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Manufacturing Technology: Metal Cutting and Machine Tools - P.N.Rao
Ch. 7/1
MILLING
The Milling Process is characterised by
Interrupted cutting:Each of the cutting edges removesmaterial for only part of the rotation of the milling cutter. Asa result, the cutting edge has time to cool before itremoves material again. Thus the milling operation ismuch more cooler compared to turning.
Small size of chips: though the size of the chips is small, in
view of the multiple cutting edges in contact a largeamount of material is removed and as a result thecomponent is generally completed in a single pass only,and
Variation in chip thickness: This contributes to the non-steady state cyclic conditions of varying cutting forcesduring the contact of the cutting edge with the chipthickness varying from zero to maximum size or vice
versa.
The varieties of milling machines available are:
a) Knee and Column typeHorizontalVerticalUniversal
Turret type
Machinedsurface
Feed
Workpiece
Chip
Peripheral milling
Cutter axis of rotation
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b) Production (Bed) typeSimplexDuplexTriplex
c) Plano millersd) Special type
Rotary tableCopy milling (Die sinking machines)Key way milling machinesSpline shaft milling machines
Horizontal Knee and column type milling machine
Spindle
Head
Movement ofthe head
Column
Spindle nose
T-slot for clamping
Saddle
Accurate screwfor moving table
Knee
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Some of the Milling Operations normally carried out on vertical axis
machines
Simplex bedtype milling machine
Ways
Base
Column
Spindle
Workpiece
Table
(a) Top view
Workpiece
Face milling cutter
Quill
Column
Head
(b) Side view
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Duplex bedtype milling machine
Milling cutters are classified into various typesBased on construction:
SolidInserted tooth type
Based on mounting:Arbor mountedShank mountedNose mounted
Based on rotationRight hand rotation (Counter clockwise)Left hand rotation (Clockwise)
Based on helixRight hand helixLeft hand helix
Ways
Base
Column
Spindle
Workpiece
Table
(a) Top view
Workpiece
Face milling cutter
Column
Head
Quill
(b) Side view
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(a) Slab milling cutter (b) Slab milling cutter (c) Slitting sae
(d) Side and face cutter (f) Staggered tooth cutter (g) Side and face cutter (e) Two side and face cutter
(a) Angle milling cutter
(d) Form relieved circular cutter
(b) Angle milling cutter
(e) Form relieved circular cutter
(c) Shell end mill
(f) Wood ruff key cutter
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(a) Four flute end mill
(b) Two flute end mill
(c) Multi flute end mill
(d) Ball end mill
(e) End mill uses for making a slot
(f) End mill
(g) Slot drilll
Length overall
Length of cut
Dia of cutDia of shank
Shak dia
Shankdia
Dia
Dia
Radius
Two flute
End Mill
Section A-A
A
A
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Hand of cut:This refers to the direction in which the cutter is rotated. Whenviewed towards the spindle, when the cutter is moving counter clockwise it iscalled right hand rotation while the opposite is called the left hand rotation.
Hand of helix:In case of helical milling cutters, when viewed from the endif the flutes move in a clockwise direction it is called the right hand helixwhile the opposite is called the left hand helix. The axial cutting forcedirection depends upon the hand of the helix. If two milling cutters ofdifferent helices are arranged side by side in a gang milling operation, thenet axial force can be reduced to zero depending upon the cut taken byeach of the milling cutters.
(a) T-Slot Cutter (b) Dove Tail Cutter
(a) Peripheral miling (b) Face milling
Axialdimension
w
w
d
d
Radialdimension
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Straight teeth
Helix angle
Radial roke angle
Radial rake angle
Clearance angle
Clearance angle
Helical teeth
Force
Force
Force variation
Force variation
Time
Time
Helix angle = 0
Helix angle 0
(a)
(b)
Trailing edgeLeading edge
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Up and Down milling
Based on the directions of movement of the milling cutterand the feeding direction of the workpiece,
Up milling (conventional milling)
Down milling (Climb milling)
Advantages of Climb milling:1 Suited to machine thin and hard-to-hold parts since the workpiece is
forced against the table or holding device by the cutter.2 Work need not be clamped as tightly.3 Consistent parallelism and size may be maintained, particularly on
thin parts.4 It may be used where breakout at the edge of the workpiece could
not be tolerated.5 It requires upto 20% less power to cut by this method.6 It may be used when cutting off stock or when milling deep, thin
slots.
Disadvantages:
1 It cannot be used unless the machine has a backlash eliminator andthe table jibs have been tightened.
2 It cannot be used for machining castings or hot rolled steel, since thehard outer scale will damage the cutter.
Direction of rotation
Workpiece
Depth of cut
Feed Feed
(a) Up Milling (b) Down Milling
d dh h
h1 h1
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Thin workpiece
Parallel strips(a) (b)
Work
T-bolt Clamp
Step blockY-block
Milltable
Finger clamp(double end) Finger clamp
(single end) U-clamp
Plain slotted clampGooseneck clamp
(c)
Correct
Correct
Correct
Incorrect
Incorrect
Incorrect
Block
Block
Block
Block
Work
Work
Work
Work
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Gang milling
Typical process sequence in milling
Side and face milling cutter
Slab mill
Finishedpart
Slab millSlot mill
Shell endmill
Endmill
Anglemill
1 2
3
4
5
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Dividing head construction
Indexing method of the Divid ing head
Worm wheel
Spindle
WormBevel gear Sector
Index plate
Clamp nut
Index pin
Index clamp
Hole in index plate
Sector armIndex pin
Index crank
Sector armIndex plate
Worm shaft Worm singlethread
Worm wheel40 teeth
Index head spindle
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Index plate no. 1 of Brown and SharpeDividing head
The index plates available with the Brown and Sharpe milling machinesare
Plate no. 1: 15, 16, 17, 18, 19, 20 holesPlate no. 2: 21, 23, 27, 29, 31, 33 holesPlate no. 3: 37, 39, 41, 43, 47, 49 holes
The index plate used on Cincinnati and Parkinson dividing heads is
Plate 1: Side 1 24, 25, 28, 30, 34, 37, 38, 39, 41, 42 and 43 holesSide 2 46, 47, 49, 51, 53, 57, 58, 59, 62 and 66 holes
It is also possible to get additional plates from Cincinnati to increasethe indexing capability as follows:
Plate 2:Side 1 34, 46, 79, 93, 109, 123, 139, 153, 167, 181, 197 holes Side 2 32, 44, 77, 89, 107, 121, 137, 151, 163, 179, 193 holes
Plate 3:Side 1 26, 42, 73, 87, 103, 119, 133, 149, 161, 175, 191 holes Side 2 28, 38, 71, 83, 101, 113, 131, 143, 159, 173, 187 holes
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Compound indexing using the Index plate no. 1 of Brown and SharpeDividing head with 5 holes in 20-hole circle minus 1 hole in 15-hole circle
Differential Indexing
The change gear set available is
24, 24, 28, 32, 40, 44, 48, 56, 64, 72, 86 and 100
Workpiece
Dog
Change gear mounted at
back end of the spindle
Spindle
Change gears,compound gearing
Idlergear
Millingmachinetable
Change gear
Shaft which rotatesthe index plate
Milling machine tablefeed screw
Center
Lock for the index plate in an unlockedposition. The index plate is rotatedby gearing from the spindle
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A few points to be remembered during the differential indexing is
(a) Use the hole circles for indexing which will easily factorise with theavailable gear set. For example, in the case of Brown & Sharpe, 18,
20, 21 and 27 hole circles should be used.(b) The difference from the actual to the approximate indexing should
be a small value such that the change gear set can accommodatethis ratio. For example a total difference of 0.5 to 1.5 will be mostconvenient.
(c) The idler gear has to be provided when the index plate has to movein the opposite direction to that of the crank movement.
7.8 Machining Time Estimation
1000
ND=V
Where, V = cutting speed (surface), m/minD = diameter of the milling cutter, mmN = rotational speed of the milling cutter, rpm
Approach distance, A =
22
22
d
DD= )( dDd
Where D = diameter of the slab milling cutter
Feed, f
A
N
d
D
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d = depth of cut
Time for one pass =NZf
Al + 2minutes
Where Z = number of teeth in the milling cutterf = feed per tooth, mm
Face milling operation
Approach distance for the face milling case is given as
A =2
Dfor W =
2
Dupto D
A = )( WDW for W