machining and machine tool (indexing milling machine)

1

The Indexing or Dividing Head

2

Indexing (Dividing) Head

• Once one of the more important

attachments for milling machine

• Used to divide circumference of

workpiece into equally spaced divisions

when milling gear teeth, squares,

hexagons, and octagons

• Also used to rotate workpiece at

predetermined ratio to table feed rate

3

Index Head Parts

• Headstock with index plates

• Headstock change gears

• Quadrant

• Universal chuck

• Footstock

• Center rest

4

Index Head Parts • Swiveling block

• Mounted in base enables headstock to be tilted from 5º below horizontal to 10º beyond vertical

• Spindle • Mounted in swiveling block with 40-tooth

worm wheel, meshes with worm

• Worm • Right angle to spindle, connected to index

crank

• Direct indexing plate • Engaged by pin and attached to front of

spindle

5

Index Head Parts

6

Section view

of a dividing

head

7

Index Head Parts • Universal chuck

• Threaded onto end of spindle

8

Index Head Parts • Footstock

• Used in conjunction with headstock to support work held between centers or in chuck

• May be adjusted longitudinally, raised or lowered off center, and tilted out of parallel

9

Index Head Parts Adjustable center rest

• Holds long, slender work between centers

10

Methods of Indexing

1. Direct

2. Simple

3. Angular

4. Differential

11

Direct Indexing

• Simplest form of indexing

• Performed by disengaging worm shaft from worm wheel by means of eccentric device in dividing head

• Spring-loaded tongue lock engages numbered slots in index plate

• Used for quick indexing of workpiece when cutting flutes, hexagons, squares, etc.

12

Direct Indexing Divisions

• Direct indexing plate usually contains

three sets of hole circles or slots: 24,

30, and 36

• Number of divisions possible to index

limited to numbers that are factors of 24,

30, 36 Slots Direct indexing divisions

24 2 3 4 _ 6 8 _ __ 12 __ __ 24 __ __

30 2 3 _ 5 6 _ _ 10 __ 15 __ __ 30 __

36 2 3 4 _ 6 _ 9 __ 12 __ 18 __ __ 36

13

Example: Direct Indexing

• What direct indexing is necessary to mill eight

flutes on a reamer blank?

Slots Direct indexing divisions

24 2 3 4 _ 6 8 _ __ 12 __ __ 24 __ __

30 2 3 _ 5 6 _ _ 10 __ 15 __ __ 30 __

36 2 3 4 _ 6 _ 9 __ 12 __ 18 __ __ 36

Since the 24-hole circle is the only one divisible

by 8 (the required number of divisions), it is the

only circle that can be used in this case.

Never count the hole or slot in which

the index pin is engaged.

14

Milling a Square with Direct Indexing

1. Disengage worm and worm shaft by turning worm disengaging shaft lever if dividing head is so equipped

2. Adjust plunger behind index plate into the 24-hole circle or slot

3. Mount workpiece in dividing head chuck or between centers

4. Adjust cutter height and cut first side

15

5. Remove plunger pin using plunger pin

lever

6. Turn plate attached to dividing head

spindle one-half turn and engage

plunger pin

7. Take second cut


16

8. Measure work across flats and adjust

work height if required

9. Cut remaining sides by indexing every

six holes until all surfaces cut

10.Check for finish size


17

Simple Indexing

• Work positioned by means of crank, index plate, and sector arms

• Worm attached to crank must be engaged with worm wheel on dividing head spindle

• 40 teeth on worm wheel

• One complete turn on index crank cause spindle and work to rotate one-fortieth of a turn (ratio of 40:1)

18

Simple Indexing

• Calculating the indexing or number of turns of crank for most divisions, simply divide 40 by number of divisions to be cut or,

40Indexing =

N

19

Simple Indexing

• The indexing required to cut eight flutes:

crankindex of turns full 58

40

• The indexing required to cut seven flutes:

crankindex of turns 7

55

7

40

The five-sevenths turn involves use of

an index plate and sector arms.

20

Index Plate and Sector Arms

• Index plate

• Circular plate provided with series of equally spaced holes into which index crank pin engages

• Sector arms

• Fit on front of plate and may be set to any portion of a complete turn

21

Finishing Indexing for Seven Flutes

Index-plate hole circles

Brown & Sharpe

Plate 1 15-16-17-18-19-20

Plate 2 21-23-27-29-31-33

Plate 3 37-39-41-43-47-49

Cincinnati Standard Plate

One side 24-25-28-30-34-37-38-39-41-42-43

Other side 46-47-49-51-53-54-57-58-59-62-66

Choose any hole

circle that is divisible

by denominator 7

5/7 = /21

So, 5 full turns plus

15 holes on 21 hole

circle!

15

22



Brown & Sharpe

Plate 1 15-16-17-18-19-20

Plate 2 21-23-27-29-31-33

Plate 3 37-39-41-43-47-49


One side 24-25-28-30-34-37-38-39-41-42-43

Other side 46-47-49-51-53-54-57-58-59-62-66

Choose any hole


by denominator 7

5/7 = /49


35 holes on 49 hole

circle!

35

23



Brown & Sharpe

Plate 1 15-16-17-18-19-20

Plate 2 21-23-27-29-31-33

Plate 3 37-39-41-43-47-49


One side 24-25-28-30-34-37-38-39-41-42-43

Other side 46-47-49-51-53-54-57-58-59-62-66

Choose any hole


by denominator 7

5/7 = /28


20 holes on 28 hole

circle!

20

24



Brown & Sharpe

Plate 1 15-16-17-18-19-20

Plate 2 21-23-27-29-31-33

Plate 3 37-39-41-43-47-49


One side 24-25-28-30-34-37-38-39-41-42-43

Other side 46-47-49-51-53-54-57-58-59-62-66

Choose any hole


by denominator 7

5/7 = /42


30 holes on 42 hole

circle!

30

25



Brown & Sharpe

Plate 1 15-16-17-18-19-20

Plate 2 21-23-27-29-31-33

Plate 3 37-39-41-43-47-49


One side 24-25-28-30-34-37-38-39-41-42-43

Other side 46-47-49-51-53-54-57-58-59-62-66

Choose any hole


by denominator 7

5/7 = /49


35 holes on 49 hole

circle!

35

26

Cutting Seven Flutes

1. Mount B&S Plate 2 index plate on dividing head

2. Loosen index crank nut and set index pin into hole on 21-hole circle

3. Tighten index crank nut and check to see that the pin enters hole easily

4. Loosen setscrew on sector arm

5. Place narrow edge of left arm against index pin

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6. Count 15 holes on 21-hole circle

• Do not include hole in which index crank

pin is engaged.

7. Move right sector arm slightly beyond

fifteenth hole and tighten sector arm

setscrew

8. Align cutter with work piece

9. Start machine and set cutter to top of

work by using paper feeler


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10.Move table so cutter clears end of work

11.Tighten friction lock on dividing head

before making each cut and loosen

lock when indexing for spaces

12.Set depth of cut and take first cut

13.After first flute has been cut, return

table to original starting position


29

14.Withdraw index pin and turn crank clockwise five full turns plus the 15 holes indicated right sector arm

• Release index pin between 14th and 15th holes and gently tap until it drops into 15th hole

15.Turn sector arm farthest from pin clockwise until it is against index pin


30

16.Lock dividing head; continue machining and indexing for remaining flutes


The arm farthest from the pin is held and

turned. If the arm next to the pin were held

and turned, the spacing between both

sector arms could be increased when the

other arm hits the pin. This could result in

an indexing error not noticeable until the

work was completed.

31

Angular Indexing

• Setup for simple indexing may be

used

• Must calculate indexing with angular

distance between divisions instead

number of divisions

• One complete turn of index crank

turns work 1/40 of a turn

• 1/40 of 360º equals 9 degrees

9

required degrees of no. degrees in Indexing

32

Angular Indexing

Calculate indexing for 45º

59

45 Indexing

5 complete turns

33

Angular Indexing

Calculate indexing for 60º

3

26

9

60 Indexing

6 full turns plus 12 holes on 18 hole

circle

34

Angular Indexing

Calculate indexing for 24'

Divide 24'/540' = 4/90

4/90 = 1/22.5

1 hole on a 22.5 hole circle

The nearest is a 23 hole circle. Indexing

would be 1 hole on a 23 hole circle with a

slight error (approximately 1/2 minute). A

need for higher accuracy requires

differential indexing.

35

Angular Indexing

Calculate indexing for 24º30'

• First, convert angle into minutes

(24 x 60') = 1440' now add 30' = 1470‘

Convert 9° to minutes 9°x90’ = 540’

Divide 1470'/540' = 2 13/18

2 full turns and 13 holes on 18

hole circle

36

Differential Indexing

• Used when 40/N cannot be reduced to a

factor of one of the available hole circles

• Index plate must be revolved either

forward or backward part of a turn while

index crank turned to attain proper

spacing (indexing)

• Change of rotation effected by idler gear or

gears in gear train

37

Differential Method • Number chosen close to required

divisions that can be indexed by simple

indexing

• Example: Assume index crank has to be

rotated 1/9th of a turn and only 8-hole

circle

• Crank moved 1/9th, index pin contacts plate

at spot before first hole

• Exact position would be the difference

between 1/8th and 1/9th of a revolution of

the crank

38

Differential Method cont.

72

1

72

8

72

9

9

1

8

1

one-seventy-second of a turn short of

first hole

Since there is no hole at this point, it is

necessary to cause plate to rotate backward

by means of change gears one-seventy-

second of a turn of pin will engage in hole.

39

Method of Calculating the Change Gears

gear (worm) driven

gear (spindle) driver

A

40 x N) -(A ratio gear Change

A = approximate number of divisions

N = required number of divisions

If A is greater than N, resulting fraction is positive and

the index plate must move in same direction as crank

(clockwise). This positive rotation uses an idler gear.

If N is greater than A, resulting fraction is negative and

index plate must move counterclockwise. This negative

rotation required use of two idler gears.

40

Gearing

• Simple

• One idler for positive rotation of index

plate and two idlers for negative

rotation

• Compound

• One idler for negative rotation of index

plate and two idlers for positive rotation

41

Example:

Calculate the indexing and change gears required

for 57 divisions. The change gears supplied with

the dividing head are as follows:

24, 24, 28, 32, 40, 44, 48, 56, 64, 72, 86

The available index plate hole circles are as follows:

Plate 1: 15, 16, 17, 18, 19, 20

Plate 2: 21, 23, 27, 29, 31, 33

Plate 3: 37, 39, 41, 43, 47, 49

57

40

N

40 Indexing

No 57 hole circle so select

number close to 57

7

5

56

40

5/7 would be 15 holes

on 21-hole circle

Choose plate 2: 21 holes

42

Example: continued

The fraction is negative and simple gearing is to be

used, the index plate rotation is counterclockwise

and two idlers must be used.

gear) (worm 56

gear) (spindle 40

8

8x

7

5- gears Change

7

5

56

40 x

56

40x 57) - (56

A

40x N) -(A ratio Gear

1

43

• For indexing 57 divisions, a 40-tooth

gear is mounted on the dividing head

spindle and a 56-tooth gear is mounted

on the worm shaft.

• Index idlers must be used. plate rotation

is negative and two

• After proper gears installed, the simple

indexing for 56 divisions should be

followed

Example: continued

44

Wide-Range Dividing Head

• Possible for 2 to 400,000 divisions

• Large index plate contains 11 hole circles on each side

• Small index plate mounted in front of large, contains a 54 hole and a 100-hole circle

• 40:1 ratio between worm and dividing head spindle

45

A –

large

index

plate

B - crank

C –

small

index

plate

D - crank G – gear housing

46

Indexing for Divisions

• One turn of small crank drives index

head spindle 1/100 of 1/40, or 1/4000 of

a turn

• Ratio of large index crank to dividing head

40:1

• Ratio of small index crank 100:1

47


• One hole on 100-hole circle of small

index plate C = 1/100 x 1/4000

• 1/400,000 of a turn

• Formula for indexing divisions =

400,000/N

48


No. of turns

of large

index crank

No. of holes on

100-hole circle

of large plate

No. of holes on

100-hole circle

of small plate

4 0 0 0 0 0 4 0 4 0 0 0

N Number of

Divisions

x x

49


For 1250 divisions

400000/1250

40|00|00

1250

Since ratio of large index crank is 40:1 ,

any number that divides into 40 (first two

numbers) represents full turns of large

index crank

No. of turns

of large Index

Crank = 0

One hole on 100-hole

circle produces 1/4000

of a turn; any number

divides into 4000 are

indexed on large plate

20

No. turns

100-hole=

Large plate

3 20 holes on the

100-hole circle

small plate

4 0 0 0 0 0 4 0 4 0 0 0

N

3 0

Zero turns of large crank, 3 turns of 100-hole

large plate and 20 holes on 100-hole small plate

50

Angular Indexing with the Wide-Range Divider

• Indexing in degrees, minutes, and

seconds easily accomplished

• Both large and small index cranks set

on 54-hole circle of each plate

• Each space on 54-hole large plate will

cause dividing head spindle to rotate 10'

• Each space on 54-hole small plate will

cause work to rotate 6"

51

Angular Indexing: cont.

plate) small on (indexed 6

N Seconds

plate) large on (indexed 10

N Minutes

plate) large on (indexed9

N Degrees

Example: Index for an angle of 17º36'18"

turns 9

81

9

17

One full turn + 48 holes on large plate

6' of r with3 10

36

3 holes on large plate

636

378

6

18x60)(6'

One full turn + 9 holes on small plate

One full turn + 51 holes on large plate

52

Linear Graduating

• Operation of producing accurate

spaces on piece of flat or round stock

• Align workpiece parallel with table

travel

• Dividing head spindle geared to lead

screw of milling machine for accurate

longitudinal movement of table

• 1 revolution of index crank = 1/40th

revolution of spindle and lead screw

53

Linear Graduating: cont.

• Rotation of lead screw (4 threads per

inch) would cause table to move 1/40th x

1/4th or 1/160th = .0025 in.

• Formula for calculating indexing for

linear graduations in thousandths of an

inch

.00625

N Example: Movement of table .001 in

turns

4

16

1

.00625

.001

4 holes on 25-hole circle

54

• If lead screw of metric milling machine has pitch of 5mm, 1 turn of index crank would move table 1/40th of 5 mm or 0.125 mm

• Point of toolbit used for graduating generally ground to V-shape


55

• Uniformity of line length controlled by accurate movement of crossfeed handwheel

• Uniformity of line width maintained if work held absolutely flat and table height never adjusted


machining and machine tool (indexing milling machine)

Engineering

indexing dividing head

methods of indexing

index head parts headstock

index pin

index head parts footstock

simple indexing work

dividing head chuck

quick indexing of workpiece