Documenti di Didattica
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in conjunction with
Section 22.3 and 22.4 in the text book Fundamentals of Modern Manufacturing Third Edition Mikell P. Groover 5/8/2008
Outline
Introduction to milling Cutting conditions in milling Milling machines, milling cutters, and tool holding 3-2-1 approach Edge finding CNC machining CAD/ CAM Lab objectives Lab Procedure Summary
Introduction to milling
Milling is a machining operation in which a workpart is fed past a rotating cylindrical tool usually with multiple cutting edges. The cutting tool in milling is called a milling cutter and cutting edges are called teeth. The geometric form created by milling is a plane surface. Other geometries can be created either by means of the cutter path or cutter shape.
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Introduction to milling
The machine tool that traditionally performs this operation is a milling machine (Mill). Milling is an interrupted cutting operation; the teeth enter and exit the work during each revolution. This subjects the teeth to a cycle of impact force and thermal shock on every revolution. The tool material and cutter geometry must be designed to withstand these conditions.
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Introduction to milling
There are two basic types of milling operations:
- Peripheral milling: the axis of the cutter is parallel to the surface being machined, and the machining is performed by cutting edges on the outside periphery of the cutter. - Face milling: the axis of the cutter is perpendicular to the surface being milled, and machining is performed by cutting edges on both the end and outside periphery of the cutter.
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Introduction to milling
Peripheral milling
Face milling
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Introduction to milling
In peripheral milling, the rotation direction of the cutter distinguishes two forms of milling: Up (conventional) milling: the direction of motion of the cutter teeth is opposite the feed direction when the teeth cut into the work. Down (climb) milling: the direction of motion of the cutter teeth is the same as the feed direction when the teeth cut into the work.
Introduction to milling
Conventional milling
Climb milling
fr = f * n t * N
Where: f: chip load (in/ tooth) nt: number of teeth on the cutter N: spindle speed (rev/ min)
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Milling Machines
Milling machines can be classified as horizontal and vertical: 1. Horizontal milling machines:
Horizontal spindle Suitable for peripheral milling
Milling Machines
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Milling Machines
Instead of the name vertical knee-and-column mill, you will hear the name BridgePort a lot in the Machine shop
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Milling machines
In milling machines: The knee can move in the z-direction. The saddle is placed over the knee and can move in the y-direction . The table is placed over the saddle and can move in the x-direction.
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Milling machines
To move the knee, saddle, or table, you have to rotate corresponding traverse cranks. A micrometer is associated with each of the three cranks. Using these micrometers, you can measure the distance travelled. (some mills have digital readouts to display the x, y, and z coordinates).
The simplest and most common way to clamp the work during milling is to use a vise. (you will use a vise to clamp the work in the lab).
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Milling machines
The Vise you will be using in the lab
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Milling Cutters
The milling cutter you will use in the lab is a: HSS, , 4-flute, non-center cutting end mill
There are no cutting edges at the center
A flute
Diameter
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Tool holding
There are many ways to mount the cutter in the machine spindle. The most common ways are: 1- Collets
2- Chucks
3-2-1 approach
In order to define the location of the work in the three dimensional space, the 3-2-1 approach is usually used: To define the location in the z-direction, place the work on a plane with known z-coordinate. [a plane is defined by 3 points]. While the work is on the plane, slide it until it touches a line with known y-coordinate (for example). [a line is defined by 2 points]. While the work is touching both the plane and the line, slide it in the x-direction until it touches a pin (1 point) with known x-coordinate.
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Edge Finding
In order to machine a feature in the work in the proper location, the location of the cutter should be defined with respect to certain references, usually the Datum Planes of the work. Assuming that a datum surface is perfectly flat, the cutter can be located with respect to this datum using a tool called the Offset Edge Finder. The Offset Edge Finder consists of a shank with a floating tip that is retained by an internal spring. The edge finder tip is accurately machined to a known diameter, usually 0.2 or 0.5 in.
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Edge Finding
The edge finder you will use in the lab
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Edge Finding
The procedure for using an Edge Finder:
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Edge Finding
The procedure for using an Edge Finder (continued)
Turn the table or spindle cranks and move the workpiece until it contacts the rotating edge finder tip. Continue to slowly advance the workpiece against the edge finder tip until the tip suddenly moves sideways. Stop movement at this moment. The machine spindle is now positioned a distance equal to the edge finder tip radius from the edge of the work. Lower the work or raise the quill If you want to drill a hole 1 in away from the datum plane, then you have to move the work a distance equal to 1 in plus the radius of the edge finder.
Machine Tool Practices, by R. Kibbe, R. Meyer, J. Neely, and W. White
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CNC machining
Numerical Control (NC) is a form of programmable automation in which the mechanical actions of a piece of equipment are controlled by a program containing coded alphanumeric data. The data represent relative position between a workhead (the spindle or cutting tool in case of NC machining) and the workpiece. Both the motion of the tool with respect to the workpiece and sequence of motions can be controlled in NC machining.
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CNC machining
NC system consists of three basic components:
1. Part program: a code (set of commands) which describes the sequence of operations to be done. 2. Processing equipment: the unit which performs the manufacturing operations according to the part program. 3. Machine control unit (MCU): stores the program and executes it by converting each command into actions by the processing unit.
If the MCU is a computer, then the NC is called CNC (Computer Numerical Control)
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CNC machining
In CNC machining, more than one axis can be controlled simultaneously. These axis are: - x, y, z axes (linear axes) - a, b, c axes (rotational axes around x, y, z axes respectively)
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CNC machining
In 2-axis milling machines, the x and y axes can be controlled simultaneously. In 3-axis milling machines, the x, y, and z axes can be controlled simultaneously. In 2 milling machines, the z-axis is fixed at a certain value and then the x and y axes are controlled simultaneously.
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CNC machining
G-code, M-code and others are used in CNC programming.
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CAD/ CAM
CAD/ CAM stands for Computer-Aided Design/ ComputerAided Manufacturing. The CAD software is used to construct the initial workpiece geometry. The CAM software is used to generate the cutting tool path. The CAD geometry can be saved and retrieved at any time.
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CAD/ CAM
The programmer can see a simulation of the tool path before actual production and corrects the program mistakes accordingly. Portion of the tool path generated can be automated such as milling around the outside periphery of the part, milling a pocket into the surface of the part, surface contouring, and certain point-to-point operations. These routines are usually called Macros
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Lab Objectives
The objectives of this lab are:
Lab Procedure
The following procedure will be followed in the lab:
Part1: Manual Milling 1- Peripheral mill one end of the workpiece to form a flat and perpendicular surface. 2- Reposition the work in the vice so that the unfinished end is protruding . 3- Use the edge finder to establish at the front-left corner of the part. (see part print in Appendix A) 4- Peripheral mill the protruding end to achieve the 1.75 dimension.
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Lab Procedure
Part1: Manual milling (Continued)
5- Face mill the top of the workpiece to achieve the 0.313 dimension. 6- On the mill, center drill the hole locations. 7- If time permits, move the workpiece to the drill press and drill the holes.
Note: For all milling operations in this lab, do not exceed 0.025 depth of cut
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Lab Procedure
Part2: CNC demo
1- Observe the Haas machining center demonstration. 2- Observe the sample parts made on the CNC mill. 3- Observe the CAM demo.
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Pictures
A picture showing the peripheral milling operation
Feed direction
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Pictures
A picture showing the face milling operation
Feed direction
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Pictures
Pictures showing center drilling on the vertical mill
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Pictures
The part you will machine using the CNC milling machine
Machined part
Initial stock
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Pictures
The CNC milling machine you will use in the lab
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Summary-Machining II Lab
This lab preparation material introduced:
Basic principles of milling CNC machining and CAD/ CAM systems Lab objectives and procedures Pictures
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Appendix A
The part you will machine in the lab
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