METAL CUTTING: Milling Operations

METAL CUTTING: Milling Operations

1. MILLING

   • removal of material from complex shapes
   • axis of rotation to the direction of feed
   • interrupted cutting operation
     • teeth of the milling cutter enter and exit the workpiece during each revolution
       • Subjects the tool to a cycle of impact force and thermal shock on every rotation

2. BASIC CONCEPTS

   • Workpiece are typically moving linearly and cutters rotate
   • Cutting is discontinuous
   • Multiple cutting points with multiple cutting teeth are used
   • Complex shapes could be cut by moving workpiece/cutting tool relative to each other in a 3D space

3. MILLING OPERATIONS

   • SLAB
     • In a plane parallel to the axis of the cutter
     • Cross section of the milled surface corresponds to the contour of the cutter
   • FACE
     • At right angles to the axis of rotation of the cutter
     • Milled surface is flat
       • no relationship to the contour of the cutter
   • END
     • cutter diameter is less than the work width so a slot is cut into the part
   • SLOTTING
     • cuts a narrow ridge into the surface
   • SLITTING
     • rotary tool- steel cutting tool with peripheral teeth, used in a milling machine to remove material
   • SIDE MILLING
     • Side-milling cutter to machine one vertical side
   • FORM
     • Uses a mill with a unique shape to create that shape into the workpiece
   • STRADDLE
     • Milling 2 parallel vertical surfaces simultaneously by using two side-milling cutters
   • CONVENTIONAL
     • Diameter of the cutter is greater than the work part width
       • cutter overhangs the work on both sides
   • SURFACE CONTOURING
     • A ball-nose cutter is fed back and forth across the work along a curvilinear path at close intervals
   • POCKET
     • Used to mill shallow pockets into the flat parts
   • PROFILE
     • The outside periphery of a flat part is cut

4. Widely used in the tool and die making inductry

   • Commonly used in the manufacturing industry

5. COMPONENTS

   • COLUMN houses
     • spindle
     • bearings
     • gearbox
     • clutches
     • shafts
     • pumps
     • shifting mechanisms
   • Knee
     • supporting the table
     • up or down motion along the Z axis

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