Professional Documents
Culture Documents
Milling Machines
Section 12
59-2
Milling Machines
Used to produce one or more machined
surfaces accurately on workpiece
One or more rotary milling cutters
PowerPoint to accompany
The Vertical
Milling Machine
Unit 59
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
59-4
Objectives
List four main uses of a vertical milling
machine
Describe how angular surfaces can be
machined
List three types of vertical milling
machines
State the purposes of the main parts of
a knee and column machine
59-5
59-6
Variety of Operations
Gear cutting
Face milling
Drilling
End milling
Boring
Keyway cutting
Jig boring
Dovetail cutting
T-slot and circular
Many facing operations
slot cutting
done with fly cutter
(cost reduction).
59-7
Ram-Type
Vertical Milling
Machine
59-8
59-9
PowerPoint to accompany
Cutting Speed,
Feed, and Depth
of Cut
Unit 60
60-11
Objectives
Select cutting speeds and calculate
the r/min for various cutters and
materials
Select and calculate the proper
feeds for various cutters and
materials
Follow the correct procedure for
taking roughing and finishing cuts
60-12
Feed
Too slow, time wasted and cutter chatter
Too fast, cutter teeth can be broken
Depth of cut
Several shallow cuts wastes time
60-13
Cutting Speed
Speed, in surface feet per minute (sf/min) or
meters per minute (m/min) at which metal
may be machined efficiently
Work machined in a lathe, speed in specific
number of revolutions per min (r/min)
depending on its diameter to achieve proper
cutting speed
In milling machine, cutter revolves r/min
depending on diameter for cutting speed
60-14
Important Factors in
Determining Cutting Speed
60-15
ft/min
m/min ft/min
1220
65120
5080
Carbide Cutter
150250
m
4575
10002000 30060
2035 200400
1525
125200
60120
4060
Free m steel
100150
3045 400600
12018
Machine steel
70100
2130 150250
4575
Stainless steel
3080
Tool steel
6070
1025
1820
100300
125200
4060
60-16
Inch Calculations
For optimum use from cutter, proper speed
must be determined
Diameter of cutter affects this speed
Calculate speed required to revolve a 3-in. diameter
high-speed steel milling cutter for cutting machine
steel (90 sf/min).
simplify formula
CS ( ft )
90
12 xCS
4 xCS
r / min
4 x90 360
r / min
120
3
3
60-17
60-18
60-19
60-20
in.
mm
Alloy steel
.006
0.15 .005
Aluminum
.022
0.55
Slotting
and Side
Mills
in. mm in.
0.12 .004 0.1
60-21
60-22
91
D
3.5
Feed(in/min) = N x CPT x r/min
=12 x .010 x 91
= 10.9 or 11 in/min
60-23
60-24
60-25
60-26
60-27
60-28
Depth of Cut
Roughing cuts should be deep
Feed heavy as the work and machine will permit
May be taken with helical cutters having fewer
teeth
PowerPoint to accompany
End Mills
Unit 61
61-30
Objectives
Name two types of material of
which end mills are made and
state their application
Describe the purpose of two-flute
and multiple-flute end mills
Know the purpose of climb and
conventional milling
61-31
End Mills
Greatly improved since days of carbon-steel
cutting tools
High-speed steel (HSS) cutting tools
maintain very important place in metalcutting industry
Variables influencing cutter decision
Part shape, work material, wear resistance of
tool, red hardness, machine condition
61-32
61-33
61-34
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61-35
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
61-36
Threecommontypesandtherelationshipofthe
radiustothetooldiameter.
61-37
61-38
61-39
61-40
61-41
Direction of Cut
61-42
Abrasion
Wearing-away action caused by metallurgy of
workpiece
dulls cutting edges and cause "wear lands"
61-43
Chipping or Crumbling of
Cutting Edges
Small fractures occur and small areas of
cutting edges chip out when cutting forces
impose greater load on cutting edges
Material left uncut imposes greater cutting load
Condition progressive
Once started will lead to total cutter failure
61-44
Clogging
Some workpiece materials have "gummy"
composition
Chips long, stringy and compressible
61-45
PowerPoint to accompany
Vertical Mill
Operations
Unit 62
62-47
Objectives
Align the vertical head and vise to
within .001 in. (0.02 mm)
Insert and remove end mills from
spring collets
Accurately machine a block square
and parallel
Drill holes to an accurate location
62-48
62-49
62-50
62-51
62-52
62-53
Collets
Hold end mills, cutting tools and accessories in
machine spindle
Spring collet
Pulled into spindle by draw-bar
that closes on cutter shank
Driven by means of friction between collet and cutter
Solid collet
More rigid
Pulled into spindle by draw-bar
Driven by setscrews that bear
against flats of cutter shank
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
62-54
To Mount a Cutter in a
Spring Collet
1. Shut off electric power to machine
2. Place proper
cutter, collet,
and wrench
on piece of
masonite,
wood, or
soft plastic
on table
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Permission required for reproduction or display.
62-55
3.
4.
5.
6.
7.
8.
9.
10.
62-56
62-57
62-58
Machining a
Block Square and Parallel
59-59
62-60
Procedure to Machine an
Angular Surface
1. Lay out angular surface
2. Clean vise
3. Align vise with direction
of feed
Utmost importance
62-61
62-62
62-63
62-64
62-65
Woodruff Keys
Used when keying shafts and mating parts
Woodruff keyseats can be cut more
quickly than square keyseats
Semicircular in shape and can be purchased in
standard sizes designated by E numbers
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62-66
PowerPoint to accompany
Horizontal Milling
Machines and
Accessories
Unit 64
64-68
Objectives
Recognize and explain the
purposes of four milling machines
Know the purposes of the main
operational parts of a horizontal
and a vertical milling machine
Recognize and state the purposes
of four milling machine accessories
and attachments
64-69
Classification of Horizontal
Milling Machines
1. Manufacturing-type
2. Special-type
3. Knee-and-column-type
64-70
Plain Manufacturing
Type Milling Machine
64-71
64-72
64-73
Vises
Universal
Vise
Plain Vise
Swivel Base
Vise
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
64-74
Fixturing
Systems
Easy-to-adjust Stop
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
Quick-change
self-locking system
64-75
PowerPoint to accompany
Milling Cutters
Unit 65
65-77
Objectives
Identify and state the purposes of
six standard milling cutters
Identify and state the purposes of
four special-purpose cutters
Use high-speed steel and carbide
cutters for proper applications
65-78
Light-duty
Light-duty helical
Heavy-duty
High-helix
65-79
65-80
Heavy-Duty Plain
Milling Cutters
Have fewer teeth than light-duty type
Provide for better chip clearance
65-81
65-82
65-83
65-84
65-85
65-86
65-87
Angular Cutters
Single-angle
Teeth on angular surface
May or may not have teeth on flat
45 or 60
Double-angle
Two intersecting angular surfaces
with cutting teeth on both
Equal angles on both side of line
at right angle to axis
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Permission required for reproduction or display.
65-88
Concave
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Convex
Gear Tooth
65-89
Metal-Slitting Saws
65-90
T-Slot Cutter
Used to cut wide horizontal groove at
bottom of T-slot
After narrow vertical groove machined with
end mill or side milling cutter
65-91
Dovetail Cutter
Similar to single-angle milling cutter with
integral shank
Used to form sides of dovetail after tongue
or groove machined
Obtained with 45, 50, 55, or 60 angles
65-92
PowerPoint to accompany
Milling Machine
Setups
Unit 66
66-94
Objectives
Mount and remove a milling
machine arbor
Mount and remove a milling cutter
Align the milling machine table and
vise
66-95
66-96
66-97
66-98
66-99
PowerPoint to accompany
The Indexing, or
Dividing, Head
Unit 68
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
68-101
Objectives
Calculate and mill flats by simple
and direct indexing
Calculate the indexing necessary
with a wide-range divider
Calculate the indexing necessary
for angular and differential
indexing
68-102
68-103
Universal chuck
Footstock
Center rest
68-104
G gear housing
D - crank
A large index plate
B - crank
C small index
plate
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