Chapter4 MILLING PROCESS

FIG. 1 Typical parts and shapes produced by various cutting processes

Fig. 2 Schematic illustration of milling machines

Fig. 3 Milling machines

Fig 4 Nomenclature of a common milling cutter

Left hand cutter

right hand cutter

Left hand spiral

right hand spiral

Fig. 5 Left and right hand cutters.

Helical Plain

Fig. 6 Milling Cutters. a ) Helical b ) Plain

Slab mill

Helical mill Course tooth mill

Helical mill (arbor type)

Staggered tooth mill

Side mill

Interloching mill

Metal slitting saw

Fig. 7 Various types of milling cutters

Two-lip end mill

Shell end mill T-slot end mill

Double-end end mill

Woodruff Keyslot end mill

Fig. 8 Various types of end mills

Corner rounding cutter

Covex formed cutter

Gear tooth cutter

Single angle cutter

Double angle cutter

Concave formed cutter

Fig. 9 Angle, concave, convex, corner and gear cutters

Amount of travel using large diameter cutter

Large diameter cutter

Amount of travel using small diameter cutter

Direction of cut

Material being removed Small diameter cutter workpiece

Fig. 10 Effect of milling cutter diameter on workpiece travel

Fig. 12The standard milling machine arbor

Arbor Spindle

Intermediate arbor support

Arbor support

Draw in bolt Fig.11 Tapers used for Milling machine arborrs

Milling cutter

Journal bearing Arbor nut

Fig. 13 Arbor installation

Fig. 14 Typical milling arbors

Milling machine adapters Fig. 15 Typical Collet types Fig. 16 Adapters

Chuck adapter

Fig. 17 Quick change adapter and tool holder.

Standard machine table vise

swivel vise The universal vise Fig. 18 examples of various vises

Fig. 19 The index head and footstock

Fig. 21 Offset boring head

Fig. 20 Rotary table

Angle plate

V-Block and clamp

V-clamp

C- clamp

Step block C- clamp

Bent tail machine clamp

Finger machine clamp

Strap clamp

Fig.22 Various mounting tools

Fig. 23 locating keys or tongues on the underside of the vise bases should be located correctly in relation to the T-slots on the milling machine table vise.

Not correct
Workpiece Vise

Correct

Parallel Selection of Parallels Workpiece Vise

Parallel Workpiece

Centering of workpiece in vise

Workpiece Vise Workpiece

Strap block Locating the workpiece at end of vise

Fig. 24 correct mounting of workpiece in a vise

Fig. 25 using hold down straps Fig. 26 The indexing plate

Brown and Sharpe type Plate I - 15, 16, 17, 18, 19, 20 holes Plate 2 - 21, 23, 27, 29, 31, 33 holes Plate 3 - 37, 39, 41, 43, 47, 49 holes

Cincinnati type First side - 24, 25, 28, 30, 34, 37, 38, 39, 41, 42, 43 holes Second side - 46, 47, 49, 51, 53, 54, 57, 58, 59, 62, 66 holes

a) Slab milling
Arbor

b) Face milling

c) End milling

Cutter
Spindle

Spindle Shank End mill

Arbor

d)

e)

Fig. 27 Examples of Milling Cutters and Operations

Fig. 28 Face-milling operation showing (a) action of an insert in face milling; (b) climb milling; (c) conventional milling; (d) dimensions in face milling. The width of cut, w, is not necessarily the same as the cutter radius.

(a)

(b)

f v

Fig. 29 (a) Slab milling operation, showing depth of cut, d, feed per tooth, f, chip depth of cut, tc, and workpiece speed, v. (b) Schematic illustration of cutter travel distance lc to reach full depth of cut.

TABLE 1 Typical capacities and maximum workpiece dimensions for milling machines

Machine tool

Maximum dimension m (ft)

Power (kW)

Maxi mum speed

Milling machines (table travel) Knee-andcolumn Bed Numerical control 1.4 (4.6) 4.3 (14) 5 (16.5) 20 4000 rpm

Note: Larger capacities are available for special applications.

= Rotational speed of the milling cutter, rpm f = Feed, mm/tooth or in./tooth D = Cutter diameter, mm or in. n = Number of teeth on cutter v = Linear speed of the workpiece or feed rate, mm/min or in./min

V = Surface speed of cutter, m/min or ft/min =D N f = Feed per tooth, mm/tooth or in/tooth =v /N n l = Length of cut, mm or in. t = Cutting time, s or min =( l+lc ) v , where lc =extent of the cutters first contact with workpiece MRR = mm3/min or in.3/min

TABLE 1 Parameters and formulae of the milling process

=w d v , where w is the width of cut

Torque = N-m or lb-ft ( Fc ) (D/2) Power = kW or hp = (Torque) ( ), where = 2 N radians/min

Note: The units given are those that are commonly used; however, appropriate units must be used in the formulas.

Fig. 31 A typical setup for plain milling

Fig. 33 Straddel milling of a hexagon

Fig. 32 is a typical example of angular milling.

Fig. 34 Face milling

Fig. 35 Face milling of angular surfaces

Fig. 36 Gange milling.

Fig. 37 Form milling

Cutter centered over the shaft Fig. 38 Fly cutting tools

Key is milled to required length Fig. 40 Milling rounded end key slot waysKey is milled to required length Fig. 39 The Woodruff key slot milling cutter

Fig. 41 T-slot milling cutter

Fig. 42 Parting of a solid stock

Fig. 43 The splines are cut by straddle milling