MILLING MACHINE

Presented by: Izer Alarcon

Definition

A machine that uses a multi-toothed milling cutter to remove metal from the workpiece surface to create flat and angular surfaces and grooves.

Types

Vertical Milling Machine Horizontal Milling Machine Combination Milling Machine (vertical and horizontal) Universal Milling Machine (vertical and horizontal with a swiveling table)

Parts

Milling Cutters

Milling cuttersare cutting tools typically used inmilling machines or machining centres. They remove material by their movement within the machine or directly from the cutter's shape.

Types of Milling Cutters

End mill Slot drill Roughing end mill Ball nose cutter Slab mill Side-and-face cutter Involute gear cutter Hob Face mill Fly cutter Woodruff cutter Hollow mill Dovetail cutter Shell mill

Modular principle Mounting methods

How to sharpen milling cutters?

First you need to divide the cutters you have into types: End mills Slab mills Face mills Side mills Note: Most milling cutters have a teeth on their cylindrical shape and on one or two ends/sides. The teeth wear faster on the edges that do the most work and, while it can be either edge depending on how the tool was used, there are edges that need sharpening more often than others. There are many ways to sharpen milling cutters: Using sharpener that is appropriate for the cutter Using a surface grinder is not really a good tool for sharpening the cutters

Collet Chuck

Acollet is a holding device (specifically, a subtype ofchuck) that forms acollararound the object to be held and exerts a strong clamping force on the object when it is tightened, usually by means of a tapered outer collar. It may be used to hold a workpiece or a tool.

Cutting Speed and Feed

Surface cutting speed (Vc):This is the speed at which each tooth cuts through the material as the tool spins. Spindle speed (S):This is the rotation speed of the tool, and is measured in revolutions per minute (rpm). Diameter of the tool (D) Feed per tooth (Fz):This is the distance the material is fed into the cutter as each tooth rotates. Feed rate (F):This is the speed at which the material is fed into the cutter. Depth of cut:This is how deep the tool is under the surface of the material being cut.

Different Indexing

Simple Work positioned by means of crank, index plate, and sector arms Worm attached to crank must be engaged with worm wheel on dividing head spindle 40 teeth on worm wheel One complete turn on index crank cause spindle and work to rotate one-fortieth of a turn (ratio of 40:1)

Indexing =

40 N

Direct Simplest form of indexing Performed by disengaging worm shaft from worm wheel by means of eccentric device in dividing head Spring-loaded tongue lock engages numbered slots in index plate Used for quick indexing of workpiece when cutting flutes, hexagons, squares, etc. Direct indexing plate usually contains three sets of hole circles or slots: 24, 30, and 36 Number of divisions possible to index limited to numbers that are factors of 24, 30, 36

Angular Setup for simple indexing may be used Must calculate indexing with angular distance between divisions instead number of divisions One complete turn of index crank turns work 1/40 of a turn 1/40 of 360 equals 9 degrees

no. of degrees required Indexing in degrees = 9

Differential Used when 40/N cannot be reduced to a factor of one of the available hole circles Number chosen close to required divisions that can be indexed by simple indexing Index plate must be revolved either forward or backward part of a turn while index crank turned to attain proper spacing (indexing) Change of rotation effected by idler gear or gears in gear train

Safety

All operators of any machinery should wear all required safety glasses and ear protection. Many machine shops also require the personnel to wear steel-toed footwear as a precaution from heavy metal items falling onto the floor and then onto unprotected toes. Keep all areas around the milling machine clean and free of all metal debris. Oil absorbent must be spread around the machine if cutting lubricant is spilled. This helps alleviate any slipping hazards around the machine's operational area. Machine operators must keep all clothing tightly buttoned and long shirttails must be tucked into the pants. Loose clothing can be caught in the rotating machinery and the operator pulled into the moving cutting tools. Long hair must be pulled back and placed under the

Tooling

Keep all tooling clean and in good working order. No broken tooling should be inserted into a milling machine. The broken tool can break again and pieces be ejected from the machine. Flying metal pieces can be a hazardous condition. Allow the milling machines spindle to come to a complete stop, either on its own or through the use of the motor brake. Attempting to use your hand to stop a moving spindle will cause serious injury. Check to make sure all tooling is tight in the locking collets. Most collets have a doublelocking mechanism to ensure the tool stays in the collet and tool holder.

Milling Machine

Inspect the machine prior to use. Someone else may have damaged the machine and not reported any problems. Check the machine for proper lubrication levels. Inspect all electrical connections and cords to ensure that no broken wires are visible. Test run the motor and spindle speed to ensure the rotation and speed is correct. Move the table manually to lubricate the ways and test the ball screws. Damaged or improper operation of the table can cause a work piece to be thrown from any mountings Secure all vises tightly to the table with only approved methods. Improperly mounted vises can cause a work piece to be thrown from its secure position.

Different Types of Gears

External and internal gears

Spur

Helical Skew gears

Double helical

Bevel

Spiral bevels

Hypoid

Crown

Worm

Non-circular

Rack and pinion

Epicyclic

Sun and planet

Harmonic drive

Cage gear

Magnetic gear