JJ 104 WORKSHOP TECHNOLOGY 1 MILING MACHINE

INTRODUCTION
Milling

is the machining process of using rotary cutters to remove material from a workpiece advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a wide variety of different operations and machines, on scales from small individual parts to large, heavy-duty gang milling operations. It is one of the most commonly used processes in industry and machine shops today for machining parts to precise sizes and shapes.

TYPES OF MILLING MACHINE

Mill orientation is the primary classification for milling machines. The two basic configurations are vertical and horizontal. However, there are alternate classifications according to method of control, size, purpose and power source.

PARTS OF MILLING MACHINE

1.Face milling cutter 2.Spindle 3.Spindle head

4.Column
5.Table ( X-Axis ) 6.Saddle (Z-Axis ) 7.Knee ( Y-Axis )

8.Base
9.Spindle switch 10.Spindle speed gear lever 11.Spindle speed control lever 12.Oil tank 13.Table manual wheel 14.Table lock bar 15.Saddle automatic moving bar 16.Saddle automatic moving control dial 17.Saddle manual wheel 18.Knee manual wheel

Vertical Milling Machine

1.Base 2.Column 3.Console 4.Transversal Carriage 5.Table 6.Bridge 7.Axis tool

Horizontal Milling Machine

1. Base: It gives support and rigidity to the machine and also acts as a reservoir for the cutting fluids. 2. Column: The column is the main supporting frame mounted vertically on the base. The column is box shaped, heavily ribbed inside and houses all the driving mechanisms for the spindle and table feed.

3. Knee: The knee is a rigid casting mounted on the front face of the column. The knee moves vertically along the guide ways and this movement enables to adjust the distance between the cutter and the job mounted on the table. The adjustment is obtained manually or automatically by operating the elevating screw provided below the knee.
4. Saddle: The saddle rests on the knee and constitutes the intermediate part between the knee and the table. The saddle moves transversely, i.e., crosswise (in or out) on guide ways provided on the knee.

5. Table: The table rests on guide ways in the saddle and provides support to the work. The table is made of cast iron, its top surface is accurately machined and carriers T-slots which accommodate the clamping bolt for fixing the work. The worktable and hence the job fitted on it is given motions in three directions: a). Vertical (up and down) movement provided by raising or lowering the knee. b). Cross (in or out) or transverse motion provided by moving the saddle in relation to knee. c). Longitudinal (back and forth) motion provided by hand wheel fitted on the side of feed screw. In addition to the above motions, the table of a universal milling machine can be swiveled 45 to either side of the centre line and thus fed at an angle to the spindle.

6. Overarm: The Overarm is mounted at the top of the column and is guided in perfect alignment by the machined surfaces. The Overarm is the support for the arbor. 7. Arbor support: The arbor support is fitted to the Overarm and can be clamped at any location on the Overarm. Its function is to align and support various arbors. The arbor is a machined shaft that holds and drives the cutters. 8. Elevating screw: The upward and downward movement to the knee and the table is given by the elevating screw that is operated by hand or an automatic feed.

PRINCIPAL OF MILLING MACHINE

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.

Machined (dimesin) 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 rotatory speed of the cutting tool and the feed rate of the workpiece depend upon the type of material being machined. During the machining process, the work piece can be moved up and down (Y-axis), left and right (X-axis) and also back and front (Z-axis)

METHOD OF UP CUT AND DOWN CUT OF MILLING MACHINE

Method to be used will depend on the machine and the face mill cutter that has been selected. Generally down cut machining offers longer tool life than up cut milling.

the metal is removed in form of small chips by a cutter rotating against the direction of travel of the workpiece. In this type, the chip thickness is minimum at the start of the cut and maximum at the end of cut. As a result the cutting force also varies from zero to the maximum value per tooth movement of the milling cutter. The major disadvantages of up-milling process are the tendency of cutting force to lift the work from the fixtures and poor surface finish obtained. But being a safer process, it is commonly used method of milling.

Down milling is also known as climb milling. In this method, the metal is removed by a cutter rotating in the same direction of feed of the workpiece.
The effect of this is that the teeth cut downward instead of upwards. Chip thickness is maximum at the start of the cut and minimum in the end. In this method, it is claimed that there is less friction involved and consequently (seterusnya) less heat is generated on the contact surface of the cutter and workpiece.

TYPES OF MILLING CUTTER

Milling cutters are cutting tools typically used in milling machines or machining centres to perform milling operations . They remove material by their movement within the machine or directly from the cutter's shape

Side Milling Cutters Milling Cutters Concave Straight Teeth For milling male half For slotting and light duty circles. side milling. These cutters can be ganged or used as straddle mills.

Milling Cutters Convex For milling female half circles.

Milling Cutters Plain Light Duty For light milling or finishing cuts.

Plain - Heavy Duty Helical Plain Milling Cutter For heavy stock removal For slab or face milling furnished with 45 degree mild steels ideal for light left hand helix. to intermittent cut on thin parts. These can be run at high speeds and produce smooth finishes without leaving feed marks.

Single Angle Milling Double Angle Milling Shank Type Milling Cutters Cutters Cutters - Concave Single Angle Cutters are Double Angle Cutters are Shank Type Concave utilized for milling ratchet used for milling notches, Milling Cutter with weldon teeth or dovetails. grooves, serrations or shank.To be used in threads. Double Angle manual or NC Machining Cutters are available in Centers. For Milling Male 45, 60 or 90 degree. Half Circles.

Shank Type Milling Single Angle for Angular Double Angle for Angular Cutters - Convex Milling Milling Shank Type Convex Single Angle Milling Cutter For Notches, V-Grooves Milling Cutter with Weldon for Chamfers and other and other angular milling Shank. To be used in angular milling operations. operations. manual or NC Machning Centers. For Milling Female Half Circles.

Corner Rounding Milling Cutters Arbor Type. Available in Right Hand or Left Hand Cutters. Specifically designed to mill radii on various materials.

Woodruff Key Seat Cutters 1/2" diameter Straight Shank. Ideal for cutting standard and woodruff keyways in steel and other ferrous materials.

Staggered Tooth Woodruff Key Seat Cutters Arbor Type. Staggered Tooth Woodruff Key Seat Cutters. High Speed Steel.

Corner Rounding End Mills Use for rounding corners and adapting many screw machine applications as end forming tools to form a specific radius.

CUTTING TOOL HOLDER

Solid collet
Has a precision ground shank that fits the spindle on the milling machine

Split collet
Widely used to hold cutters Effective cutter holding devices

Work piece holder

Work table

The simplest method of holding a workpiece for milling is to clamp it directly to the worktable. Adequate tee slots are provided for this purpose. Care should be taken to avoid machining the table if necessary, the workpiece should be raised on a pair of parallels.

Vice

A vice is the most versatile piece of equipment for holding workpieces.

It must be positioned,to ensure accurate alignment with machine movements.

Rotary table

A rotary table is used where part of the surface being machined is of a circular nature. In this case, the table is moved to bring the workpiece in the correct position under the cutter. The workpiece is then rotated past the cutter to produce a circular profile. The circular table is provided with tee slots, to enable clamping of the workpiece.

A central hole enables setting of the workpiece about the centre of rotation and enables the rotary table to be set central with the machine spindle. Concentric circles on the table surface are provided to aid the initial setting of the workpiece roughly central.

RPM,Feed rate, cutting time

RPM

Feed Rate

Safety procedures

Safety procedures

Proper dress All machine guards should be in place prior to starting up a milling machine. Report any unsafe or dangerous practices by those around you to the person in charge.

Be careful when handling tools or sharp-edged workpiece to avoid getting cut; use shop towel to protect your hands.

The cutting tools need to be securely fastened in the machine spindle to prevent any movement during the cutting operation. Excessive feed rates can break the cutting tool.
Never leave a running machine unattended.

Indexing

Indexing is the operation of dividing the periphery of a piece of work into any number of equal parts. Used to divide circumference of workpiece into equally spaced divisions when milling gear teeth, squares, hexagons, and octagons

Indexing is accomplished by using a special attachment known as dividing head or index head as shown in Fig.

the indexing calculation to machine a square is :

Index crank turns = 40/N = 40/4 = 10

Where N is the required number of divisions. The available index plate has 8 circles of 24, 25, 28, 30, 34, 37, 38 and 39 holes. Three of these hole circles, (24, 30, and 39) can be divided by this lowest common denominator of 3.

To operate the index head

1. 2. 3. 4. 5.

Unlock the spindle and pull back the crank pin plunger. Rotate the crank the required number of turns plus the fraction of a turn. Set the sector arms to keep track of the additional holes beyond the full turn of the crank. Bring the crank pin around until it just drops into the required hole. If you overshoot the position, back off well past required hole and come up to it once again. This will eliminate any backlash in worm and worm gear assembly.

Plain or Simple Dividing Head

The plain dividing head comprises a cylindrical spindle housed on a frame, and a base bolted to the machine table. The index crank is connected to the tail end of the spindle directly, and the crank and the spindle rotate as one unit. The index plate is mounted on the spindle and rotates with it. The spindle may be rotated through the desired angle and then clamped by inserting the clamping lever pin into anyone of the equally spaced holes or slots cut on the periphery of the index plate. This type of dividing head is used for handling large number of workpieces, which require a very small number of divisions on the periphery. 1. Swiveling block 2. Live centre 3. Index crank 4. Index plate.