for convenience, depending on the nature, size, shape of the workpiece
being milled.

A milling machine is a machine tool used for the shaping of metal and other solid materials.
Its basic form is that of a rotating cutter which rotates about the spindle axis, and a table to which
the workpiece is affixed. Milling operation involves movement of the rotating cutter sideways as well
as 'in and out'. The cutter and workpiece move relative to each other, generating a tool path along
which material is removed.

Milling machine may be operated manually or by CNC (computer numerical control). A milling
machine may also be used for drilling, slotting, making a circular profile and gear cutting by having
suitable attachments. (Mechanical Booster, 2017)
2. DIFFERENCE BETWEEN HORIZONTAL-AXIS AND VERTICAL-AXIS MILLING MACHINE

Basically, the milling machines are divided into two types, first is horizontal milling
machine and second is vertical milling machine. They are further classified as knee-type, ram-
type, manufacturing or bed type and planer-type milling machine, etc.

Most of the milling machine classified above has self-electric driven motor, coolant systems,
power operated table feed and variable spindle speeds.

 Horizontal Milling Machine: In horizontal milling machine, as the name implies, the axis of
rotation of the spindle (i.e. the tooling system) is horizontal to the table. And for this reason, it
is called a horizontal milling machine. The rotary cutter is fixed into the spindle in the
horizontal axis. The main part of machine horizontal milling machine is base, Column, Knee,
Saddle, Table, Overarm, Arbor Support and Elevating Screw.

Fig. 2: A Horizontal Milling Machine (Source: Mechanical Booster, 2017)

 Vertical Milling Machine: In vertical milling machine, as the name implies, the spindle axis
is perpendicular to the table and for this reason it is called vertical milling machine. The
rotary cutter is fixed into the spindle in the vertical axis.

Fig. 2: A Vertical Milling Machine (Source: Mechanical Booster, 2017)

Fig. 3: A Vertical Milling Machine (Source: Mechanical Booster, 2017)

3. MAIN PARTS OF A MILLING MACHINE:

The parts of the horizontal milling machine are:

a. Column & Base: The Column including base is the main casting of the horizontal
milling machine that supports all other parts of the milling machine. The column
contains an oil reservoir and a pump which lubricates the spindle. The column rests on
the base and base contains coolant reservoir and a pump which is used during
machining operation that requires coolant.

b. Knee: It is a casting that supports the saddle and table. All gearing mechanism is
enclosed within the knee. It is fastened to the column by dovetail ways. The knee is
supported and adjusted by a vertical positioning screw (elevating screw). The elevating
screw is used to adjust the knee up and down by raising or lowering the lever either
with the help of hand or power feed.
c. Saddle and Swivel Table: Saddle is present on the knee and supports the table. It
slides on a horizontal dovetail on the knee and dovetail is parallel to the axis of the
spindle (in horizontal milling machine).

d. Power Feed Mechanism: It is the knee which contains the power feed mechanism. It is
used to control the longitudinal (left and right), transverse (in and out) and vertical (up
and down) feeds to get the desired rate of feed on the machine, the feed selection lever is
positioned as indicated on the feed selection plates.

e. Table: This is a rectangular casting which is present on the top of the saddle. It is used
to hold the work or work holding devices. It contains several T-slots for holding the work
and work holding devices (i.e. jigs and fixtures). The table can be operated by hand or by
power. To move the table by hand, engage and turn the longitudinal hand crank. To
move it through power, engage the longitudinal direction feed control lever.

f. Spindle: This is a shaft used to hold and drive the cutting tools of the milling machine.
The spindle is mounted on the bearings and supported by the column. The spindle is
driven by the electric motor through gear trains. The gear trains are present within the
column. The face of the spindle lies near the table and has an internal taper machined
on it. The internal taper at the front face of the spindle permits only tapered cutter
holder or arbor. It has two keys at the front face which provides positive drive for the
cutter holder or arbor. The drawbolt and jamnut is used to secure the holder and arbor
in the spindle.

g. Over Arm / Overhanging Arm: This is a horizontal beam at the top face of the column.
The overarm is used to fastened arbor (cutter holder) support. It may consist of one or
two cylindrical bars which slide through the holes in the column.

h. Arbor Support: An arbor is considered as an extension of the machine spindle on which

cutters are securely mounted and rotated. It supports the outer end of the arbor. It also
helps in aligning the outer end of the arbor with the spindle. It prevents the springing of
outer end of the arbor during cutting operations.

i. Tailstock: A tailstock is a device used on different types of milling machines. It has a

Dead Center while the Headstock has a Live Center. A Dead Center is just that - dead. It
has no moving parts. It is really nothing more than a metal shaft with a point.
(source: parts-recycling.com) while a Live Center is similar, but the shaft has a bearing
that allows it to turn. (source: Z Live Center). A tailstock is particularly useful when the
workpiece is relatively long and slender. Failing to use a tailstock can cause "chatter,"
where the workpiece bends excessively while being cut. It is also used on a lathe to hold
drilling or reaming tools for machining a hole in the work piece.
4. PARTS OF A TAILSTOCK AND THEIR FUNCTIONS

Fig. 4: A Tailstock and its Parts (Source: Mechanical Booster, 2017)

Fig. 5: A Tailstock and its Parts – more detailed (Source: Mechanical Booster, 2017)

1. The Body: The body is the part of the tailstock that holds every other part together. It
houses the barrel, the spindle and all other parts that are mounted on it.

2. Barrel: The barrel is fitted into the bore of the tail-stock body and is prevented from
rotation by the feather key. The barrel has a threaded portion at its end.
 3. Spindle with washer & nut: The spindle is inserted into the barrel through the threaded
portion at its end.

4. Centre: The Dead Centre is incorporated on a tapered hole at the front end of the barrel.

5. Spindle Bearing: The spindle bearing is placed between the hand wheel and the tail-stock body

6. Hand Wheel: The hand wheel is mounted on the spindle by a key and is retained in
position by a nut. When the hand wheel is operated, the barrel is made to move in or out of
the tail-stock body.

7. Clamping Lever: In the required position of the barrel, clamping may be made by means of
the clamping lever, to restrict further advancing of the barrel, which in turn moves the
Dead Centre of the Tailstock.

8. Stud: This is fitted to the tail-stock body.

9. Feather Key: The feather key is a fastener that holds the barrel in place, it is located
underneath the barrel.

10. Screw: The screw is a fastener that helps to fix the spindle bearing to the body.

11. Tailstock Clamping Bolt: This is a bolt used for clamping the tailstock to the milling
machine bed or table. (found in the Fig 4. above)

TOPIC: Design Modification and Fabrication of Tailstock for Horizontal Milling Machine.

TASKS TWO:
1. Determine the critical design components and parameters.
2. List out components and parameters needed for the design.
3. State the design modifications and parameters in view.
4. Stress calculations, Material Selection, Sizes and product drawing, etc.

1. CRITICAL DESIGN COMPONENTS AND PARAMETERS

A good knowledge of material to be used for the critical design of tailstock components
can help prevent failure and enhance performance of the equipment for serviceability.
 Barrel
 Body
 Bed

2. LIST OF COMPONENTS AND PARAMETERS NEEDED FOR THE DESIGN.

 Tailstock Clamping Bolt (Can be obtained in retail stores);
 Spindle;
 Dead Centre;
 Barrel;
 Clamp (Can be obtained in retail stores);
 Screw;
 Handwheel;
 Bush;
 Setover Screw;
 Bed; and
 Bush.
 3. DESIGN MODIFICATIONS AND PARAMETERS IN VIEW.
There is no system, generally, without shortcomings; hence, the efficiency of a tailstock falls, as the tips
are made wider over a period of time. However, the selection of imperative materials and proper design
modification and fabrication techniques will overcome the defect mentioned above and operate at high
efficiency and durability.
The tailstock of the horizontal milling machine in the Science and Engineering Workshop (S.E.W.) is worn-
out, damaged and requires replacement (as shown in Fig. 6 below) and this is main purpose of this design
modification and fabrication.
The following design modifications and parameters will be richly considered.
 The reference design has no Clamp
 The reference design has no Screw
 The reference design has no Hand Wheel
 The reference design has no Tailstock Clamping Bolt
 The reference design has no Setover Screw
 The reference design has no Spindle

Fig. 6: A horizontal milling machine with damaged tailstock at the SE (Source: Theophilus M. & Kanuhor T., 2017)

Our design will feature all the parts and parameters of a standard tailstock for a horizontal milling
machine with all the components which are not found our reference design.
Here are the Discussions and Requirements for further corrections from yesterday's meeting...

1. DESIGN
For a Horizontal Milling Machine Design, use any similar horizontal milling machine design found
on the internet, get all design specifications, when the School of Engineering Workshop is open, we
can apply those design specifications with little modifications to suit the design parameters for the
one in the workshop.

2. DEFINITION
For the definition of a Milling Machine, highlight the unique characteristics that cannot be found in other
machines. E.g. THE WAY IT CUTS and THE PURPOSE OF MACHINING. Use a unique definition for
the milling machine that uniquely describe and differentiate it from other machines.

3. PRINCIPLE OF OPERATION
Give an in-depth description and explanation of how a Horizontal Milling Machine Works.
Take note of the following:

- The basic process(es) that brings about milling.

- The movement of workpiece and the milling cutter.
- The relative motions that exists between the workpiece and the cutter, types of motion, their effect
and direction of the cutting motion.
- Use sketches to show your illustrations for clarity and better understanding.

NOTE:
- The Spindle Axis: This is the axis about which the rotary cutter is fixed.
- Make reference to the Figures in your explanation when showing details of how the milling
machine works.

1. Base: It gives support and rigidity to the machine and also acts as a reservoir for the cutting fluids.
2. Column: The column is the main supporting frame mounted vertically on the base. The column is box shaped,
heavily ribbed inside and houses all the driving mechanisms for the spindle and table feed.
3. Knee: The knee is a rigid casting mounted on the front face of the column. The knee moves vertically along the
guide ways and this movement enables to adjust the distance between the cutter and the job mounted on the
table. The adjustment is obtained manually or automatically by operating the elevating screw provided below the
knee.
4. Saddle: The saddle rests on the knee and constitutes the intermediate part between the knee and the table. The
saddle moves transversely, i.e., crosswise (in or out) on guide ways provided on the knee.
5. Table: The table rests on guide ways in the saddle and provides support to the work. The table is made of cast
iron, its top surface is accurately machined and carriers T-slots which accommodate the clamping bolt for fixing the
work. The worktable and hence the job fitted on it is given motions in three directions:
a). Vertical (up and down) movement provided by raising or lowering the knee.
b). Cross (in or out) or transverse motion provided by moving the saddle in relation to knee.
c). Longitudinal (back and forth) motion provided by hand wheel fitted on the side of feed screw.
In addition to the above motions, the table of a universal milling machine can be swiveled 45° to either side of the
centre line and thus fed at an angle to the spindle.
6. Overarm: The Overarm is mounted at the top of the column and is guided in perfect alignment by the machined
surfaces. The Overarm is the support for the arbor.
7. Arbor support: The arbor support is fitted to the Overarm and can be clamped at any location on the Overarm.
Its function is to align and support various arbors. The arbor is a machined shaft that holds and drives the cutters.
8. Elevating screw: The upward and downward movement to the knee and the table is given by the elevating screw
that is operated by hand or an automatic feed.