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Milling Machine 9
Milling Machine 9
By feeding the workpiece into the rotating cutter, material is cut away from this workpiece in the form of small chips to create the desired shape.
Parts that are fabricated completely through milling often include components that are used in limited quantities, perhaps for prototypes, such as custom designed fasteners or brackets.
Fundamentals of Chip-Type Machining Processes Another application of milling is the fabrication of tooling for other processes. For example, three-dimensional molds are typically milled.
Milling is also commonly used as a secondary process to add or refine features on parts that were manufactured using a different process.
Due to the high tolerances and surface finishes that milling can offer, it is ideal for adding precision features to a part whose basic shape has already been formed.
Cylindrical milling, in which the tool shaft is parallel to the work surface of the workpiece. The chip removal is done with the edges of the side edge of the tool. The chips produced in cylindrical milling are comma shaped.
Frontal milling, in which tool shaft is perpendicular to the work surface. In this case, the tool will cut with the front teeth, obtaining chips of uniform thickness.
Fundamentals of Chip-Type Machining Processes Basic types of milling cutter and operations
Fundamentals of Chip-Type Machining Processes Climb Milling and conventional Milling In consequence that the force employed in the chip removal is not always the same. Some vibrations can be generated which damage the machine, tool and work piece surface.
Milling machines
Milling machines
Milling machines
Milling machine classification: It is based on design, operation, or purpose. Knee and column: type machines have the table and saddle supported on the vertically adjustable knee gibbed to the face of the column. The table is fed longitudinally on the saddle, and the latter transversely on the knee to give three feeding motions
Milling machines Knee-Type machines: are made with horizontal or vertical spindles. Horizontal universal machines, have a swiveling table for cutting helices. the plain machines are used for jobbing or production work, the universal for toolroom work. Vertical milling machines, with fixed or sliding heads are otherwise similar to the horizontal type. They are used for face or end milling and are frequently provided with a rotary table for making cylindrical surfaces. Fixed-bed machines, have a spindle mounted in a head dovetailed to and sliding on the face of the column. the table rests directly on the bed. They are simple and rigidly built and are used primarily for high-production work. These machines are usually provided with work holding fixtures and may be constructed as plain or multiple-spindle machines, simple or duplex.
Milling machines Planner-Type millers: are used only on the heaviest work. They are used to machine a number of surfaces on a particular part or group of parts arranged in series in fixtures on the table.
Milling machines
Milling- machine accessories Milling machine arbors, they are used to hold milling cutter in the milling machine. The cutters are driven by a key on the arbor and are held in place by collars which fit over the arbor.
The collar are clamped together by a nut on the end of the arbor. Two types of arbors Style A; it has a small diameter cylindrical surface at its end. This cylindrical surface fits in the arbor support bushing; and its small size permits the of the arbor support to be made smaller. This has an advantage when a small-diameter milling cutter is used which necessitates that the workpiece be brought up close to the arbor Style B; it has one or more collars of the comparatively large diameter which are used in the arbor support. The large arbor support bushing in which these collars are placed provide a better support for the arbor and allow higher cutting loads to be supported.
Milling- machine accessories Spindle nose tooling, it is required to hold milling cutters , drills, reamers, drill chuck, collect chuck and other special cutting tool.
Milling- machine accessories Milling machine vise, they are important accessory to the milling machine. These precision tools, which should be handled with care, are used to hold and to locate the workpiece in the correct position for a wide variety of milling operations.
Milling- machine accessories Vertical milling machine attachment, the attachment and standard or special auxiliary devices intended to be fastened to or joined with one or more components of the milling for the purpose of augmenting the range, versatility, productivity or accuracy of operation.
Therefore, 6 full turns of the crank plus 12 spaces on an 18-hole circle is the correct indexing for 6 divisions.
Therefore, 30 holes on a 39-hole circle is the correct indexing for 52 divisions. When counting holes, start with the first hole ahead of the index pin.
Where n= Spindle speed (in revolutions per minute). Vc = cutting speed of milling cutter D = diameter of milling cutter
Milling cutters Are made in a wide variety of shape and sizes, and can be classified in various ways, such as :
Purpose or use of the cutters, woodruff keyseat cutters, T-slot cutters, gear cutters, etc.
woodruff keyseat
T-slot cutters
Gear cutters
Milling cutters
Construction characteristics, solid cutters, carbide-tipped cutters
Milling cutters
Method of mounting (arbor type, shank type, etc)
Milling cutters
Relief of teeth Profile cutters which produce flat, curved, or irregular surfaces, with the cutter teeth sharpened on the land. Formed cutter which are sharpened on the face to retain true cross-sectional form of the cutter.
Milling cutters Selecting the Cutter A careful study of the drawing must be made to determine what cutter is best suited for the job. Flat surfaces may be milled with a plain milling cutter mounted on an arbor. Deeper cuts may generally be taken when using narrow cutters than with wide cutters. The choice of milling cutters should be based on the size and shape of the workpiece. If a wide area is to be milled, fewer traverses will be required using a wide cutter. If large quantities of metal are to be removed, a coarse tooth cutter should be used for roughing and a finer tooth cutter should be used for finishing. A relatively slow cutting speed and fast table feed should be used for roughing, and a relatively fast cutting speed and slow table feed used for finishing. The surface should be checked for accuracy after each completed cut.