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Prepared by : J.M.PATEL
Milling Processes
Milling is one of the basic machining processes. Milling is a very versatile process capable of producing simple two dimensional flat shapes to complex three dimensional interlaced surface configurations.
The Process
The milling process:
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
MILLING METHODS
Conventional or up milling methods
Milling Method
End Milling
Straddle milling
Gang Milling
Operating Parameters
Rpm
CS converted into Rpm based on cutter diameter
Feed rate
Feed per tooth Table feed rate
1. 2. 3.
According to configuration of work holding table/bed Knee type: horizontal & vertical knee milling machine. Planer type Rotary type
1. Feed dial Used to regulate table feeds Spindle Provides drive for attachments, arbors, cutters Over arm Provides for correct alignment and support of arbor and various attachments Can be adjusted and locked in various positions Arbor support Fitted to over arm and can be clamped Aligns and supports various attachments Elevating screw Gives upward or downward movement to knee and table (manually or automatically) Spindle speed dial Set by crank used to regulate spindle speed
Base
Gives support and rigidity to machine and Acts as reservoir for cutting fluids
Column face
Precision-machined and scraped section used to support and guide knee when moved vertically
Knee
Houses feed mechanism attached to column face and moved vertically. Saddle On top of knee moved in or out by means of cross feed hand wheel (manually or automatically) Swivel table housings Enables table to be swiveled 45 either side of centerline
Milling Machines
Bed
Used extensively in production milling operations Rigid construction capable of heavy cuts Table is mounted directly to the bed Spindle head moves vertically to set depth of cut Head locks into position for cut Base of machine functions as a coolant reservoir
http://www.engineersedge.com/manufacturing/images/milling-machines.gif
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Variation of Machines
Variations include:
Profilers and duplicators
http://www.machinetoolschina.com
Process Accuracy
Accuracy of milling machines
Factors to consider
Fixture Rigidity of machine tool Accuracy of the spindle Cutter condition Coolant Type Delivery method Material condition
Milling Cutters
Workholding Devices
Vise Chucks Rotating tables Angle plates Special fixtures Universal dividing head Modular fixturing systems Clamp work to table
Workholding Devices