Milling Process

Milling process and its effect on surface quality

M.E 407 Lab Lectures Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh Anwar Khalil Sheikh

Milling Processes
Milling is a very versatile process capable of producing simple two dimensional flat shapes to complex three dimensional interlaced surface configurations.

The milling process:

o o o o o Typically uses a multi-tooth cutter Work is fed into the rotating cutter Capable of high MRR Well suited for mass production applications Cutting tools for this process are called milling cutters
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Machined Surfaces by Milling

Mechanical Engineering Department

Typical parts and shapes produced by Various Milling processes

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Classifications

Peripheral / plain/Slab milling

Face milling

Milling operations are classified into two major categories:

Peripheral (side)
Generally in a plane parallel to the axis of the cutter Cross section of the milled surface corresponds to the contour of the cutter

Face
Generally at right angles to the axis of rotation of the cutter Milled surface is flat and has no relationship to the contour of the cutter Combined cutting action of the side and face of the milling cutter
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Peripheral / plain / Slab Milling

Conventional Milling

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Climb milling

Peripheral milling

Slab milling

Slotting

Side milling

Straddle milling

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Face Milling

Profile milling

Pocket milling

Surface contouring

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Milling Cutter
High Speed Steel (HSS) Carbide Cobalt Coatings TiN (Titanium Nitride)

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Milling Cutters

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Milling machines

Variations include:

Horizontal Vertical Universal CNC

(a) Schematic illustration of a horizontal-spindle column-and-knee-type milling machine. (b) Schematic illustration of a vertical-spindle column-and-knee-type
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Milling Movie

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Parameters and Process Capabilities

Slab-milling operation, showing

depth of cut, d;

feed per tooth, f;

chip depth of cut, tc; workpiece speed, v. Diameter of cutter D Length of cut L

Schematic illustration of cutter travel distance to reach full depth of cut.

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Speeds and Feeds for Milling

Cutting Speed, V= DN V = cutting speed (m/min) D = diameter of mill (mm) N = rotation of the mill (rpm)

Table Feed Rate, v = f n N

v = Table Feed Rate (mm/min)

f = feed rate (mm/tooth) n = number of teeth

Metal Removal Rate, MRR = Volume / t MRR = w dv (mm3/s)

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Cutting Time for Slab Milling

Cutting Time, t = (L + A ) / v (min) L = length of cut mm A = allowance for approach and over travel = 2f (D - d)1/2 (mm) v = table feed rate (mm/min) d= depth of cut (mm)

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Cutting Speeds in Milling

WORKPIECE MATERIAL Aluminum alloys vast iron, gray Copper alloys High-temperature alloys Steels Stainless steels Thermoplastics and thermosets Titanium alloys

CUTTING SPEED m/min 300-3000 90-1300 90-1000 30-550 60-450 90-500 90-1400 40-150 ft/min 1000-10,000 300-4200 300-3300 100-1800 200-1500 300-1600 300-4500 130-500

Note: (a) These speeds are for carbides, ceramic, cermets, and diamond cutting tools. Speeds for high-speed steel tools are lower than indicated. (b) Depths of cut, d, are generally in the range of 1 mm-8 mm (0.04 in.-0.3 in). (c) Feeds per tooth, f, are generally in the range of 0.08 mm/rev-0.46 mm/rev (0.003 in./rev 0.018 in./rev).

Approximate range of recommended cutting speeds for milling operations.

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Cutting Speeds in Milling

Objectives:
I. To become familiar with the Milling machine, Milling cutters, and the mechanics of process variables.

2. To study the effect of Milling process variables

(a) Cutting speed, V. (b) The table feed velocity , v. Coolant on surface roughness
M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Design of Experiment
Table: 1 Milling Process (Changing Cutting Speed, V)
Workpiece Material: Cutting Tool Material: Cutting Tool Name: Diameter of cutting Tool, D = Number of Teeth on tool, n = in

No 1

F = feed (in/tooth)

N (rpm)

V= Cutting Speed (fpm)

v = Table Speed (in/min)

in)
(no coolant)

in)
(with coolant)

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Design of Experiment
R (

Table: 2 Milling Process (Changing Table Cutting speed v) Workpiece Material: Cutting Tool Material: Cutting Tool Name:

Diameter of cutting Tool, D = in Number of Teeth on tool, n =

No

F = feed (in/tooth)

N (rpm)

V= Cutting Speed (fpm)

v = Table Speed (in/min)

in)
(no coolant)

in)
(with coolant)

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Report writing for Milling

1. Cover Page 2. Objectives of Experiment 3. List of Equipment and tooling 4. A brief procedure of experiment (step by step) 5. Complete the Table 1 and Table 2 by using the Microsoft Excel for each test condition. 6. Sample calculation for one test by using the formulas. 7. Plot Ra (no coolant) and Ra (with coolant) vs Cutting speed (V) on the same graph paper 8. Plot Ra (no coolant) and Ra (with coolant) vs Table speed (v) on the same graph paper 9. What uses can you have for these plots?

10. 11.

Discussion of the Results Conclusions and Comments

Conclude your report with the remarks, What you learned from the experiment and any further improvement in the experiment.

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

EXPERIMENTAL SETUP

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Feed and depth of cut settings

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh

Surface analyzer

M.E 407 Lab Lectures: Prepared by Mr. Hassan Iqbal , Mr Mohudin Ahmed & Dr. Anwar Khalil Sheikh