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workshop and know its functions and operations. To produce a milled article involving face milling, drilling and end milling. To practice and master the skills of handling the milling machine, whether it be manual or automated. To understand the basic milling operations. To learn the safety guide lines in handling the milling machine.
APPARATUS Gage block Wrench Engineering square Vernier caliper Small face mill with carbide inserts Two flute, single-end end mill with diameter 8mm Two flute, single-end end mill with diameter 20mm Four flute, single-end end mill with diameter 16mm Vertical milling machine Soft Hammer (plastic) Parallel Blocks Dial indicator Collet Hook spanner Angle file
PROCEDURES
This workshop activity is divided into two parts, Milling 1 and Milling 2. In Milling 1, only the face milling is dealt with and later on, drilling, slotting and end milling in Milling 2. Milling 1
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Milling 2 1. For this part of the activity, the drilling was done first, then slotting and finally the end milling. 2. The alignment of the machine plays an important part in this activity. the demonstrator showed how to use a dial indicator to align the table used for Milling 2. 3. A 20 x 13mm deep hole was to be drilled at the center of the block. The 2-flute drill with diameter 20mm was chosen and adjusted until it is directly on top of the marking for the hole. Then a 13mm deep hole is drilled. 4. Then the slotting was done. It requires the 2-flute cutting tool with diameter of 8mm. The block was clamped and adjusted so that the 2flute drill touches the part to be removed accurately. The machine is zeroed as mentioned above in Milling 1. 0.2 to 0.3 mm was removed in one pass until a depth of 15mm was obtained. 5. Last but not least, end milling was done with a 4-flute 16mm drill. The steps for end milling are similar to the slotting process. 6. As before, the sharp edges were removed with an angle file and the work piece was completed. Refer to the next page for the drawing of the piece.
For the horizontal milling machine, there are two methods of milling, the up milling and down milling. The up milling, also known as conventional milling, is when the work piece is fed against the direction of the cutter rotation. The depth of cut gradually increases on the successively engaged cutting edges as the chip is first cut off at the thinnest place. Therefore, the machining process involves no impact loading, thus ensuring smoother operation of the machine tool and longer tool life. The quality of the machined surface obtained by up milling is not very high. Nevertheless, up milling is commonly used in industry, especially for rough cuts. Up milling tend to pull the work piece up, therefore, proper clamping is necessary in obtaining a satisfactory result.
When the direction of the cutter rotation is the same as the feed motion, down or climb milling is under way. The maximum depth of cut is achieved directly as the cutter engages with the work piece. The chip formation of down milling opposes that of up milling where the chip thickness gradually decreases. This results in a kind of impact, or sudden loading. Therefore, this method cannot be used unless the milling machine is equipped with a backlash eliminator on the feed screw. The advantages of this method include higher quality of the machined surface and easier clamping of work pieces as the cutting forces act downward.
The most suitable type of milling cutter for a particular milling operation depends on such factors as : The kind of cut to be made The material to be cut The number of parts to be machined The type of milling machine available Solid cutters of small size will usually cost less, initially, than inserted blade types; for long-run production, inserted-blade cutters will probably have a lower overall cost. Depending on either the material to be cut or the amount of production involved, the use of carbide-tipped cutters in preference to high-speed steel or other cutting tool materials may be justified. Rake angles depend on both the cutter material and the work material. Carbide and cast alloy cutting tool materials generally have smaller rake angles than high-hspeed steel tool materials because of their lower edge strength and greater abrasion resistance. Soft work materials permit higher radial rake angles than hard materials; thin cutters permit zero or practically zero axial rake angles; and wide cutters operate smoother with high axial rake angles.
There are the features of milling cutter used to identify the major features of the milling cutter. The teeth are said to be radial when each tooth face lies along a line that cuts through the center of the cutter. Teeth are cut either with a radial tooth face or at zero degree., positive rake angle to radial line. There may be two or three clearance on the standard teeth form. A formed tooth-milling cutter has a contour, or tooth outline, of a particular shape. A concave milling cutter with a specific diameter produces a rounded shape. A gear cutter machines a gear tooth that conforms to specific design requirement.
The type of cutter depends on either the material to be cut or the number of part to be machined. The milling cutters have different shapes and types. Arbor types are those, which have a hole for mounting on an arbor or spindle. The arbor may be vertical or horizontal depending on the milling machine type.
In this activity, there are three types of milling operations that are dealt with, which are the slab milling, face milling and end milling. Slab milling, also called peripheral milling is basically done on a horizontal milling machine, whereby the axis of cutter is parallel to the work piece surface to be machined. The resulting chip have a shape of a wedge. There was no horizontal milling machine in the work shop that I know of. So, for this part, we had to use the vertical milling machine.
Face milling and end milling are both done on the vertical milling machine as the cutter is mounted on an axis perpendicular to the work piece. In face milling, the machine is evenly stressed, resulting in the removal of chips with an even thickness. The cutter in end milling can be tilted on machine tapered surfaces. The cutter has either straight or tapered shanks for smaller and lighter cutter sizes, respectively. End milling can produce flat surface and
Some calculations are involved in milling operations which are for: Cutting Speed The cutting speed in milling is the peripheral speed of the cutter S = D N where d is the cutter diameter and N is the revolution per minute. The cutting speed selection depends on both the work piece and cutter materials.
Feed Rate The linear feed rate in milling is expressed as the rate of feed in mm/min. It is the distance in mm which the milling table travels in one minute. Feed rate is determined from the equation F = f N Z where f is the feed per tooth cutter (mm/tooth), Z is the number of teeth on the cutter periphery (number of teeth/rev) and N is the rotational speed of the cutter (rev/min). Cutting Time Is given by the expression T = L / F where L is the travelling distance of the milling table. It depends on the work piece length (l), the approach and over travel allowances. The approach usually taken as the radius of the cutter in rough milling and as the diameter of the cutter in finish milling. The over travel is usually taken as 2 to 5 mm. Metal Removal Rate The metal removal rate (MMR) in mm3/min is given by MMR = lwd /T where l is work piece length in mm, w is the width of the work piece and d is the depth of the cut.
Inevitably I faced some difficulties in completing this activity but thankfully, there was nothing majorly wrong. There were insufficient machines to cater me and my group, so we had to wait for quite a long time as each person took a lot of time to finish especially for Milling 2. The finishing obtained was
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CONCLUSION
Alhamdulillah, praise be to Allah SWT for it is with His grace that I was able to finish this activity within the allotted time. All of the objectives have been achieved as I am now able to operate the milling machine, both the manual and automatic as I have had the privilege of using both in doing this activity. Now, I have better understanding of the milling machine; name and function of its components, and how to use them. The practical work using this machine gave an opportunity to me to practice the proper way in applying the basic operations besides develop some skills and technique on those operations. While milling, a lot of care and alertness have to be practiced in order to produce a good work piece. The safety rules must also always be adhered to.
ANSWERS TO QUESTIONS
1. Write down the characteristics and advantages of down milling rotation. The characteristics of down milling rotation are the direction of the cutter rotation is same as the feed motion, where the cutter tooth is almost parallel to the top surface of the workpiece. The chip formation is
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In face milling operation, the work piece dimensions are 125mm by 250mm. The cutter is 150mm diameter, has 8 teeth and rotates at 300 rpm. The depth of cut is 3.125mm and the feed is 0.125mm / tooth. Calculate the cutting time and metal remove rate, given: N = 300 rpm, D = 150 mm, f = 0.125 mm/tooth, Z = 8
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Case of rough milling. Traveling distance, L = 250 + (150 / 2) = 325 mm Feed rate, F = 0.125 x 300 x 8 = 300 mm/min Cutting time, T = 325 / 300 = 1.083 min Metal removal rate = (250 x 125 x 3.125) / 1.083 = 90172 mm3/min
b) Case of finish milling. Traveling distance, L = 250 + 150 = 400 mm Feed rate, F = 0.125 x 300 x 8 = 300 mm/min Cutting time, T = 400 / 300 = 1.333 min Metal removal rate = (250 x 125 x 3.125) / 1.333 = 73260 mm3/min
REFERENCES
8 8 Course manual Machine Tool Practice (6th Edition) by Prentice Hall Machinerys Handbook (26th Edition) by Industrial Press
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