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Horizontal Milling
Horizontal milling machines have a spindle or cutters mounted on
a horizontal arbor above an X-Y table. Some horizontal mills have
a table, known as universal table, that features a rotary function
for machining at different angles. Horizontal mills are optimal for
machining heavier pieces because the cutters have support from
the arbor, as well as a bigger cross-section area than a vertical
mill. The design of the horizontal milling machine allows for the
rapid removal of material off of the piece one is machining. These
types of milling machines can range in size from something small
enough to fit on a tabletop to room-sized machines.
Vertical Milling
Vertical milling machines have a spindle that moves in a vertical
orientation over the table, working on the top and bottom sides of
the object being machined. Vertical milling machines lend
themselves to standing machinists and detailed work. These
machines tend to be taller than they are wide since their
operation is vertical, which works well when dealing with die
sinking. Die sinking is when a cavity of a particular size and shape
is machined into a steel block. The opening can then be used for
Turret
Turret milling machines are classified as vertical milling machines
because the spindle is positioned vertically; it is considered a
versatile machine since it can create a wide selection of shapes.
Like a drill press, this milling machine features a quill that when
lowered or raised can create different cutting depths; the quill
works in conjunction with a part under the table called a "knee" to
machine a piece. The table on this machine moves both parallel
and perpendicular to allow the machinist to make easier cuts, but
this maneuverability can add stress on the table. Turret milling
machines also tend to be smaller since it is difficult to move a
quill on a larger machine.
Bed Mill
With bed milling machines, the table moves against the axis of
the spindle. This machine does not create as much flexibility in
shape cutting like a turret milling machine, but this type of
configuration is often used on larger machines.
OBJECTIVE:
1.To understand the function and feature provided by the indexing
milling machine.
2.To learn the tool and equipment needed while operating the
machine.
3.To understand the safety precaution when operate and handling
of indexing milling machine.
4. Introduction and working principle of milling machine,
5. Different type of milling operations,
6. Different type of milling machine and their main parts,
7. Specifications of milling machines
SAFETY RULES
1.Safety glasses worn at all times,by everyone in the shop.
2.No long sleeves,no gloves,no open toe shoes,and no jewelry or
watches.
3.Long hair must be secred behind your head.
4.Become thoroughly familiar with the machine before operating
it.
5.When in doubt,always ask a supervisor or shop manager.
6.Never use the mill (or any other equipment) when tired or
rushed for time.
7.Only attempt work that you have been approved to do and are
comfortable doing.
8.Get additional training,refresher courses and approval as
necessary. ASK FOR HELP.
9.Never reach anywhere over,around or near any rotating cutter.
10.Stop the machine every time the cutter is not cutting,not being
used , or you are changing tools/parts.
Conclusion
Milling machines are important for cutting and shaping wood and
metal, among other solid materials. These machines are an
invaluable resource for any business or individual seeking to
create precision pieces in a work or personal shop environment.
There are several different types of milling machines, but the two
main types are classified by the orientation of their spindle:
horizontal and vertical. Since milling machines are a big
investment, it is best to research which kind best fits one's budget
and needs before purchasing one particular kind of mill over
another. Milling machines can be purchased at machinery shops
or dealers. They can also be bought second hand and at reduced
prices from warehouse liquidation sales or previous owners,
although it is important to check the working condition of a used
mill before purchasing it. Mills can also be found online through
any authorized dealer or on auction sites like eBay. Milling
machines are an integral part of the industrial world, so owning
Base
It provides rest for all parts of milling machine including column. It
is made of
Column
It is a type of rigid vertical long box. It houses driving mechanism
of spindle, table
knee is also fixed to the guide ways of column.
Knee
Knee can be adjusted at a height on the column. It houses the
feed mechanism of
the table and other controls.
Saddle
Saddle is placed at the top of the knee. Saddle provides guide
ways for the
movement of the table.
Table
Table rests on the saddle. It consists of T shaped slots for
clamping the
workpiece. Movements of the table (feed motions) are given in
very controlled
manner be lead screw.
Overhanging Arm
Arbor
It holds rotating milling cutters rigidly and mounted on the
spindle. Sometimes
arbor is supported at maximum distance from support of
overhanging arm like a
cantilever, it is called stub arbor. Locking provisions are provided
in the arbor
assembly to ensure its reliability.
Spindle
Spindle is projected from the column face and provided with a
tapered hole to
accommodate the arbor. Performance of a milling machine
depends on the
MILLING MACHINE
registers one half of a revolution. Set the bezel to zero. Use the
manual cross feed to run the indicator across the face of the vise.
If the vise is squared, the indictor will remain at zero. If the dial
indicator does not read zero, tap lightly with a soft hammer to
realign the vise. Repeat this procedure until the dial indicator
reads zero through the full travel across the face of the vise jaw.
Tighten down the T-bolts be careful not to change the vise
orientation.
3. Setting Spindle Speed & High/Low Gearing
Spindle speed is set by turning the speed crank on the right side
of the spindle. The spindle must be on and rotating to adjust the
speed. There is a manual display (dial) on the head of the
machine that shows the speed in rpm. The spindle speed dial has
two scales, one for low range, and one for high range. The
machine is switched between ranges with SPEED RANGE lever
on the right side of the machine head. Switching this lever must
be done with the spindle not running! Sometimes, the spindle
must be rotated slightly (by hand) to allow the
This can work for end mills up to .750 diameter in size. Beyond
that size, you will have to make multiple passes or use a
flycutter.Fly cutting, which is also called single point milling, is
one of the most versatile milling operations. It is done with a
single-point cutting tool shaped like a lathe tool bit. It is held and
rotated by a fly cutter arbor. You can grind this cutter to almost
any form that you need. It is more economical to grind the desired
form on a lathe-type tool bit than to buy a pre-ground form cutter,
which is very expensive and usually suitable only for one
particular job. For milling slots, end mills are an idea tool. They
will produce a slot to within two one-thousandths of an inch in one
pass. If greater accuracy is required, use an end mill a little
smaller than the desired slot. Measure the slot you produced and
then open it to the desired dimension with a second pass. Note
that the depth of cut should not exceed three times the diameter
of the cutter.
Advantages
1. The metal is removed at a faster rate as the cutter has got
multiple cutting edges and rotates at a higher speed.
2. It is possible to perform machining by mounting more than one
cutter at a time.
3. The table of the machine can be moved to an accuracy of
0.02mm.
4. It is very useful since various cutters and precise tools can be
machined.
Disadvantages
1. The cost of the milling machine is high.
2. As milling cutters cost high, the investment for procuring tools
is more.
3. The production cost will increase if we carry out the operations
performed in a shaper or a drilling machine with a milling
machine.
Indexing heads
Cross-section of an indexing head
A dividing head mounted on the table of a small milling machine.
The direct indexing plate and center are visible facing the camera.
An interchangeable indexing plate is visible on the left side.
Indexing is an operation of dividing a periphery of a cylindrical
workpiece into equal number of divisions by the help of index
REFERENCES
https://en.wikipedia.org/wiki/Indexing_head
http://collections.infocollections.org/ukedu/en/d/Jgtz104ae/3.html
http://www.lathes.co.uk/index/