Project includes considering various parameters and sampling of chips form and giving a optimum parameter set , various do's and don'ts during machining, observation to make machining more effective.

1. PROJECT
AIM:- ANALYSIS OF CHIPS FORMED IN
PLANO MILLERS AND BORING MACHINES
IN BM-1
BY SURAJ SINGH PATWAL

2. Number of
axis
Table Size
Travel (a) X
(b)Y
(c)Z
(d)W
(e)U
P-5 P-4 HB-3 HB-11
X,Y,Z,W,U X,Y,Z,W X,Y,Z,W X,Y,Z,W
7500*2250 6000*3000 12500*3760 8300*3760
8200 6000 12500 12000
4600 3000 3000 3500
1000 1000 400 400
2600 3000 1600 1600
500 - - -
Spindle
Diameter(m
m)
275 250 200 200
Spindle rpm 10-1000 700 600 600
SPECIFICATIONS OF MACHINES

3. 90 deg
lead angle
75 deg
lead angle
45 deg
lead angle
LEAD ANGLE
90
4575
w/p
w/pw/p

4. MILLING
CLIMB MILLING CONVENTIONAL MILLING
CUTTER
ROTATES
IN
ANTICLOC
KWISE
DIRECTION
FEED
FEED
CUTTER
ROTATES
IN
ANTICLOC
KWISE
DIRECTION
Action
of
force
applied
to
work
Action
of
force
applie
d to
work

9. HB3
RPM=410
FEED=200
DOC=1,2,3
RPM=284
FEED=300
DOC=.2
RPM=504
FEED=129
DOC=.5

10. HB-3
RPM=202
FEED=4.5
DOC=1.5
RPM=269
FEED=200
DOC=1
RPM=222
FEED=200
DOC=.3
RPM=240
FEED=40
DOC=.5
RPM=251
FEED=150
DOC=.8
RPM=251
FEED=150
DOC=.5
RPM=418
FEED=80
DOC=.3
RPM=448
FEED=90
DOC=.5

11. HB-3
RPM=504
FEED=129
DOC=.5
RPM=306
FEED=125
DOC=.2
RPM=448
FEED=166
DOC=.6
RPM=448
FEED=90
DOC=.5
RPM=299
FEED=70
DOC=.5
RPM=319
FEED=100
DOC=.8
RPM=301
FEED=150
DOC=.5

12. P-5
RPM=187
FEED=200
DOC=1
RPM=250/275
FEED=400
DOC=1.5
RPM=240
FEED=40
DOC=.5
RPM=800
FEED=400
DOC=.15
RPM=190
FEED=210
DOC=1
RPM=205
FEED=260
DOC=.145
RPM=200
FEED=280
DOC=.5

13. HB-11
RPM=538
FEED=40
DOC=1
RPM=229
FEED=200
DOC=1
RPM=241
FEED=200
DOC=.5
RPM=270
FEED=150
DOC=.8
RPM=270
FEED=85
DOC=.8
RPM=258
FEED=250
DOC=.21
RPM=244
FEED=50
DOC=2
RPM=231
FEED=50
DOC=1

14. HB-11
RPM=182
FEED=420
DOC=1.5
RPM=182
FEED=45
DOC=3
RPM=182
FEED=525
DOC=3
RPM=182
FEED=340
DOC=3

15. P-4
RPM=200
FEED=250
DOC=.25
RPM=200
FEED=256
DOC=.15
RPM=210
FEED=196.6
DOC=.5
RPM=210
FEED=280
DOC=.6
RPM=210
FEED=210
DOC=.6

16. W/P
EFFECT OF DIAMETER OF CUTTER WRT WIDTH OF CUT
CUTTE
R IF CUTTER DIAMETER IS EQUAL TO
WIDTH OF CUT
• THEN THE CHIP WILL BE FORMED AT THE ENTRY
AND EXIT OF THE CUT WILL BE VERY THIN
AND THE CHIPS CANNOT CARRY AWAY HEAT AS
WELL AS THICKER CHIPS, THEREFORE HEAT IS
TRANSFER BACK INTO THE INSERT , CAUSING
EDGE FAILURE.
• WORK-HARDENING IS ALSO MORE LIKELY TO
OCCUR IN THE ENTRY AND EXIT AREAS.
25% of
cutter
body

17. DO’S AND DON’T
• AT 45DEG LEAD ANGLE , NEVER GIVE HIGH DEPTH OF CUT DOC<=4MM BUT CAN BE
USED FOR HIGHER FEED RATE.
• FOR THIN WALL WORK PEACE (BOLSTER), WHEN PERPENTICULARITY REQUIRED AT
THE EDGES OF PLATE THEN USE SOLDER CUTTER .
• 75 DEG CUTTER IS NOT USED FOR WEAK MACHINES/WORKPIECE/FIXTURES BECAUSE
OF HIGHER VALUE OF RADIAL FORCE.
• ALWAYS USE CLIMB MILLING.
• FOR BETTER TOOL LIFE , 25 % OF THE CUTTER BODY SHOULD BE OUTSIDE THE WORK
PIECE.
• CUTTING FLUID SHOULD BE USED WHEN RECOMMENDED.
• NEVER GIVE HIGH VALUE OF DOC IN A THIN PLATE,IT WILL CAUSE VIBRATIONS.

18. OBSERVATION
• IN MILLING THICKNESS OF CHIPS DEPEND ON FEED AND WIDTH OF CHIPS DEPEND ON
DOC.
• CORRESPONDING TO THE LARGER FEED CHIP SIZES REDUCES,IF WE KEEP RPM AND DOC
CONSTANT.
• AS WE INCREASES THE DOC FROM 1MM, 2MM,3MM, CHIPS COLOR VARIES FROM WHITE
, GOLD AND BLUE, IT MEANS WITH INCREASE IN DOC,MORE HEAT IS RELEASED.
• IF FEED INCREASES THEN VIBRATION INCREASES AND CHANCES OF BREAKING OF BITS
INCREASES.
• LARGER IS THE DOC , HEAT REALSE MORE AND TOOL BITS BREAK AND ALSO PRODUCE
DAMAGE TO CUTTER.
• IF VIBRATIONS ARE MORE THEN DISTORTED CHIPS ARE FORMED AND IT EFFECTS