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Milling and Grinding Machines
Milling and Grinding Machines
3. Milling Processes
4. Straddle Milling and Gang Milling; Milling Machine Specification 5. Principle of Working of Grinding Machines and Their Classification 6. Bonding Materials Used in Grinding Wheels; Types of Grinding Machines 7. Surface, Cylindrical and Center Less Grinding 8. Self Test
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List of Topics:
Types of Milling Machines Summary and Review Questions
Introduction
Milling is one of the most versatile machining processes or a metal cutting process for removing excess material from a work piece with a rotating multiple cutting tools. Each tooth removes a small amount of metal in each revolution; hence metal removal rate is high. Milling can be used to produce a very large variety of intricate shapes and size. A milling machine is a machine tool used to produce parts having flat as well as curved shapes of metal and other solid materials. Its basic form is that of a rotating cutter or end mill which rotates about the spindle axis (similar to a drill), and a movable table to which the work piece is affixed. That is to say the cutting tool generally remains stationary (except for its rotation) while the work piece moves to accomplish the cutting action. cont'd ...
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Milling operation
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3. Rotary Millers
4. Planetary Millers
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Review Questions
1. What is a milling machine? 2. What is meant by multi-point cutting tool? 3. Explain how milling machines are classified.
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End of Lecture
Milling Processes
Up-Milling Down-Milling Comparison of Up Milling and Down Milling Processes Column and Knee Type Milling Machine Horizontal Milling Machine Vertical Milling Machine
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Up-milling
Animation
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Animation
Down-milling 3 of 12
No
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The material removed by the milling cutter starts with a minimum thickness and ends with a
maximum thickness.
The material removed by the milling cutter starts with a maximum thickness and ends with a minimum
thickness.
The cutting force of the milling cutter acts upwards tends to lift the work piece from the
table, results in greater clamping force.
The cutting force of the milling cutter acts down wards, push the work piece in down direction results
in lesser clamping force.
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The chips accumulate at the cutting zone and interfere with cutting tool.
It is difficult to pour the coolant directly at the cutting zone. In up milling greater speeds and feeds are not possible. In up milling good surface finish can be obtained.
Chips are disposed off easily and do not interfere with cutting tool.
The coolant can be poured directly at the cutting zone. In down milling greater speeds and feeds are possible. In down milling good surface finish can be obtained.
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cont'd ...
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Review Questions
1. Explain up milling and down milling with the help of sketches. 2. What are the differences between up milling and down milling? 3. Explain with a neat sketch the working of column and knee type vertical milling machine. 4. Explain with a neat sketch the working of column and knee type horizontal milling machine.
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End of Lecture
Milling Operations
Slab or Plain Milling Face Milling Slotting Angular Milling Form Milling Summary and Review Questions
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Face milling 4 of 8
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Angular milling 6 of 8
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Review Questions
1. What are the different operations that can be performed on a milling machine? 2. Explain with neat sketches the working of a) Plain milling b) Face milling c) Slotting d) Angular milling e) Form milling
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End of Lecture
Gang Milling
Straddle Milling Summary and Review Questions
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Gang Milling
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Straddle Milling
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Review Questions
1. Explain with a neat sketch how gang-milling operation is performed on a milling machine. 2. Explain with a neat sketch how straddle-milling operation is performed on a milling machine. 3. Explain how a milling machine is specified.
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End of Lecture
List of Topics:
Reasons for Grinding Grinding Wheel Abrasives Summary and Review Questions
Introduction
Grinding is a metal removal process or a finishing process, where metal is removed due to abrasive action of rotating grinding wheel. By grinding, good surface finish is obtained on the work piece. Always grinding is used as a finishing process. The amount of material removed by grinding process varies from microns to millimeters.
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2. Tolerances required preclude machining. Grinding can produce flatness tolerances of less than 0.0025 mm (0.0001 in) on a 127 x 127 mm (5 x 5 in) steel surface if the surface is adequately supported.
Grinding Operation
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Grinding Wheel
Abrasives
The abrasives which are used for manufacturing grinding wheels are of two types, they are Natural and synthetic abrasive particles. 1. Natural abrasive particles are sand stone, quartz, corundum and diamond. 2. Synthetic abrasive particles are silicon carbide, cubic boron nitride and aluminum oxide.
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Review Questions
1. What is grinding? What are the advantages of grinding?
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End of Lecture
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cont'd ...
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The above table shows the grit or grain size number. Greater the grit number smaller the grit size. Grade: The grade of the grinding wheel indicates the bond strength. This is the bonding strength, which holds the grits intact. The grade of the wheel is represented by alphabets. A indicates the softest grinding wheel and Z indicates the hardest grinding wheel. Soft Medium Hard A I Q B J R C K S D L T E M U F N V G O W H P X
Z cont'd ...
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Glazing: After continuous use of grinding wheel, the cutting edges wear off and get a glass appearance on the surface of the wheel. This is known as glazing. Loading: During grinding, material is removed from the work piece. This material fills the gap between the grits results in inefficient in cutting. This is known as loading. Dressing: Both glazing and loading will decrease the material removal rate from the work piece. Dressing is a process to remove both glazed and loaded wheel and make it useful for cutting operation. cont'd ...
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Review Questions
1. What is a bonding material? Why it is required? 2. What are the bonding materials generally used in a grinding wheel? 3. Explain the following terms related to bonding materials a) Grit b) Grade c) Structure
d) Glazing
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End of Lecture
Cylindrical Grinding
Surface Grinding Center Less Grinding Summary and Review Questions
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The figure shows a cylindrical grinding machine. The main parts are bed, table headstock, tailstock and wheel. cont'd ...
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cont'd ...
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Surface grinding
Explain
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cont'd ...
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Review Questions
1. With a neat sketch explain surface grinding. 2. With a neat sketch explain cylindrical grinding. 3. With a neat sketch explain center less grinding. 4. What are the advantages of center less grinding?
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End of Lecture