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Milling Machine

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Milling Machine Milling Machine • It is a machine tool in which metal is removed by means of a revolving cutter with many teeth , each tooth having a cutting edge which removes metal from a work piece. • Cutting can be Horizontal Transversely or Vertically Vertical Horizontal Classification of milling machine • Column and knee type • Fixed bed type • Planer type • Production type • Special purpose Classification of milling machine 1 Column and knee type • Horizontal • Vertical -- Vertical position of cutter spindle • Universal -------Swivel • Ram type Universal --- arm which slide forward and back word .cutter can be angled Planer type Production type • Rotary table • Drum type • Pantograph, profiling & tracer controlled milling machine Special purpose • Thread type milling m/c • Gear milling • Planetary type 2 Manufacturing or fixed bed type :- in this vertical motion is impart to spindle or arbor instead of table • Simplex Spindle • Duplex Spindle • Triples Spindle Rotary table milling machine:- This machine construction is a modification to a vertical milling machine.The face milling cutters are mounted on two or more vertical spindles and a number of workpieces are clamped on the horizontal surface of a circular table which rotates about vertical axis.The cutters may be set at different heights relative to the work so that when one of the cutter is roughing the pieces the other is finishing them. Rotary table milling machine • Drum milling Drum milling machine • The drum milling machine is similar to a rotary table milling machine in that work-supporting table which is called drum and it rotates in a horizontal axis. The face milling cutters mounted on three or four spindle heads rotate in a horizontal axis and removal metal from workpieces supported on both the faces of drum. The finished machined parts are removed after on complete turn of the drum, and then the new ones are clamped to it. • Planetary milling :- work is held stationery and while cutter moves in a planetary path to finish a circular surface ,either internally or externally. • Pantograph, profiling & tracer controlled milling machine :- can duplicate a job by using a pantograph mechanism which permits the size of the work piece reproduced to be smaller than, equal to or greater than the size of a template or model used for the purpose. • A pantograph is a mechanism that is generally constructed of four bar which are joined in the form of pantograph. Pantograph machine are available in two dimensional or three dimensional models. • Profiling machine duplicates the full size of the template attached to the machine. This is practically a vertical milling machine or bed type in which the spindle can be adjusted vertically and cutter head horizontally across the table. The movement of cutter regulated by a hardened guide pin Milling operation • Plain or slab milling • Face milling • Angular milling • Form milling • Straddle milling • Gang milling • End milling • T slot milling • Dove tail milling • Saw milling • Involutes gear cutting Plain or slab milling It is used to machine flat and horizontal surface Face milling for m/c a flat surface which is at right angle to the axis of rotation of the rotating cutter Angular milling Angle milling cutter is used Form milling :- the milling cutter is used has the shape of the cutting teeth conforming to the profile of surface to be produce Straddle milling in which a pair o side milling cutters is used for milling two // vertical surface Gang milling End milling for producing narrow slots, grooves and keyways using end mill cutter T slot milling Dove tail milling Saw milling Involutes gear cutting end milling cutter is used which carries the profile on its cutting teeth corresponding to the required profile of the gap between gear teeth Milling Process • UP milling process:- The work piece is fed opposite to the cutters tangents velocity. The chip thickness at start is zero increases to max. at the end of the cut . • Down milling process :- The work piece is fed in same direction as that of the cutters tangents velocity. Machine size • Dim of table in cm • HP of driving motor • Spindle speed • Feed Indexing • Indexing is the method of dividing the periphery of a piece of work into any number of equal parts. The attachment used for performing indexing is known as indexing head. The indexing operation can be adapted for cutting gears, ratchet wheels, keyways, fluted drills, taps and reamers. The indexing head serves as an attachment for holding and indexing the work in doing the above tasks. • There are three different types of indexing heads namely: • 1. Plain or simple dividing head :- IT is hand operated and used for simple indexing • 2. Universal dividing head :- IT can be done by hand or gear drive depending on the operation • 3. Optical dividing head.:- It is the most precision attachment and is therefore ,used for very precision indexing . Type of indexing • Rapid or direct indexing :- work on small no. of division like sq. hexagonal etc. • Simple indexing • Compound indexing :- when the number of division require is outside the range that can be obtained by simple indexing use two circle of index plate • Differential indexing :- use gear train • Angular indexing : - it is used when to cut grooves or slot at the centre of the circle upon which they are spaced Compound indexing • n1/N1 ± n2/N2 • n is no. of hole in N hole circle • n1/N1 ± n2/N2 = 40/Ndiv . Factor of division required X factors of difference of hole circles ------------------------------------------------------------------------------------------ Factor of 40 X factor of first hole circle N 1 X factor of second hole N 2 • If numerator is cancelled out therefore selection of N 1 and N 2 is correct Differential indexing Cutting speed • Vc = Π DN/1000 m/min • D = dia of cutter mm • N = cutting speed in rpm Feed f = f t .Z.N ft feed rate per tooth Z is number of cutting teeth of the cutter periphery • MRR = W d f , mm3/min W is width of cut d = depth of cut f = Rate of feed • Machining timing is the time require for one pass of width of cut for milling or machining a surface tm = Length of cut / Feed rate = L/f L0 = √ (d(D-d) .5 Drilling • Drilling is a process of making hole or enlarge a hole in an object by facing a rotating tool called “Drill”. Drill is generally called ‘twisted drill’ Material used for drill Carbon steel , HSS , Carbide tipped • Drill Machine :- A power operated machine tool which hold the drill in its spindle rotating at high speed and when manually actuated to move linearly simultaneously against the work piece produce a hole . • Specification of a drill Machine • Size of drill m/c table • Largest bit the m/c can hold • Max size of the work piece that can be held. • Power of the motor, spindle speed Various type of drill machine • Portable drilling machine – max diameter of drill • Sensitive or bench drilling - machine are specified by the diameter of the diameter of largest work piece that can be drilled • Radial drill machine is specified by the length of arm and column diameter. • Multiple spindle drill machine is specified by the drill area, the size and the number of hole a machine can drill Portable drilling machine Sensitive or bench drilling Machine light duty machine they are usually mounted on work bench Radial drill machine Multiple spindle drill machine Gang drill machine when several drill spindles are mounted on a single table Turret Drill machine Deep hole drilling machine • Axis: The imaginary straight line which forms the longitudinal center line of the drill • Body: The portion of the drill extending from the shank or neck to the outer corners of the cutting lips • Body Diameter Clearance: That portion of the land that has been cut away so it will not rub against the walls of the hole • Chip Breaker: Nicks or Grooves designed to reduce the size of chips; they may be steps or grooves in the cutting lip or in the leading face of the land • Chisel Edge: The edge at the end of the web that connects the cutting lips • Chisel Edge Angle: The angle included between the chisel edge and the cutting lip, as viewed from the end of the drill • Clearance: The space provided to eliminate undesirable contact between the drill and the workpiece • Clearance Diameter: The diameter over the the cut away portion of the drill lands • Heel: The trailing edge of the land • Helix Angle: The angle made by the leading edge of the land with a plane containing the axis of the drill • Land: The peripheral portion of the body between adjacent flutes • Land Width: The distance between the leading edge and the heel of the land measured at a right angle to the leading edge • Neck: The section of reduced diameter between the body and the shank of a drill Oil Grooves: Longitudinal straight or helical grooves in the shank, or grooves in the lands of a drill to carry cutting fluid to the cutting lips Oil Holes • Point angle • 60 o for wood • 100 o for soft and medium cast iron • 118 o for soft and medium hard brass and copper • 125 o – 135 o for heat treated steel ,drop forging alloy steels, SS • 150 o for steel rails , armor plate • Helix angle :- Large for soft material and small for hard material • High helix drills: This drill has a high helix angle, which improves cutting efficiency but weakens the drill body. It is used for cutting softer metals and other low strength materials. • Low helix drills: A lower than normal helix angle is sometimes useful to prevent the tool from "running ahead" or "grabbing" when drilling brass and similar materials.
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