Milling Machine
Content
Milling Machine
Contents
• Milling Machines: types of machines, horizontal, universal, vertical, Cutters and their applications, Operation on milling machines, Use of dividing head and circular table. Direct, simple, compound, differential and angular indexing and helical milling operation. Table feed in milling. Work holding devices.
10/1/2012 Prof.Irfan Shaikh 2
What is Milling Machine?
• A milling machine is a machine tool that removes metal as the work is fed against a rotating multipoint cutter. • The milling cutter rotates at high speed and it removes metal at a very fast rate with the help of multiple cutting edges. • One or more number of cutters can be mounted simultaneously on the arbor of milling machine. This is the reason that a milling machine finds wide application in production work. • Milling machine is used for machining flat surfaces, contoured surfaces, surfaces of revolution, external and internal threads, and helical surfaces of various crosssections. • In many applications, due to its higher production rate and accuracy, milling machine has even replaced shapers and slotters. 10/1/2012 Prof.Irfan Shaikh 3
Typical Milled jobs
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Principle of Milling operation
• In milling machine, the metal is cut by means of a rotating cutter having multiple cutting edges. For cutting operation, the workpiece is fed against the rotary cutter. • As the workpiece moves against the cutting edges of milling cutter, metal is removed in form chips of trochoid shape. • Machined surface is formed in one or more passes of the work. • The work to be machined is held in a vice, a rotary table, a three jaw chuck, an index head, between centers, in a special fixture or bolted to machine table. • The rotary speed of the cutting tool and the feed rate of the workpiece depend upon the type of material being machined.
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Workpiece Tolling during Milling Operation
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TYPES OF MILLING CUTTERS
(1) Plain milling cutters, (2) Side milling cutters, (3) Face milling cutter, (4) Angle milling cutters, (5) End milling cutter, (7) T-slot milling cutter, (8) Formed cutters, (9) Metal slitting saw,
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TYPES OF MILLING CUTTERS
Plain milling cutter
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Prof.Irfan Shaikh
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TYPES OF MILLING CUTTERS
Face milling cutter with inserted teeth
Side milling cutter
Plain metal-slitting saw cutter
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Prof.Irfan Shaikh
9
TYPES OF MILLING CUTTERS
Angle milling cutter
T-slot cutter
End mill cutter
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Up – Milling Method
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Down – Milling Method
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12
Plain Milling Machining Parameters
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Prof.Irfan Shaikh
13
Types of Milling Machines
The milling machines are available in different shapes and sizes. These machines may be classified as follows: (1) Column and knee type milling machines (a) Horizontal milling machines (b) Vertical milling machines (c) Ram type milling machines (2) Bed type milling machines (a) Manufacturing or fixed bed type milling machines (b) Horizontal bed type milling machines (c) Vertical bed type milling machines (3) Planer type milling machines (4) Special purpose milling machines
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Plain horizontal milling machine.
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Universal milling machine.
• The construction of a universal milling machine is similar to that of the plain milling machine, except that it is more accurate and has a sturdier frame and its table can be swiveled with an angle up to 50°. • Universal milling machines are usually equipped with an index or dividing head that allows for the cutting of gears and cams.
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Actual Universal milling machine.
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17
Schematic of Vertical milling machine.
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Actual Vertical milling machine.
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Bed Type Milling Machines
• Bed type milling machines are comparatively heavier and rigid than column and knee type milling machines. • In these machines, the table is mounted over a fixed bed in the place of a knee. • The spindle head imparts the cross or vertical motion instead of a table. Depending on the number of spindle heads provided in these machines, they can be ‘named as simplex, duplex and triplex milling machines. • Their types may be classified as horizontal or vertical, based on the orientation of the spindle axis.
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Prof.Irfan Shaikh
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Schematic of Bed Type Milling Machines
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Machining center
• A machining center is comprised of a multipurpose CNC machine that is capable of performing a number of different machining processes. • A machining center has a tool magazine in which many tools are held. Tool changes are automatically carried out, and so are functions such as coolant turn-on/off. • Machining centers are, therefore, highly versatile and can perform a number of machining operations on a workpiece with a single setup. • Parts having intricate shapes can easily be produced with high accuracy and excellent repeatability.
10/1/2012 Prof.Irfan Shaikh 22
Universal dividing head
• The universal dividing head is an attachment mounted on the worktable of a universal milling machine that is employed for cutting gears. • The function of the dividing head is to index the gear blank through the desired angle each time the metal between two successive teeth is removed. • Therefore, this attachment is sometimes known as an index head. • A universal dividing head, which consists of the body, the swivel block, the work spindle and its center, the index plate, and the index crank with a latch pin.
10/1/2012 Prof.Irfan Shaikh 23
Universal dividing head (contd..)
• The workpiece (with one of its ends supported by the center of the work spindle) is rotated through the desired angle by rotating the index crank through an angle that is dependent upon the desired angle. • The index crank is fixed to a shaft thatis, in turn, attached to a worm-gear reducer with a ratio of 40 to 1 . • Consequently, 40 turns of the index crank result in only one full turn of the workpiece. • This index plate has six concentric circles of equally spaced holes to assist in measuring and controlling any fraction of revolution in order to crank the correct angle. • The following equation is used to determine the angle through which the crank is to be rotated in gear
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Universal dividing head (contd..)
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Schematic of Universal dividing head
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Operations performed on milling machine
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Operations performed on milling machine (contd..)
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Operations performed on milling machine (contd..)
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Operations performed on milling machine (contd..)
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Operations performed on milling machine (contd..)
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Contents
• Milling Machines: types of machines, horizontal, universal, vertical, Cutters and their applications, Operation on milling machines, Use of dividing head and circular table. Direct, simple, compound, differential and angular indexing and helical milling operation. Table feed in milling. Work holding devices.
10/1/2012 Prof.Irfan Shaikh 2
What is Milling Machine?
• A milling machine is a machine tool that removes metal as the work is fed against a rotating multipoint cutter. • The milling cutter rotates at high speed and it removes metal at a very fast rate with the help of multiple cutting edges. • One or more number of cutters can be mounted simultaneously on the arbor of milling machine. This is the reason that a milling machine finds wide application in production work. • Milling machine is used for machining flat surfaces, contoured surfaces, surfaces of revolution, external and internal threads, and helical surfaces of various crosssections. • In many applications, due to its higher production rate and accuracy, milling machine has even replaced shapers and slotters. 10/1/2012 Prof.Irfan Shaikh 3
Typical Milled jobs
10/1/2012
Prof.Irfan Shaikh
4
Principle of Milling operation
• In milling machine, the metal is cut by means of a rotating cutter having multiple cutting edges. For cutting operation, the workpiece is fed against the rotary cutter. • As the workpiece moves against the cutting edges of milling cutter, metal is removed in form chips of trochoid shape. • Machined surface is formed in one or more passes of the work. • The work to be machined is held in a vice, a rotary table, a three jaw chuck, an index head, between centers, in a special fixture or bolted to machine table. • The rotary speed of the cutting tool and the feed rate of the workpiece depend upon the type of material being machined.
10/1/2012 Prof.Irfan Shaikh 5
Workpiece Tolling during Milling Operation
10/1/2012
Prof.Irfan Shaikh
6
TYPES OF MILLING CUTTERS
(1) Plain milling cutters, (2) Side milling cutters, (3) Face milling cutter, (4) Angle milling cutters, (5) End milling cutter, (7) T-slot milling cutter, (8) Formed cutters, (9) Metal slitting saw,
10/1/2012 Prof.Irfan Shaikh 7
TYPES OF MILLING CUTTERS
Plain milling cutter
10/1/2012
Prof.Irfan Shaikh
8
TYPES OF MILLING CUTTERS
Face milling cutter with inserted teeth
Side milling cutter
Plain metal-slitting saw cutter
10/1/2012
Prof.Irfan Shaikh
9
TYPES OF MILLING CUTTERS
Angle milling cutter
T-slot cutter
End mill cutter
10/1/2012
Prof.Irfan Shaikh
10
Up – Milling Method
10/1/2012
Prof.Irfan Shaikh
11
Down – Milling Method
10/1/2012
Prof.Irfan Shaikh
12
Plain Milling Machining Parameters
10/1/2012
Prof.Irfan Shaikh
13
Types of Milling Machines
The milling machines are available in different shapes and sizes. These machines may be classified as follows: (1) Column and knee type milling machines (a) Horizontal milling machines (b) Vertical milling machines (c) Ram type milling machines (2) Bed type milling machines (a) Manufacturing or fixed bed type milling machines (b) Horizontal bed type milling machines (c) Vertical bed type milling machines (3) Planer type milling machines (4) Special purpose milling machines
10/1/2012 Prof.Irfan Shaikh 14
Plain horizontal milling machine.
10/1/2012
Prof.Irfan Shaikh
15
Universal milling machine.
• The construction of a universal milling machine is similar to that of the plain milling machine, except that it is more accurate and has a sturdier frame and its table can be swiveled with an angle up to 50°. • Universal milling machines are usually equipped with an index or dividing head that allows for the cutting of gears and cams.
10/1/2012 Prof.Irfan Shaikh 16
Actual Universal milling machine.
10/1/2012
Prof.Irfan Shaikh
17
Schematic of Vertical milling machine.
10/1/2012
Prof.Irfan Shaikh
18
Actual Vertical milling machine.
10/1/2012
Prof.Irfan Shaikh
19
Bed Type Milling Machines
• Bed type milling machines are comparatively heavier and rigid than column and knee type milling machines. • In these machines, the table is mounted over a fixed bed in the place of a knee. • The spindle head imparts the cross or vertical motion instead of a table. Depending on the number of spindle heads provided in these machines, they can be ‘named as simplex, duplex and triplex milling machines. • Their types may be classified as horizontal or vertical, based on the orientation of the spindle axis.
10/1/2012
Prof.Irfan Shaikh
20
Schematic of Bed Type Milling Machines
10/1/2012
Prof.Irfan Shaikh
21
Machining center
• A machining center is comprised of a multipurpose CNC machine that is capable of performing a number of different machining processes. • A machining center has a tool magazine in which many tools are held. Tool changes are automatically carried out, and so are functions such as coolant turn-on/off. • Machining centers are, therefore, highly versatile and can perform a number of machining operations on a workpiece with a single setup. • Parts having intricate shapes can easily be produced with high accuracy and excellent repeatability.
10/1/2012 Prof.Irfan Shaikh 22
Universal dividing head
• The universal dividing head is an attachment mounted on the worktable of a universal milling machine that is employed for cutting gears. • The function of the dividing head is to index the gear blank through the desired angle each time the metal between two successive teeth is removed. • Therefore, this attachment is sometimes known as an index head. • A universal dividing head, which consists of the body, the swivel block, the work spindle and its center, the index plate, and the index crank with a latch pin.
10/1/2012 Prof.Irfan Shaikh 23
Universal dividing head (contd..)
• The workpiece (with one of its ends supported by the center of the work spindle) is rotated through the desired angle by rotating the index crank through an angle that is dependent upon the desired angle. • The index crank is fixed to a shaft thatis, in turn, attached to a worm-gear reducer with a ratio of 40 to 1 . • Consequently, 40 turns of the index crank result in only one full turn of the workpiece. • This index plate has six concentric circles of equally spaced holes to assist in measuring and controlling any fraction of revolution in order to crank the correct angle. • The following equation is used to determine the angle through which the crank is to be rotated in gear
10/1/2012 Prof.Irfan Shaikh 24
Universal dividing head (contd..)
10/1/2012
Prof.Irfan Shaikh
25
Schematic of Universal dividing head
10/1/2012
Prof.Irfan Shaikh
26
Operations performed on milling machine
10/1/2012
Prof.Irfan Shaikh
27
Operations performed on milling machine (contd..)
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Prof.Irfan Shaikh
28
Operations performed on milling machine (contd..)
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Prof.Irfan Shaikh
29
Operations performed on milling machine (contd..)
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Prof.Irfan Shaikh
30
Operations performed on milling machine (contd..)
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Prof.Irfan Shaikh
31
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