This document provides an overview of milling machines, including their basic functions, classifications, and applications. It discusses the purposes of milling machines in producing flat and contoured surfaces. Milling machines are classified based on their purpose, configuration, spindle orientation, and degree of automation/production rate. Common types include knee type, bed type, planer type, and rotary table type machines. CNC milling machines offer increased flexibility, reduced changeover times, and ability to machine complex geometries compared to conventional machines.
The document discusses the lathe machine tool. It describes the main parts of a lathe including the bed, headstock, spindle, tailstock, carriage and tooling. It explains the different types of lathes such as engine lathes, bench lathes, and special purpose lathes. It also outlines various operations that can be performed on a lathe like turning, facing, threading and drilling.
Milling cutters are cutting tools used in milling machines and other machine tools to remove material. There are various types of milling cutters that are used for different operations like shaping faces, cutting slots, making gears, and more. Some common types include end mills, slitting cutters, gear cutters, and face mills. End mills can cut in all directions and are used for operations like profiling and slot cutting.
Milling operations-types of milling cutter. Gear cutting – forming and generation principle and construction of gear milling, hobbing and gear shaping processes –finishing of gears.
The document discusses various sheet metal processes including shearing, bending, drawing, and special forming processes. It provides details on:
- Common shearing operations like punching, blanking, and notching used to cut sheet metal.
- Forming processes like bending, stretching, and drawing that cause shape changes without cracking or excessive thinning.
- Special high-pressure forming techniques like hydroforming, rubber pad forming, spinning, and super plastic forming.
- Factors that influence formability and properties of sheet metals like strength, ductility, formability, and factors that affect drawing operations.
Broaching is a machining process that uses a toothed tool called a broach to remove material in a single pass. Broaching was first used in the 1850s and was commonly used to rifle gun barrels during World War 1. Broaching machines can perform horizontal, vertical, continuous, and rotary broaching. Broaching tools are designed based on the material, size and shape of the cut, required tolerances, and production rates. Broaching provides high production rates and accuracy for complex hole shapes and surfaces.
Manufacturing engineering iii (ppt on jig boring machine)Taran Singh Saini
Jig boring machines are used to produce highly precise holes in components. They allow for greater accuracy of hole location, dimensions, and surface finish than other machining methods. Jig boring machines have heavy, rigid construction for stability. There are two main types: single column machines for small parts, and double column machines for larger workpieces. Boring tools are typically made of hardened steel or carbides, and come in various shapes suited for different boring applications. Jig boring involves rotating the tool to remove metal from a stationary workpiece, providing accurate hole features essential for parts like jigs, fixtures, and dies.
This document discusses various sheet metal forming processes and operations. It describes how sheet metal is produced by rolling metal into thin sheets less than 6 mm thick. Common applications of sheet metal include aircraft bodies, automobile bodies, and household utensils. The document outlines various cutting, bending, drawing, and forming operations used to shape sheet metal, including shearing, punching, bending, deep drawing, spinning, and roll forming. It also discusses defects in forming processes and components of dies used in sheet metalworking.
Shaping, planing and slotting operationssabry said
This document provides information about shaping, planning and slotting operations. It discusses the key differences between these processes, describes the machines used such as shapers and planers, and covers operating conditions like cutting speed, feed, depth of cut, and material removal rate. It also includes examples of problems calculating machining time and cost for specific shaping and planning jobs.
The document discusses the lathe machine tool. It describes the main parts of a lathe including the bed, headstock, spindle, tailstock, carriage and tooling. It explains the different types of lathes such as engine lathes, bench lathes, and special purpose lathes. It also outlines various operations that can be performed on a lathe like turning, facing, threading and drilling.
Milling cutters are cutting tools used in milling machines and other machine tools to remove material. There are various types of milling cutters that are used for different operations like shaping faces, cutting slots, making gears, and more. Some common types include end mills, slitting cutters, gear cutters, and face mills. End mills can cut in all directions and are used for operations like profiling and slot cutting.
Milling operations-types of milling cutter. Gear cutting – forming and generation principle and construction of gear milling, hobbing and gear shaping processes –finishing of gears.
The document discusses various sheet metal processes including shearing, bending, drawing, and special forming processes. It provides details on:
- Common shearing operations like punching, blanking, and notching used to cut sheet metal.
- Forming processes like bending, stretching, and drawing that cause shape changes without cracking or excessive thinning.
- Special high-pressure forming techniques like hydroforming, rubber pad forming, spinning, and super plastic forming.
- Factors that influence formability and properties of sheet metals like strength, ductility, formability, and factors that affect drawing operations.
Broaching is a machining process that uses a toothed tool called a broach to remove material in a single pass. Broaching was first used in the 1850s and was commonly used to rifle gun barrels during World War 1. Broaching machines can perform horizontal, vertical, continuous, and rotary broaching. Broaching tools are designed based on the material, size and shape of the cut, required tolerances, and production rates. Broaching provides high production rates and accuracy for complex hole shapes and surfaces.
Manufacturing engineering iii (ppt on jig boring machine)Taran Singh Saini
Jig boring machines are used to produce highly precise holes in components. They allow for greater accuracy of hole location, dimensions, and surface finish than other machining methods. Jig boring machines have heavy, rigid construction for stability. There are two main types: single column machines for small parts, and double column machines for larger workpieces. Boring tools are typically made of hardened steel or carbides, and come in various shapes suited for different boring applications. Jig boring involves rotating the tool to remove metal from a stationary workpiece, providing accurate hole features essential for parts like jigs, fixtures, and dies.
This document discusses various sheet metal forming processes and operations. It describes how sheet metal is produced by rolling metal into thin sheets less than 6 mm thick. Common applications of sheet metal include aircraft bodies, automobile bodies, and household utensils. The document outlines various cutting, bending, drawing, and forming operations used to shape sheet metal, including shearing, punching, bending, deep drawing, spinning, and roll forming. It also discusses defects in forming processes and components of dies used in sheet metalworking.
Shaping, planing and slotting operationssabry said
This document provides information about shaping, planning and slotting operations. It discusses the key differences between these processes, describes the machines used such as shapers and planers, and covers operating conditions like cutting speed, feed, depth of cut, and material removal rate. It also includes examples of problems calculating machining time and cost for specific shaping and planning jobs.
Unit 3A1 Lathe turning and related operationsMechbytes
Coverage of machine tools classification, types, functions and Lathe machine, Turning & related operations, Lathe construction, parts, accessories and attachments
jigs and fixtures, types of fixtures, definition of jigs and fixtures, types of jigs, application of jigs and fixtures, difference between jigs and fixtures
This document discusses jigs and fixtures, which are devices used to hold workpieces in place for machining or assembly processes. It defines jigs and fixtures and describes their main purposes. Some key points covered include:
- Jigs are used to guide cutting tools and locate components for machining. Fixtures are fixed to machine tables and locate work for cutting.
- Common jig components include locating pins, bushings, and clamps to securely hold workpieces. Fixtures also use bases, clamps, and set blocks.
- Proper design of locating surfaces is important for accuracy, including using small surfaces, avoiding sharp corners, and supporting workpieces evenly.
- Jigs and fixtures
This document discusses various sheet metal processing techniques. Sheet metal can be cut and bent into different shapes from thin, flat metal pieces. Common sheet metal operations include cutting through techniques like shearing, blanking, punching, notching, perforating, slitting, and lancing. Forming techniques shape the metal and include bending, roll forming, spinning, deep drawing, and stretch forming. Each technique is described in one or two sentences with examples provided for some methods.
Milling machines perform machining operations through rotating cutters that remove material from the workpiece. There are several types of milling machines including vertical, horizontal, and universal milling machines. Milling operations include plain milling for flat surfaces, angular milling for chamfers and grooves, straddle milling for parallel surfaces, face milling for perpendicular surfaces, and form milling for complex contours. Cutters are held using various arbors, collets, chucks, and adapters. Workpieces are mounted to the machine table, angle plate, fixtures, between centers, in a chuck, or vise depending on the operation.
gear and thread manufacturing,metal cutting,manufacturing processes,Productio...Prof.Mayur Modi
The document discusses various methods for manufacturing gears and threads. It describes casting, metal forming, powder metallurgy, and metal removal as common methods for making gears. Metal forming techniques include roll forming, extrusion, stamping, and coining. Metal removal techniques involve gear cutting, shaping, planing, hobbing, and broaching. The document also outlines various threading manufacturing methods such as lathe cutting, chasing, die threading, tapping, milling, rolling, grinding, casting, and whirling.
UNIT III SHAPER, MILLING AND GEAR CUTTING MACHINESKarthik R
Shaper - Types of operations. Drilling ,reaming, boring, Tapping. Milling operations-types of milling
cutter. Gear cutting – forming and generation principle and construction of gear milling ,hobbing
and gear shaping processes –finishing of gears.
This document provides information about various machining processes and machine tools. It describes machining as a metal removing process using machine tools and cutting tools. Lathe machines are commonly used to produce cylindrical surfaces and other operations like turning, drilling, boring, etc. Other machine tools discussed include milling machines, drilling machines, grinding machines, shaping machines, and planning machines. The document provides detailed descriptions of various operations that can be performed on these machines.
The document discusses jigs and fixtures, which are devices used to precisely locate and secure workpieces for machining. It describes the key functions of jigs and fixtures as locating, clamping, and supporting workpieces. The main difference between jigs and fixtures is that jigs also include provisions for guiding cutting tools. The document outlines principles for properly locating and securing workpieces, such as the 3-2-1 locating principle, and discusses various types of locators, clamps, and other elements used in jig and fixture design.
This document provides guidelines and considerations for designing sheet metal parts that can be efficiently manufactured. It discusses various sheet metal forming processes like blanking, piercing, bending, deep drawing and provides examples of different press tools. It also outlines guidelines for blank and hole design to enable economical manufacturing like minimum section sizes, radii on corners, hole diameters relative to material thickness. Process details covered include principles of plastic deformation and shearing, effects of cutting clearance and calculating flat blank length for bending.
1. The document discusses various types of lathes and their parts and operations. It describes the main parts of a lathe including the bed, headstock, tailstock, carriage, and feed mechanism.
2. It explains different lathe types such as engine lathes, bench lathes, toolroom lathes, and automatic lathes. It also discusses work holding devices, centers, and chucks.
3. The document provides details on lathe specifications, headstock mechanisms, feed mechanisms, and quick change gear boxes to facilitate various turning operations.
Metal cutting involves removing unwanted material from a workpiece. In orthogonal cutting, the cutting tool edge is perpendicular to the direction of motion, so chip flow is perpendicular to the cutting edge. In oblique cutting, the cutting tool edge is at an angle to the direction of motion, so chip flow is sideways. Orthogonal cutting results in higher heat concentration, shorter tool life, and poorer surface finish than oblique cutting. Oblique cutting is used for most industrial processes like drilling and milling.
This document discusses various work holding devices used on lathes: three jaw chucks and four jaw chucks for holding cylindrical stock, collet chucks for small parts, and magnetic chucks for thin pieces. Lathe centers provide support between centers, while lathe dogs provide a firm connection between spindle and workpiece. Mandrels hold hollow or drilled workpieces. Rests provide extra support for long workpieces. Face plates allow irregularly shaped pieces to be mounted on the lathe headstock.
1) Screw threads are commonly used for fastening parts together, clamping objects, transmitting motion and power, and making precision measurements of length.
2) There are various methods for manufacturing screw threads, including machining using lathes and taps, thread milling, rolling, and grinding.
3) Thread manufacturing methods are chosen based on factors such as the required accuracy, material properties, batch size, and thread specifications. Machining is suitable for high accuracy threads while rolling is faster but provides less accuracy.
Milling is a machining process that uses rotary cutters to remove material from a workpiece by feeding the workpiece into a spinning tool. There are two main types of milling machines: horizontal and vertical. Horizontal milling machines have a horizontally mounted spindle and cutter above the worktable, while vertical milling machines have a vertically oriented spindle and cutter that can plunge to cut the workpiece. The type of milling machine used depends on factors like the shape, size, and number of sides needing machining of the workpiece.
Sheet metal operations are cold-working processes that can manufacture low-cost metal parts in high volumes quickly. Sheet metal is metal between 0.006-0.25 inches thick that can be cut, bent, or stretched into various shapes. Common sheet metal operations include embossing to add raised or sunken designs using heat and pressure, coining to add similar impressions to both sides, spinning to shape metal over a rotating mandrel, stretch forming to simultaneously stretch and bend metal over a die, and nibbling which cuts contoured shapes using overlapping slits.
The document describes various lathe operations including: facing, turning, taper turning, chamfering, parting, threading, drilling, boring, knurling, and spinning. Facing involves machining a flat surface across the face of a workpiece. Turning removes material from cylindrical and conical external surfaces by rotating the workpiece as the tool is fed parallel to the axis of rotation. Taper turning produces a conical surface by feeding the tool at an angle to the workpiece axis. Chamfering bevels the edges of a workpiece. Parting separates one section of a workpiece from the rest using a cutoff tool. Threading produces threads on the outer surface of a cylindrical workpiece using a specific
Broaching is a machining process that uses a broach tool to remove material. There are different types of broaches and broaching methods depending on the operation. Broaching provides high production rates and accuracy for machining holes, slots and surfaces. It is well-suited for mass production but requires expensive broach tools and fixtures.
The document discusses various mechanical fastening and assembly methods. It describes common threaded fasteners like screws, bolts, nuts and how they are used. Other fastening methods discussed include rivets, press fits, shrink fits, snap fits, retaining rings, staples and sewing. The document also covers design for assembly principles to reduce assembly costs through minimizing part counts and ease of assembly.
The document discusses different types of milling processes and machines. It describes peripheral milling and face milling operations. Peripheral milling involves rotating the cutter parallel to the workpiece surface, and can be slab milling, slotting, side milling or straddle milling. Face milling produces a surface perpendicular to the cutter axis using cutter face and periphery. The document also covers different milling cutters, machines, and basic cutting conditions for milling operations.
Unit 3A1 Lathe turning and related operationsMechbytes
Coverage of machine tools classification, types, functions and Lathe machine, Turning & related operations, Lathe construction, parts, accessories and attachments
jigs and fixtures, types of fixtures, definition of jigs and fixtures, types of jigs, application of jigs and fixtures, difference between jigs and fixtures
This document discusses jigs and fixtures, which are devices used to hold workpieces in place for machining or assembly processes. It defines jigs and fixtures and describes their main purposes. Some key points covered include:
- Jigs are used to guide cutting tools and locate components for machining. Fixtures are fixed to machine tables and locate work for cutting.
- Common jig components include locating pins, bushings, and clamps to securely hold workpieces. Fixtures also use bases, clamps, and set blocks.
- Proper design of locating surfaces is important for accuracy, including using small surfaces, avoiding sharp corners, and supporting workpieces evenly.
- Jigs and fixtures
This document discusses various sheet metal processing techniques. Sheet metal can be cut and bent into different shapes from thin, flat metal pieces. Common sheet metal operations include cutting through techniques like shearing, blanking, punching, notching, perforating, slitting, and lancing. Forming techniques shape the metal and include bending, roll forming, spinning, deep drawing, and stretch forming. Each technique is described in one or two sentences with examples provided for some methods.
Milling machines perform machining operations through rotating cutters that remove material from the workpiece. There are several types of milling machines including vertical, horizontal, and universal milling machines. Milling operations include plain milling for flat surfaces, angular milling for chamfers and grooves, straddle milling for parallel surfaces, face milling for perpendicular surfaces, and form milling for complex contours. Cutters are held using various arbors, collets, chucks, and adapters. Workpieces are mounted to the machine table, angle plate, fixtures, between centers, in a chuck, or vise depending on the operation.
gear and thread manufacturing,metal cutting,manufacturing processes,Productio...Prof.Mayur Modi
The document discusses various methods for manufacturing gears and threads. It describes casting, metal forming, powder metallurgy, and metal removal as common methods for making gears. Metal forming techniques include roll forming, extrusion, stamping, and coining. Metal removal techniques involve gear cutting, shaping, planing, hobbing, and broaching. The document also outlines various threading manufacturing methods such as lathe cutting, chasing, die threading, tapping, milling, rolling, grinding, casting, and whirling.
UNIT III SHAPER, MILLING AND GEAR CUTTING MACHINESKarthik R
Shaper - Types of operations. Drilling ,reaming, boring, Tapping. Milling operations-types of milling
cutter. Gear cutting – forming and generation principle and construction of gear milling ,hobbing
and gear shaping processes –finishing of gears.
This document provides information about various machining processes and machine tools. It describes machining as a metal removing process using machine tools and cutting tools. Lathe machines are commonly used to produce cylindrical surfaces and other operations like turning, drilling, boring, etc. Other machine tools discussed include milling machines, drilling machines, grinding machines, shaping machines, and planning machines. The document provides detailed descriptions of various operations that can be performed on these machines.
The document discusses jigs and fixtures, which are devices used to precisely locate and secure workpieces for machining. It describes the key functions of jigs and fixtures as locating, clamping, and supporting workpieces. The main difference between jigs and fixtures is that jigs also include provisions for guiding cutting tools. The document outlines principles for properly locating and securing workpieces, such as the 3-2-1 locating principle, and discusses various types of locators, clamps, and other elements used in jig and fixture design.
This document provides guidelines and considerations for designing sheet metal parts that can be efficiently manufactured. It discusses various sheet metal forming processes like blanking, piercing, bending, deep drawing and provides examples of different press tools. It also outlines guidelines for blank and hole design to enable economical manufacturing like minimum section sizes, radii on corners, hole diameters relative to material thickness. Process details covered include principles of plastic deformation and shearing, effects of cutting clearance and calculating flat blank length for bending.
1. The document discusses various types of lathes and their parts and operations. It describes the main parts of a lathe including the bed, headstock, tailstock, carriage, and feed mechanism.
2. It explains different lathe types such as engine lathes, bench lathes, toolroom lathes, and automatic lathes. It also discusses work holding devices, centers, and chucks.
3. The document provides details on lathe specifications, headstock mechanisms, feed mechanisms, and quick change gear boxes to facilitate various turning operations.
Metal cutting involves removing unwanted material from a workpiece. In orthogonal cutting, the cutting tool edge is perpendicular to the direction of motion, so chip flow is perpendicular to the cutting edge. In oblique cutting, the cutting tool edge is at an angle to the direction of motion, so chip flow is sideways. Orthogonal cutting results in higher heat concentration, shorter tool life, and poorer surface finish than oblique cutting. Oblique cutting is used for most industrial processes like drilling and milling.
This document discusses various work holding devices used on lathes: three jaw chucks and four jaw chucks for holding cylindrical stock, collet chucks for small parts, and magnetic chucks for thin pieces. Lathe centers provide support between centers, while lathe dogs provide a firm connection between spindle and workpiece. Mandrels hold hollow or drilled workpieces. Rests provide extra support for long workpieces. Face plates allow irregularly shaped pieces to be mounted on the lathe headstock.
1) Screw threads are commonly used for fastening parts together, clamping objects, transmitting motion and power, and making precision measurements of length.
2) There are various methods for manufacturing screw threads, including machining using lathes and taps, thread milling, rolling, and grinding.
3) Thread manufacturing methods are chosen based on factors such as the required accuracy, material properties, batch size, and thread specifications. Machining is suitable for high accuracy threads while rolling is faster but provides less accuracy.
Milling is a machining process that uses rotary cutters to remove material from a workpiece by feeding the workpiece into a spinning tool. There are two main types of milling machines: horizontal and vertical. Horizontal milling machines have a horizontally mounted spindle and cutter above the worktable, while vertical milling machines have a vertically oriented spindle and cutter that can plunge to cut the workpiece. The type of milling machine used depends on factors like the shape, size, and number of sides needing machining of the workpiece.
Sheet metal operations are cold-working processes that can manufacture low-cost metal parts in high volumes quickly. Sheet metal is metal between 0.006-0.25 inches thick that can be cut, bent, or stretched into various shapes. Common sheet metal operations include embossing to add raised or sunken designs using heat and pressure, coining to add similar impressions to both sides, spinning to shape metal over a rotating mandrel, stretch forming to simultaneously stretch and bend metal over a die, and nibbling which cuts contoured shapes using overlapping slits.
The document describes various lathe operations including: facing, turning, taper turning, chamfering, parting, threading, drilling, boring, knurling, and spinning. Facing involves machining a flat surface across the face of a workpiece. Turning removes material from cylindrical and conical external surfaces by rotating the workpiece as the tool is fed parallel to the axis of rotation. Taper turning produces a conical surface by feeding the tool at an angle to the workpiece axis. Chamfering bevels the edges of a workpiece. Parting separates one section of a workpiece from the rest using a cutoff tool. Threading produces threads on the outer surface of a cylindrical workpiece using a specific
Broaching is a machining process that uses a broach tool to remove material. There are different types of broaches and broaching methods depending on the operation. Broaching provides high production rates and accuracy for machining holes, slots and surfaces. It is well-suited for mass production but requires expensive broach tools and fixtures.
The document discusses various mechanical fastening and assembly methods. It describes common threaded fasteners like screws, bolts, nuts and how they are used. Other fastening methods discussed include rivets, press fits, shrink fits, snap fits, retaining rings, staples and sewing. The document also covers design for assembly principles to reduce assembly costs through minimizing part counts and ease of assembly.
The document discusses different types of milling processes and machines. It describes peripheral milling and face milling operations. Peripheral milling involves rotating the cutter parallel to the workpiece surface, and can be slab milling, slotting, side milling or straddle milling. Face milling produces a surface perpendicular to the cutter axis using cutter face and periphery. The document also covers different milling cutters, machines, and basic cutting conditions for milling operations.
The document describes milling machine operations. It defines milling, the main components of milling machines, and different types of milling machines including horizontal, vertical, and speciality machines. It also explains various milling techniques such as plain milling, face milling, end milling, and gang milling. Key parts of milling machines like the spindle, table, and arbor are identified. Methods like up milling and down milling are compared.
This document provides instruction on milling machine operations. It describes the setup, operation, and adjustment of milling machines, including their major components such as the column, knee, saddle, table, spindle, overarm, and arbor support. It also describes different types of milling machines like knee-type, ram-type, and attachments like arbors. The purpose is to introduce students to milling machines and discuss cutter types for various milling operations.
This document provides information about CNC milling. It discusses learning outcomes, introduces milling processes and classifications. It describes the theory of CNC milling machines, including their characteristics, geometry, coordinate systems, zero and reference points, and programming structure. It also covers cutting values, clamping devices, and lists G-codes and M-functions.
This document provides information about milling and grinding machines. It defines milling as a metal cutting process that removes material from a workpiece using a revolving cutting tool called a milling cutter. It also defines grinding as an abrasive machining process that removes a thin layer of material from a workpiece through the abrasive action of rotating grinding wheels. The document then describes various types of milling machines like horizontal milling machines and vertical milling machines. It also discusses grinding machines, abrasives, bonding materials, and different grinding operations like surface grinding and cylindrical grinding. Overall, the document presents an overview of milling and grinding processes and machines.
Milling cutters are cutting tools used to remove material from workpieces in milling machines. They have cutting edges and flutes to remove chips of material. Common milling cutter types include end mills, face mills, and inserted tooth cutters. Milling cutters come in various geometries and are made of materials like high-speed steel or carbide depending on the application. Cutting parameters like spindle speed, feed rate, depth of cut, and surface cutting speed determine how efficiently a milling cutter removes material from a workpiece.
This document provides information about milling machines and milling operations. It describes the major parts and differences between horizontal and vertical milling machines. Various milling operations like face milling, end milling and slot milling are explained along with principles of up and down milling. Different types of milling cutters are classified and their applications discussed. Specifications of milling machines like worktable size, movements in X, Y and Z directions and motor power are also covered.
MILLING – Cutting parameters, machine time calculation
Milling operation – Plain milling, side & face milling, form milling, gang milling, end milling, face milling, T slot milling, slitting
GEAR CUTTING – Gear cutting on milling machine – dividing head and indexing method, gear hobbing, principle of operation, advantages & limitation, hobbing tech, gear shaping, gear finishing process
Milling is the process of converting grains into flour. There are different types of mills used for milling like hammer mills, roller mills, and ball mills. Routine maintenance of mills includes daily cleaning and greasing of parts, weekly checks of hammers and nuts, and monthly inspections of welds and foundations. Safety precautions when operating mills include using personal protective equipment, avoiding loose clothing, and applying hand sanitizer. Mill efficiency can be improved by reducing non-processing times and optimizing feed rates and spindle speeds.
Vertical milling machines combine the vertical spindle of a drill press with the longitudinal and transverse movements of a milling machine, allowing them to mill in one, two, or three axes. They are equipped with variable speed spindles and can perform operations like face milling, end milling, keyway cutting, dovetail cutting, drilling, boring, and more. The ram-type vertical milling machine is the most common type and consists of a base, column, overarm, head, motor, knee, and spindle. Horizontal boring mills are large machines typically used for machining large workpieces.
Dokumen tersebut membahas tentang proses milling pada mesin pengisar, termasuk definisi proses milling, jenis-jenis mesin dan mata alat pengisar, kaedah pengisaran, operasi pengisaran, dan langkah keselamatan dalam menggunakan mesin pengisar.
The document discusses a shaper, which is a machine tool used to produce flat surfaces on workpieces. It has a single-point cutting tool mounted on a ram that reciprocates to cut material on the forward stroke only. The workpiece is held rigidly in a vice on the machine table. The document describes the main parts of a shaper, including the base, column, ram, table, and tool head. It also classifies shapers based on the direction of ram travel and driving mechanism. Shaping operations like machining horizontal and vertical surfaces are explained.
The document discusses milling processes and provides details about various milling techniques. It defines milling, describes up and down milling methods, and covers topics such as milling machines, cutters, operations, and factors that influence tool life. Examples of peripheral and face milling are illustrated.
The document discusses shapers and planers, which are reciprocating machines that produce flat surfaces using single-point cutting tools. It describes the main parts of shapers and planers and compares their key differences. Shapers have a reciprocating ram that holds the stationary cutting tool, while planers keep the tool stationary and reciprocate the workpiece. Shapers are lighter, take up less space, use a single tool, and are less accurate than planers, making them better for small batch jobs. Planers are heavier, can use multiple tools simultaneously, achieve higher accuracy, and are more suitable for mass production of large workpieces.
This document provides an overview of machining operations, focusing on turning and milling. It defines turning as producing round parts using a single-point cutting tool on a lathe, where the workpiece rotates. Milling involves using a multi-tooth cutting tool called a milling cutter to produce flat and complex shapes. Key aspects of each process like cutting speed, feed, and common tooling/machines are described. The document also discusses computer-controlled lathes and different types of lathes and milling machines used for various operations.
This document provides an overview of milling machines and milling processes. It describes the two main types of milling machines - horizontal and vertical milling machines. It outlines common cutting tools and industrial applications of milling. The key milling processes of spindle speed, feed rate, depth of cut, and cutter rotation direction are explained. Typical milling operations such as plain milling, end milling and gang milling are defined. The document also covers workholding methods and the importance of vice alignment and safety practices.
This document provides instructions for experiments in a Manufacturing Technology-II laboratory course. It includes 16 experiments covering topics like milling, grinding, gear cutting, and CNC machining. The experiments are organized in a manual with details on machine overview, procedures, objectives and results for each task. Safety guidelines are also provided to ensure safe operation of machinery in the lab.
This document provides an overview of various machine tools, including lathes, shapers, milling machines, drilling machines, and broaching machines. It discusses the construction, operations, and classifications of lathes, shapers, slotters, planers, and milling machines. It also covers topics like cutting speed, feed, depth of cut, machining time, indexing, dividing heads, drilling tools, boring, reaming, and broaching. The document aims to give the reader a comprehensive understanding of common machine tools, their workings, applications, and the mathematical relationships involved in machining operations.
Shaping Machine, -Types, various operations, feed mechanism, advantages, and limitations.
2.Planning Machine - Types, various operations, feed mechanism, advantages, and limitations.
3.Slotting Machine- Types, various operations, feed mechanism, advantages, and limitations.
4. Broaching Machine- Types, various operations, feed mechanism, advantages, and limitations.
5.Industrial visit of students to the ferrous and non-ferrous foundry
This document provides a syllabus for a manufacturing science course covering machining, joining, and non-conventional machining and welding processes. The machining section covers topics like metal cutting mechanics, machine tools like lathes, milling machines, and grinders. It discusses machining operations, tooling, workholding, and specifications. The joining section covers welding processes like gas welding and arc welding. The final section introduces unconventional processes like EDM, ECM, laser beam machining, and non-conventional welding techniques. The syllabus is divided into 5 units and provides learning objectives and references for each major topic.
Milling machines use a rotating multipoint cutter to remove material from a workpiece through feeding in various ways. There are several types of milling machines but the most common is the vertical knee-type mill which allows movement of the workpiece in multiple axes. Milling operations include plain milling for flat surfaces, face milling for perpendicular surfaces, and slot milling or angular milling for complex shapes. Milling provides fast metal removal for complex geometries through cutters that can cut on sides, ends, and faces.
GEOMETRIC OPTIMIZATION OF CNC VERTICAL MILLING MACHINE BEDIjripublishers Ijri
In this paper, a machine bed will be selected for the complete analysis for both static and dynamic loads. Then investigation
is carried out to reduce the weight of the machine bed without deteriorating its structural rigidity and the accuracy
of the machine tool by adding ribs at the suitable locations.
This document provides information about the construction and working principles of a shaper machine. It discusses the main parts of a shaper like the base, column, cross rail, saddle, table, and ram. It describes the tool head and how it holds the cutting tool and provides feed movements. It also explains the different types of shaper machines and discusses their mechanisms, including the crank and slotted link mechanism and Whitworth quick return mechanism used to convert rotational motion into reciprocating motion of the ram.
The document discusses the history and basic types of milling machines. It begins by defining a milling machine as a machine tool that uses multiple-toothed cutters to remove metal from a workpiece. Eli Whitney is credited with developing the first milling machine in the early 1800s. There are two basic types - vertical and horizontal. Vertical mills have a vertically oriented cutting tool, while horizontal mills have a horizontally oriented cutting tool. The document then discusses the basic components and functions of both vertical and horizontal milling machines.
The document discusses milling and milling machines. It defines milling as a metal cutting process that removes material from a workpiece using a rotating cutting tool called a milling cutter. A milling machine is a machine tool that uses this milling process to remove metal as the workpiece is fed against the rotating cutter. The document describes the main components and functions of milling machines, different types including column and knee mills, horizontal and vertical mills, and special purpose mills. It also outlines common milling operations like face milling and pocket milling.
MACHINING OPERATIONS AND MACHINE TOOLS
Methods of Holding the Work in a Lathe (Chuck,Collet,face Plate,Holding the Work Between Centers)
Work Holding for Drill Presses
Boring Drilling, Reaming, Tapping Milling
Peripheral Milling vs. Face Milling
Shaper and Planer
Broaching
This document provides information about basic machine tools, including lathes, drilling machines, and milling machines. It describes the classification, parts, specifications, operations, and accessories of lathes. It also discusses the working principle, classification based on design and spindle position, major parts, cutters, and milling operations of milling machines. For drilling machines, it covers classification, specifications, parts, and common operations like drilling, reaming, and tapping.
Milling is a machining process where a workpiece is fed against a rotating cylindrical tool with multiple cutting edges called a milling cutter. There are different types of milling operations depending on the positioning of the tool and workpiece, including peripheral milling where the tool axis is parallel to the work surface and face milling where the tool axis is perpendicular. The key parts of a milling machine include the base, column, knee, saddle, table, overarm, arbor, and spindle. Cutting parameters that must be controlled include cutting speed, feed rate, and depth of cut.
MILLING MACHINE PPT 2: PARTS AND CLASSIFICATION OF MILLING MACHINESPOLAYYA CHINTADA
The document discusses the parts, types, and classifications of milling machines. It describes the main components of milling machines including the base, column, knee, saddle, table, overhanging arm, front brace, spindle, and arbor. It classifies milling machines as column and knee type, fixed bed type, planner type, and production type. Within these classifications, it provides details about horizontal milling machines, vertical milling machines, universal milling machines, omniversal milling machines, simplex milling machines, and other specific types of milling machines such as drum milling machines and tracer controlled milling machines.
The document discusses different types of shapers and their components and working principles. It describes three main types of shaper driving mechanisms: crank and slotted lever mechanism, Whitworth quick return mechanism, and hydraulic shaper mechanism. The crank and slotted lever mechanism uses a rocker arm and crank pin arrangement to convert rotational motion to reciprocating motion of the ram, providing a quick return stroke that is faster than the cutting stroke to increase efficiency.
Milling Machine - Types, various operations, Accessories, and attachments,
2.Grinding Machine - Types, various operations, Accessories, and attachments,
3.Grinding wheels Abrasives, bonds and bonding processes grit, grade and structure of the wheel, wheel shapes, wheel specifications
There are several types of milling machines defined by their construction and how they operate. The column and knee type milling machine consists of a column attached to a base that allows for vertical movement of the knee. The planer milling machine can perform operations with multiple tools simultaneously on a workpiece held on a table. The fixed-bed milling machine has a rigid bed without any ability to move vertically or horizontally, instead the spindle head moves. Special milling machines can perform various operations like plain, face, side, slot, and angular milling through movement of the spindle or workpiece.
This document provides an introduction to CNC milling. It begins by defining NC and CNC, explaining that CNC refers to a computer connected to an NC machine to increase versatility. It then discusses the basic components of an NC system, including the program of instructions, control unit, and machine tool. The document outlines different milling processes like face milling and end milling. It also explains machine coordinate systems and CAD/CAM software integration. Advantages of CNC include increased productivity and accuracy while limitations include high costs.
The document provides an overview of milling operations and machines. It discusses:
1) The basic working principle of milling, where a rotating cutting tool (milling cutter) with multiple teeth machines a workpiece by moving it past the cutter.
2) The main types of milling operations including peripheral, face, and special operations like end milling and contouring.
3) The different categories of milling machines including column and knee machines, fixed bed machines, and special machines. Common machine specifications are also outlined.
1. Workshop on Machine Tools & Applications. June 9-13, 2008
MILLING MACHINES
M.V.TADVI
Lecturer
Dept. of Mechanical Engineering
SVNIT, Surat
Instructional Objectives
(i) State the basic functions and purposes of using milling machines
(ii) Classify milling machines and illustrate their configurations
(iii) Visualise kinematic system of commonly used milling machines and explain its working
principle.
(iv) Show and briefly describe the various applications of milling machines using different
types of milling cutters.
(i) Basic functions and purposes of using milling machines
The basic function of milling machines is to produce flat surfaces in any orientation as well
as surfaces of revolution, helical surfaces and contoured surfaces of various configurations.
Such functions are accomplished by slowly feeding the workpiece into the equispaced
multiedge circular cutting tool rotating at moderately high speed as indicated in Fig. 1. Upmilling
needs stronger holding of the job and downmilling needs backlash free screw-nut systems for
feeding.
Cutting motion Cutting motion
Fig. 1 Schematic views of conventional up and down milling
Milling machines of various type are widely used for the following purposes using proper
cutting tools called milling cutters :
• Flat surface in vertical, horizontal and inclined planes
• Making slots or ribs of various sections
• Slitting or parting
• Often producing surfaces of revolution
• Making helical grooves like flutes of the drills
• Long thread milling on large lead screws, power screws, worms etc and short thread
milling for small size fastening screws, bolts etc.
• 2-D contouring like cam profiles, clutches etc and 3-D contouring like die or mould
cavities
Dept. of Mechanical Engg., S. V. National Institute of Technology, Surat
2. Workshop on Machine Tools & Applications. June 9-13, 2008
• Cutting teeth in piece or batch production of spur gears, straight toothed bevel
gears, worm wheels, sprockets, clutches etc.
• Producing some salient features like grooves, flutes, gushing and profiles in
various cutting tools, e.g., drills, taps, reamers, hobs, gear shaping cutters etc.
(ii) Classification of milling machines
Milling machines can be broadly classified;
(a) According to nature of purposes of use :
• general purpose – most versatile commonly used mainly for piece or small lot
production
• single purpose – e.g., thread milling machines, cam milling machines and
slitting machine which are generally used for batch or lot production.
• Special purpose – these are used for lot or mass production, e.g., duplicating mills,
die sinkers, short thread milling etc.
(b) According to configuration and motion of the work-holding table / bed
• Knee type : typically shown in Fig. 2. In such small and medium duty machines the
table with the job/work travels over the bed (guides) in horizontal (X) and transverse
(Y) directions and the bed with the table and job on it moves vertically (Z) up and down.
Machine parts :
1. column
2. bed
3. cross slide
4. work table
5. ram
6. ram support
7. arbour support
Table feed motions : a.
longitudinal feed b. cross feed
c. vertical feed
Fig. 2 Knee type milling machine
• Bed type (Fig. 3) : Usuallyof larger size and capacity; the vertical feed is
given to the milling head instead of the knee type bed
Dept. of Mechanical Engg., S. V. National Institute of Technology, Surat
3. Workshop on Machine Tools & Applications. June 9-13, 2008
Fig. 3 Bed type milling machine
• Planer type (Fig. 4) : These heavy duty large machines, called plano-miller, look like planing
machine where the single point tools are replaced by one or a number of milling heads;
generally used for machining a number of longitudinal flat surfaces simultaneously, viz., lathe beds,
table and bed of planning machine etc.
• Rotary table type : Such open or closed ended high production milling machines
possess one large rotary work-table and one or two vertical spindles as typically shown in
Fig. 5; the positions of the job(s) and the milling head are adjusted according to the size
and shape of the job.
Fig. 4 Planer type milling machine Fig 5. Rotary table type milling
machine
(c) According to the orientation of the spindle(s).
• Plain horizontal knee type (Fig. 6)
This non-automatic general purpose milling machine of small to medium size
possesses a single horizontal axis milling arbour; the work-table can be linearly fed
along three axes (X,Y, Z) only; these milling machines are most widely used for piece or
batch production of jobs of relatively simpler configuration and geometry
Fig. 6 Plain horizontal knee type milling machine
• Horizontal axis (spindle) and swivelling bed type
Dept. of Mechanical Engg., S. V. National Institute of Technology, Surat
4. Workshop on Machine Tools & Applications. June 9-13, 2008
These are very similar to the plain horizontal arbour knee type machines but
possess one additional swivelling motion of the work- table
• Vertical spindle type
In this machine, typically shown in Fig. 7 the only spindle is vertical and works
using end mill type and face milling cutters; the table may or may not have swivelling
features
• Universal head milling machine
These versatile milling machines, typically shown in Fig. 8 not only possess both
horizontal milling arbour and the vertical axis spindle, the latter spindle can be
further tilted about one (X) or both the horizontal axes (X and Y) enabling machining
jobs of complex shape.
Fig. 7 Vertical spindle type milling machine
Fig 8 Universal head milling (a,b)
(d) According to mechanisation / automation and production rate
Milling machines are mostly general purpose and used for piece or small lot production. But like
other machine tools, some milling machines are also incorporated with certain type and degree
of automation or mechanisation to enhance production rate and consistency of product quality.
In this respect milling machines can be further classified as follows :
Dept. of Mechanical Engg., S. V. National Institute of Technology, Surat
5. Workshop on Machine Tools & Applications. June 9-13, 2008
• Hand mill (milling machine) - this is the simplest form of milling machine where
even the table feed is also given manually as can be seen in Fig. 9.
Fig. 9 Hand mill milling machin
Dept. of Mechanical Engg., S. V. National Institute of Technology, Surat
6. Workshop on Machine Tools & Applications. June 9-13, 2008
• Planer and rotary table type vertical axis milling machines are not that automated but
provide relatively higher production rate
• Tracer controlled copy milling machine, typically shown in Fig. 10 are
mechanically or hydraulically operated semi-automatic milling machines used for
lot production of cams, dies etc by copying the master piece
• Milling machines for short thread milling may be considered single purpose
and automatic machine being used for mass production of small bolts and screws.
Fig.10 Tracer controlled milling machine
• Computer Numerical Controlled (CNC) milling machine
Replacement of hard or rigid automation by Flexible automation by developing and using
CNC has made a great break through since mid seventies in the field of machine tools’
control. The advantageous characteristics of CNC machine tools over conventional ones are :
• flexibility in automation
• change-over (product) time, effort and cost are much less
• less or no jigs and fixtures are needed
• complex geometry can be easily machined
• high product quality and its consistency
• optimum working condition is possible
• lesser breakdown and maintenance requirement
Fig. 11 typically shows a CNC milling machine. The versatility of CNC milling machine has
been further enhanced by developing what is called
Machining Centre. Fig. 12 visualises one of such Machining Centres.
Dept. of Mechanical Engg., S. V. National Institute of Technology, Surat
7. Workshop on Machine Tools & Applications. June 9-13, 2008
Fig. 11 and 12 CNC milling machine and milling centre
Dept. of Mechanical Engg., S. V. National Institute of Technology, Surat
8. Workshop on Machine Tools & Applications. June 9-13, 2008
(iii) Kinematic system of milling machine
The kinematic system comprising of a number of kinematic chains of several mechanisms enables
transmission of motions (and power) from the motor to the cutting tool for its rotation at varying
speeds and to the work-table for its slow feed motions along X, Y and Z directions. In some milling
machines the vertical feed is given to the milling(cutter) head. The more versatile milling
machines additionally possess the provisions of rotating the work table and tilting the vertical
milling spindle about X and / or Y axes.
Fig. 13 typically shows the kinematic diagram of the most common and widely used milling
machine having rotation of the single horizontal spindle or arbour and three feed motions of the work-
table in X, Y and Z directions.
The milling cutter mounted on the horizontal milling arbour, receives its rotary motion at different
speeds from the main motor through the speed gear box which with the help of cluster gears splits the
single speed into desirably large number(12, 16, 18, 24 etc) of spindle speeds. Power is
transmitted to the speed gear box through Vee-belts and a safety clutch as shown in the
diagram. For the feed motions of the workpiece (mounted on the work-table) independently, the cutter
speed, rotation of the input shaft of the speed gear box is transmitted to the feed gear box through
reduction (of speed) by worm and worm wheels as shown. The cluster gears in the feed gear box enables
provide a number of feed rates desirably. The feeds of the job can be given both manually by
rotating the respective wheels by hand as well as automatically by engaging the respective
clutches. The directions of the longitudinal (X), cross (Y) and vertical (Z) feeds are
controlled by appropriately shifting the clutches. The system is so designed that the longitudinal
feed can be combined with the cross feed or vertical feed but cross feed and vertical feed cannot
be obtained simultaneously. This is done for safety purpose. A telescopic shaft with universal joints
at its ends is incorporated to transmit feed motion from the fixed position of the feed gear box to the
bed (and table) which moves up and down requiring change in length and orientation of the shaft.
The diagram also depicts that a separate small motor is provided for quick traverse of the bed and table
with the help of an over running clutch. During the slow working feeds the rotation is
transmitted from the worm and worm wheel to the inner shaft through three equi-spaced rollers
which get jammed into the tapering passage. During quick unworking work-traverse, the shaft is
directly rotated by that motor on-line without stopping or slowing down the worm. Longer arbours
can also be fitted, if needed, by stretching the over-arm. The base of the milling machine is
grouted on the concrete floor or foundation.
Dept. of Mechanical Engg., S. V. National Institute of Technology, Surat
9. Workshop on Machine Tools & Applications. June 9-13, 2008
Fig. 13 Kinematic diagram of a milling machine
(iv) Various applications of milling machines using different
types of milling cutters.
Milling machines are mostly general purpose and have wide range of
applications requiring various types and size of milling cutters.
Intermittent cutting nature and usually complex geometry necessitate making the milling
Dept. of Mechanical Engg., S. V. National Institute of Technology, Surat
10. Workshop on Machine Tools & Applications. June 9-13, 2008
cutters mostly by HSS which is unique for high tensile and transverse rupture
strength, fracture toughness and formability almost in al respects i.e. forging, rolling,
powdering, welding, heat treatment, machining (in annealed condition) and grinding.
Tougher grade cemented carbides are also used without or with coating, where feasible, for
high productivity and product quality.
Broad classifications of milling cutters
Milling cutters are broadly classified as,
(a) Profile sharpened cutters – where the geometry of the machined surfaces are
not related with the tool shape, viz;
i. Slab or plain milling cutter : straight or helical fluted
ii. side milling cutters – single side or both sided type
iii. slotting cutter
iv. slitting or parting tools
v. end milling cutters – with straight or taper shank
vi. face milling cutters
(b) Form relieved cutters – where the job profile becomes the replica of the tool-form,
e.g., viz.;
i. Form cutters
ii. gear (teeth) milling cutters
iii. spline shaft cutters
iv. tool form cutters
v. T-slot cutters
vi. Thread milling cutter
Various uses of different milling cutters and milling machines
Use of profile sharpened cutters
The profile sharpened cutters are inherently used for making flat surfaces or surface bounded
by a number of flat surfaces only.
• Slab or Plain milling cutters : -
Plain milling cutters are hollow straight HSS cylinder of 40 to 80 mm outer
diameter having 4 to 16 straight or helical equi-spaced flutes or cutting edges and are used in
horizontal arbour to machine flat surface as shown in Fig. 14.
Fig. 14 Machining flat surface by slab milling.
Dept. of Mechanical Engg., S. V. National Institute of Technology, Surat
11. Workshop on Machine Tools & Applications. June 9-13, 2008
• Side and slot milling cutters
These arbour mounted disc type cutters have a large number of cutting teeth at equal spacing on
the periphery. Each tooth has a peripheral cutting edge and another cutting edge on one face in case of
single side cutter and two more cutting edges on both the faces leading to double sided cutter. One
sided cutters are used to produce one flat surface or steps comprising two flat surfaces at right angle as
shown in Fig. 15 Both sided cutters are used for making rectangular slots bounded by three flat
surfaces. Slotting is also done by another similar cutter having only one straight peripheral cutting
on each tooth. These cutters may be made from a single piece of HSS or its teeth may be of carbide
blades brazed on the periphery or clamped type uncoated or coated carbide inserts for high
production machining.
• Slitting saw or parting tool (Fig. 15)
These milling cutters are very similar to the slotting cutters having only one peripheral cutting
edge on each tooth. However, the slitting saws are larger in diameter and much thin possess
large number of cutting teeth but of small size used only for slitting or parting
(a) parallel facing by (b) slotting by side (double sided)
two side (single) cutter
(c) Parting by slitting saw
Fig. 15 Side milling cutters and slitting saw their use
• End milling cutters or End mills
The shape and the common applications of end milling cutters (profile
sharpened type) are shown in Fig.16 The common features and
characteristics of such cutters are :
mostly made of HSS
4 to 12 straight or helical teeth on the periphery and face diameter ranges from
about 1 mm to 40 mm
very versatile and widely used in vertical spindle type milling
machines
Dept. of Mechanical Engg., S. V. National Institute of Technology, Surat
12. Workshop on Machine Tools & Applications. June 9-13, 2008
end milling cutters requiring larger diameter are made as a
separate cutter body which is fitted in the spindle through a
taper shank arbour as shown in the same figure.
Dept. of Mechanical Engg., S. V. National Institute of Technology, Surat
13. Workshop on Machine Tools & Applications. June 9-13, 2008
• Face milling cutters
The shape, geometry and typical use of face milling cutters are shown in
fig. 17.
The main features are
(a) face milling (b) angular milling
(c) slotting
(d) shell milling
Fig. 16 Use of end milling cutters and shell mill
• Face milling cutters
The shape, geometry and typical use of face milling cutters are shown in
Fig. 17
The main features are :
• usually large in diameter (80 to 800 mm) and heavy
• used only for machining flat surfaces in different orientations
• mounted directly in the vertical and / or horizontal spindles
• coated or uncoated carbide inserts are clamped at the outer
edge of the carbon steel body as shown
• generally used for high production machining of large jobs.
Dept. of Mechanical Engg., S. V. National Institute of Technology, Surat
14. Workshop on Machine Tools & Applications. June 9-13, 2008
Fig 17 Face milling cutter and their working
Use of form relieved cutters (milling)
The distinguishing characteristics of such cutters, in contrast to profile
sharpened cutters, are ;
• form of the tool is exactly replica of the job-profile to be made
• clearance or flank surfaces of the teeth are of archemedian
spiral shaped instead of flat
• teeth are sharpened by grinding the rake surface only
• used for making 2-D and 3-D contour surfaces
The configurations and applications of several form relieved type milling
cutters of common use are briefly presented.
• Form cutters
Such disc type HSS cutters are generally used for making grooves or
slots of various profiles as indicated in Fig. 4.3.18.
Form cutters may be also end mill type like T-slot cutter as shown in Fig.
4.3.19
Fig. 18 Form cutters and their use
Fig 19 cutting Tslots
• Gear teeth milling cutters
Gear milling cutters are made of HSS and available mostly in disc form like slot
milling cutters and also in the form of end mill for producing teeth of large module
gears. The form of these tools conform to the shape of the gear tooth-gaps
bounded by two involutes as shown in Fig. 20 Such form relieved cutters can
Dept. of Mechanical Engg., S. V. National Institute of Technology, Surat
15. Workshop on Machine Tools & Applications. June 9-13, 2008
be used for producing teeth of straight and helical toothed external spur gears
and worm wheels as well a
Straight toothed bevel gears.
Fig. 20 Gear milling cutters and their use
• Spline shaft cutters
These disc type HSS form relieved cutters are used for cutting the slots of
external spline shafts having 4 to 8 straight axial teeth. Fig.21 typically
shows such application.
Fig. 21 Spline shaft cutter
• Tool form cutters
Form milling type cutters are also used widely for cutting slots or flutes of
different cross section e.g. the flutes of twist drills (Fig. 22), milling cutters,
reamers etc., and gushing of hobs, taps, short thread milling cutters etc.
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16. Workshop on Machine Tools & Applications. June 9-13, 2008
Fig. 22 Cutting of drill flutes by form milling cutter
• Thread milling cutter
Such shank type solid HSS or carbide cutters having thread like annular
grooves with equi-spaced gushings are used in automatic single purpose milling
machines for cutting the threads in large lot production of screws, bolts etc. Both
internal and external threads are cut by the tool as shown in Fig. 23. The milling
cutter and its use in long thread milling (e.g. lead screws, power screws,
worms etc.) are shown in Fig. 24
Fig. 23 short thread milling Fig. 24 Long thread milling
Dept. of Mechanical Engg., S. V. National Institute of Technology, Surat
17. Some other applications of milling machines using suitable milling cutters
• Straddle milling
For faster and accurate machining two parallel vertical surfaces at a
definite distance, two separate side milling cutters are mounted at
appropriate distance on the horizontal milling arbour as shown in Fig. 25.
Fig. 25 Straddle milling
• Gang milling
In gang milling, being employed, where feasible, for quick production of complex
contours comprising a number of parallel flat or curved surfaces a proper
combination of several cutters are mounted tightly on the same horizontal milling
arbour as indicated in Fig. 4.3.26
Fig. 26 Gang milling
• Ball-nose end mill
Small HSS end mill with ball like hemispherical end , as shown in Fig. 28, is
often used in CNC milling machines for machining free form 3-
D or 2-D contoured surfaces.
Fig. 27 Ball nose end mills
Ball nose end mills may be made of HSS, solid carbide or steel body with
18. coated or uncoated carbide inserts clamped at its end as can be seen in the figure.
Beside the aforesaid applications, the versatile milling processes using several
other types of milling cutters are employed for many other machining work like cam
milling, keyway cutting, making hob cutter and so on. For enhancing capability
range of milling work a number of attachments are fitted in the milling machines. Such
milling attachments include
• universal milling and spiral milling attachment
• indexing head – simple, compound and differential type
• universal milling and spiral milling attachment
• copying attachment (mechanical and hydraulic (tracer control))
• slotting attachment
• Gear milling
Milling is a form-cutting process limited to making single gears for prototype or very
small batches of gears as it is a very slow and uneconomical method of production. A
involute form-milling cutter, which has the the profile of the space between the gears,
is used to remove the material between the teeth from the gear blank on a horizontal
milling machine. The depth of cut into the gear blank depends on the cutter strength,
set-up rigidity and machineability of the gear blank material.