LAB #4 MACHINING EXPERIMENT II MILLING Purpose: To study the operation of milling.

Machine: Milling machines Tools: sine bar, gage blocks, 6 inch dial caliper, steel ruler, fly-cutter (3 diameter high-speed end mill (!"#$ , edge-finder (%.# .

Material: &luminum block (appro'imately #$'3$ perations: &. (ecure the )orkpiece in the table of the milling machine using the *ice. !. #. 3. +lean milling machine *ise thoroughly. ,lace parallels under the )orkpiece to raise the surface to be milled abo*e the le*el of the *ise -a)s. &fter the )orkpiece is in place, tighten the *ise securely, then tap the )orkpiece lightly )ith a dead blo) hammer to seat it. .o not tighten the *ise again because this )ould alter the position of the )orkpiece and tightness of the parallels.

/. Machine (etup !. #. +heck the diameter of the cutter )ith a *ernier calipers. +alculate 0,M for cutting speed 1 !2% ft"min. V ( ft " min !# RPM = D(in 3hen using the 3hite +he*alier Mills. (et the speed of mill by ad-usting the 0,M knob and reading the speed on the analog meter. 456 and 476 scales represent high and lo) gear ranges. Note: do not cut at a speed lo)er than 8%% rpm )hile in the high gear range. (+heck )ith the lab instructor to *erify your setup before you continue . +alculate feed (in inch"min for a feed per tooth 1 %.%%3$. 9eed1 feed per tooth ' no. of cutter teeth ' 0,M Note: Power feed: speed is displayed on the digital readout. Adjust with the dial while moving away from your part. :f po)er feed is not a*ailable, use handles for manual feed. Note: The direction of feed is optional on a vertical milling machine.

3.

2.

+. Milling the top surface using fly (facemilling cutting !. #. 3. 2. 8. 6. <. =. >. !%. /efore starting the machine, be sure the cutting tool is clear of the )orkpiece. :f not, lo)er the )orkpiece by lo)ering the knee. Mo*e the table )ith the ' and y a'is handles to position the )orkpiece under the cutter. 7o)er the cutting tool or raise the table using the crank until it touches the top surface of the )orkpiece gently. (et the micrometer dial on the knee to ;ero. 7o)er the table by %.%#%$, by turning the knee hand)heel counter clock)ise. Mo*e the table longitudinally so that the cutter is clear of the )orkpiece at either end. Turn the machine on. 0aise the table (or lo)er the cutter %.%3%$ (! graduation is %.%%!$ from ;ero so that the final thickness of the )orkpiece is %.><%$?%.%%#$. @se multiple cuts and monitor the thickness of the )orkpiece. Angage the po)er feed )ith the le*er. Bote: Table tra*els in the direction of the feed engagement le*er. &fter )orkpiece has been milled on the top surface, disengage po)er feed and turn spindle off.

.. Andmilling of slots !. #. 3. 2. 8. 0eplace the face mill cutter )ith an edge finder (run the edge finder abo*e !C rpm Touch the corners of the )orkpiece to set the origin of the )orkpiece (the lab instructor )ill demonstrate the procedure . +onsider the diameter of the edge finder and offset the ;ero point accordingly. 0eplace the edge finder )ith a !"#$ end mill. Make a slot ! (through slot as sho)n in 9igure using the same procedure in +.#-+.!%. The cutting speed should be 8% ft"min and depth of the slot should be %.!%$. Dou )ill need multiple cuts. Make the slot # as sho)n in 9igure using the same procedure in +.#-+.!%. The depth of slot should be %.%8%$.

A. (lope machining !. #. @se a sine bar to set up the )orkpiece to be tilted at !%%. @se the !"#$ endmill or a fly cutter to generate the slope using multiple path cuts.

Ite!s to "e inclu#e# in the report !. #. Measured dimensions of the finished part (all the dimensions sho)n on the dra)ing +utting conditions used for each feature

3.