The document provides information about milling technology and includes the following sections:
- Introduction to milling types, movements, and cutting tools
- Machine types including conventional, CNC, and multitasking machines
- Workholding devices such as vises, clamps, rotary tables, and dedicated fixtures
- Toolholding devices including collet chucks, shrink fit, and spindle types
- Safety guidelines, applications, and a glossary are also listed as upcoming sections.
Modern precision manufacturing demands extreme dimensional accuracy and surface finish.Such performance is very difficult to achieve manually, if not impossible, even with expert operators. In cases where it is possible, it takes much higher time due to the need for frequent dimensional measurement to prevent overcutting. It is thus obvious that automated motion control would replace manual “handwheel” control in modern manufacturing. Development of computer numerically controlled (CNC) machines has also made possible the automation of the machining processes with flexibility to handle production of small to medium batch of parts. In the 1940s when the U.S. Air Force perceived the need to manufacture complex parts for highspeed aircraft. This led to the development of computer-based automatic machine tool controls also known as the Numerical Control (NC) systems. Commercial production of NC machine tools started around the fifties and sixties around the world. Note that at this time the microprocessor has not yet been invented. Initially, the CNC technology was applied on lathes, milling machines, etc. which could perform a single type of metal cutting operation. Later, attempt was made to handle a variety of workpieces that may require several different types machining operations and to finish them in a single set-up. Thus CNC machining Centres capable of performing multiple operations were developed. To start with, CNC machining centres were developed for machining prismatic components combining operations like milling, drilling, boring and tapping. Gradually machines for manufacturing cylindrical components, called turning centers were developed.
Automatically controlling a machine tool based on a set of pre-programmed machining and movement instructions is known as numerical control, or NC.In a typical NC system the motion and machining instructions and the related numerical data, together called a part program, used to be written on a punched tape. The part program is arranged in the form of blocks of information, each related to a particular operation in a sequence
of operations needed for producing a mechanical component. The punched tape used to be read one block at a time. Each block contained, in a particular syntax, information needed for processing a particular machining instruction such as, the segment length, its cutting speed, feed, etc. These pieces of information were related to the final dimensions of the workpiece (length, width, and radii of circles) and the contour forms (linear, circular, or other) as per the drawing. Based on these dimensions, motion commands were given separately for each axis of motion. Other instructions and related machining parameters, such as cutting speed, feed rate, as well as auxiliary functions related to coolant flow, spindle speed, part clamping, are also provided in part programs depending on manufacturing specifications such as tolerance and surface finish. Punched tapes are mostly obsolete.
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
The one of the major part of CNC Machine is Cutting tools or Inserts. We need to study the Cutting tools and its nomenclature throughly and also study the materials of Cutting tools and types of tools. The Cutting tools are used to remove unwanted materials in the workpiece and to provide a good finish for a customers need.So the Cutting tools is very important to CNC Machine, if there is no cutting tool in CNC Machine, there is no CNC Machine. So the cutting tools are very important to all CNC Machines
Modern precision manufacturing demands extreme dimensional accuracy and surface finish.Such performance is very difficult to achieve manually, if not impossible, even with expert operators. In cases where it is possible, it takes much higher time due to the need for frequent dimensional measurement to prevent overcutting. It is thus obvious that automated motion control would replace manual “handwheel” control in modern manufacturing. Development of computer numerically controlled (CNC) machines has also made possible the automation of the machining processes with flexibility to handle production of small to medium batch of parts. In the 1940s when the U.S. Air Force perceived the need to manufacture complex parts for highspeed aircraft. This led to the development of computer-based automatic machine tool controls also known as the Numerical Control (NC) systems. Commercial production of NC machine tools started around the fifties and sixties around the world. Note that at this time the microprocessor has not yet been invented. Initially, the CNC technology was applied on lathes, milling machines, etc. which could perform a single type of metal cutting operation. Later, attempt was made to handle a variety of workpieces that may require several different types machining operations and to finish them in a single set-up. Thus CNC machining Centres capable of performing multiple operations were developed. To start with, CNC machining centres were developed for machining prismatic components combining operations like milling, drilling, boring and tapping. Gradually machines for manufacturing cylindrical components, called turning centers were developed.
Automatically controlling a machine tool based on a set of pre-programmed machining and movement instructions is known as numerical control, or NC.In a typical NC system the motion and machining instructions and the related numerical data, together called a part program, used to be written on a punched tape. The part program is arranged in the form of blocks of information, each related to a particular operation in a sequence
of operations needed for producing a mechanical component. The punched tape used to be read one block at a time. Each block contained, in a particular syntax, information needed for processing a particular machining instruction such as, the segment length, its cutting speed, feed, etc. These pieces of information were related to the final dimensions of the workpiece (length, width, and radii of circles) and the contour forms (linear, circular, or other) as per the drawing. Based on these dimensions, motion commands were given separately for each axis of motion. Other instructions and related machining parameters, such as cutting speed, feed rate, as well as auxiliary functions related to coolant flow, spindle speed, part clamping, are also provided in part programs depending on manufacturing specifications such as tolerance and surface finish. Punched tapes are mostly obsolete.
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
The one of the major part of CNC Machine is Cutting tools or Inserts. We need to study the Cutting tools and its nomenclature throughly and also study the materials of Cutting tools and types of tools. The Cutting tools are used to remove unwanted materials in the workpiece and to provide a good finish for a customers need.So the Cutting tools is very important to CNC Machine, if there is no cutting tool in CNC Machine, there is no CNC Machine. So the cutting tools are very important to all CNC Machines
Microtechnologies: past, present and futureendika55
Microtechnologies description: past, present and future
Mikroteknologien deskribapena: lehena, oraina eta geroa
Descripción de las microtecnologías: pasado, presente y futuro
Without curious minds, our transportation system would, quite literally, come to a standstill. In a very real way, the transportation research process keeps the system moving, and that process starts with a seemingly simple question: How can we do this better? Asking that question shines the light of innovation on the status quo to help make transportation safer, smarter and more efficient.
CE Marking can in simple terms be described as a passport or ”License to sell” allowing free movement within the internal market of the European Union.
Our Industrial Safety glove is a Personnel Protective Equipment [PPE].
The legal instrument laying down the requirements for CE marking of PPE is the European Directive 89/686/EEC.
Testing according to the EN 388, EN 420, EN 407 and EN 511 is covered in this article.
Transform Westside Summit Atlanta University CenterJBHackk
The 19th Transform Westside Summit focused on the DRAFT action plan for the Atlanta University Center and its surrounding neighborhoods (the fifth of five target areas). Stakeholder and community input, market research and previous plan reviews were collected to create schematic designs and visuals for the neighborhood. The Action Plan Team shared its initial findings and recommendations for the regeneration of the neighborhoods in conjunction with planned infrastructure improvements. Questions and public input are welcome and encouraged. This is the fifth of a series of presentations to engage stakeholders and the community in creating a comprehensive Land-Use Action Plan for the Westside.
Improving Safety Culture and Safety Program can have huge dividends in profitability for the company. Not only in insurance costs but improving the overall bottom line. This was a presentation I did in Omaha for the Occupational Health and Safety.
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.
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
Presentation on different types of machine,spur gear making, single point cut...Reshad Ibn Momin
Different types of machines,such as
#Lathe Machine
#Milling Machine
#Grinding Machine
#Drilling Machine
#Shaper&Planer
and Spur Gear Making ,making of single point cutting tool.
Presented By the RESHAD,BAPPY,RAJIB,SAORAV,Kadery. (13 batch) Mechanical Engineering Dept of Chittagong University of Engineering & technology.
Manufacturing Technologies bibliography.for presentations.
Fabrikazio Teknologien aurkezpenetan erabilitako bibliografia.
Bibliografía empleada en las presentaciones de Tecnologías de Fabricación.
Manufacturing Technologies bibliography.for presentations.
Fabrikazio Teknologien aurkezpenetan erabilitako bibliografia.
Bibliografía empleada en las presentaciones de Tecnologías de Fabricación.
Microtechnologies: Past, present and futureendika55
Microtechnologies description: past, present and future
Mikroteknologien deskribapena: lehena, oraina eta geroa
Descripción de las Microtecnologías: pasado, presente y futuro
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Quality defects in TMT Bars, Possible causes and Potential Solutions.PrashantGoswami42
Maintaining high-quality standards in the production of TMT bars is crucial for ensuring structural integrity in construction. Addressing common defects through careful monitoring, standardized processes, and advanced technology can significantly improve the quality of TMT bars. Continuous training and adherence to quality control measures will also play a pivotal role in minimizing these defects.
TECHNICAL TRAINING MANUAL GENERAL FAMILIARIZATION COURSEDuvanRamosGarzon1
AIRCRAFT GENERAL
The Single Aisle is the most advanced family aircraft in service today, with fly-by-wire flight controls.
The A318, A319, A320 and A321 are twin-engine subsonic medium range aircraft.
The family offers a choice of engines
Forklift Classes Overview by Intella PartsIntella Parts
Discover the different forklift classes and their specific applications. Learn how to choose the right forklift for your needs to ensure safety, efficiency, and compliance in your operations.
For more technical information, visit our website https://intellaparts.com
Event Management System Vb Net Project Report.pdfKamal Acharya
In present era, the scopes of information technology growing with a very fast .We do not see any are untouched from this industry. The scope of information technology has become wider includes: Business and industry. Household Business, Communication, Education, Entertainment, Science, Medicine, Engineering, Distance Learning, Weather Forecasting. Carrier Searching and so on.
My project named “Event Management System” is software that store and maintained all events coordinated in college. It also helpful to print related reports. My project will help to record the events coordinated by faculties with their Name, Event subject, date & details in an efficient & effective ways.
In my system we have to make a system by which a user can record all events coordinated by a particular faculty. In our proposed system some more featured are added which differs it from the existing system such as security.
Vaccine management system project report documentation..pdfKamal Acharya
The Division of Vaccine and Immunization is facing increasing difficulty monitoring vaccines and other commodities distribution once they have been distributed from the national stores. With the introduction of new vaccines, more challenges have been anticipated with this additions posing serious threat to the already over strained vaccine supply chain system in Kenya.
About
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Automobile Management System Project Report.pdfKamal Acharya
The proposed project is developed to manage the automobile in the automobile dealer company. The main module in this project is login, automobile management, customer management, sales, complaints and reports. The first module is the login. The automobile showroom owner should login to the project for usage. The username and password are verified and if it is correct, next form opens. If the username and password are not correct, it shows the error message.
When a customer search for a automobile, if the automobile is available, they will be taken to a page that shows the details of the automobile including automobile name, automobile ID, quantity, price etc. “Automobile Management System” is useful for maintaining automobiles, customers effectively and hence helps for establishing good relation between customer and automobile organization. It contains various customized modules for effectively maintaining automobiles and stock information accurately and safely.
When the automobile is sold to the customer, stock will be reduced automatically. When a new purchase is made, stock will be increased automatically. While selecting automobiles for sale, the proposed software will automatically check for total number of available stock of that particular item, if the total stock of that particular item is less than 5, software will notify the user to purchase the particular item.
Also when the user tries to sale items which are not in stock, the system will prompt the user that the stock is not enough. Customers of this system can search for a automobile; can purchase a automobile easily by selecting fast. On the other hand the stock of automobiles can be maintained perfectly by the automobile shop manager overcoming the drawbacks of existing system.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfKamal Acharya
The College Bus Management system is completely developed by Visual Basic .NET Version. The application is connect with most secured database language MS SQL Server. The application is develop by using best combination of front-end and back-end languages. The application is totally design like flat user interface. This flat user interface is more attractive user interface in 2017. The application is gives more important to the system functionality. The application is to manage the student’s details, driver’s details, bus details, bus route details, bus fees details and more. The application has only one unit for admin. The admin can manage the entire application. The admin can login into the application by using username and password of the admin. The application is develop for big and small colleges. It is more user friendly for non-computer person. Even they can easily learn how to manage the application within hours. The application is more secure by the admin. The system will give an effective output for the VB.Net and SQL Server given as input to the system. The compiled java program given as input to the system, after scanning the program will generate different reports. The application generates the report for users. The admin can view and download the report of the data. The application deliver the excel format reports. Because, excel formatted reports is very easy to understand the income and expense of the college bus. This application is mainly develop for windows operating system users. In 2017, 73% of people enterprises are using windows operating system. So the application will easily install for all the windows operating system users. The application-developed size is very low. The application consumes very low space in disk. Therefore, the user can allocate very minimum local disk space for this application.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
5. 5
The author would like to thank all the bibliographic references and videos that
have contributed to the elaboration of these presentations.
For bibliographic references, please refer to:
• http://www.slideshare.net/endika55/bibliography-71763364 (PDF file)
• http://www.slideshare.net/endika55/bibliography-71763366 (PPT file)
For videos, please refer to:
• www.symbaloo.com/mix/manufacturingtechnology
BIBLIOGRAPHY
by Endika Gandarias
7. 7
MILLING TECHNOLOGY
INTRODUCTION
BASIC MOVEMENTS:
– Mc Cutting movement (regarding the tool)
– Ma Feed movement (regarding the part or tool)
– Mp Cutting depth movement (regarding the
part or tool)
by Endika Gandarias
Mc
Mp
Ma
8. 8
Eli Whitney milling machine
1818
Middletown milling machine
1818
Nasmyth milling machine
1829
Lincoln miller
1870
Universal milling machine
Brown-and-Sharpe
1861
Horizontal milling machine
Cincinnati
early 1900s
INTRODUCTION
by Endika Gandarias
9. 9
N
N
F
DC
ae
ap
A milling cutting tool is similar to the
turning cutting tool, but many tools called
“teeth” integrate it.
• The tool is spinning (Mc).
• One or more linear movements
(Mp & Ma) may have the tool or the
part.
INTRODUCTION
by Endika Gandarias
N Spindle speed (rpm)
Vc Cutting speed (m/min)
Dc Tool diameter (mm)
F Feed rate (mm/min)
ap Axial cutting depth (mm)
ae Radial cutting depth (mm)
11. 11
Face Milling
Shoulder Milling
(Face & Side Milling)
Side or Peripheral
Milling
• Cutting depth in axial
direction.
• It uses mainly the cutting edges
on the periphery of the tool.
• Surface roughness created by
face teeth.
• Cutting depth in axial and
radial direction.
• It uses the cutting edges on the
face and periphery of the tool.
• Surface roughness created by
face and side teeth.
• Cutting depth in radial
direction.
• It uses mainly the cutting edges
on the periphery of the tool.
• Surface roughness created by
side teeth.
INTRODUCTION: MILLING TYPES
Mc:
Cutting mov.
Ma:
Feed mov.
by Endika Gandarias
Mc:
Cutting mov.
Ma:
Feed mov.
Mc:
Cutting mov.
Ma:
Feed mov.
13. 13
Horizontal and Vertical Milling machines
According to their main rotational axis…
MACHINE TYPES
Rotational axis
direction
Rotational axis
direction
by Endika Gandarias
Horizontal Milling MachineVertical Milling Machine
14. 14
Mc: Cutting
movement
Ma: Feed
movement
Mp: Cutting depth
movement
Mc: Cutting
movement
Ma: Feed
movement
Mp: Cutting depth
movement
Horizontal and Vertical Milling machines
According to their main rotational axis…
MACHINE TYPES
by Endika Gandarias
Horizontal Milling MachineVertical Milling Machine
15. 15
MACHINE TYPES
MILLINGMACHINES
Conventional machines
Column and knee type
Vertical
Horizontal
Universal
Bed type
Copy or tracer mill
CNC machines
CNC Milling machine
Bed type
Bridge type or planer
Gantry
Travelling column
Machining centre
3 axis
4 axis
5 axis
Multitasking machine
by Endika Gandarias
16. 16
Manual movements execution.
Manual tool and part change.
Machine may have or not an overarm: Spindle mounted to a movable
housing on the column to permit positioning the milling cutter forward or
rearward in a horizontal plane.
Machine principal components:
1. Column: supports the spindle. The tool has no linear movements,
just the rotational cutting movement.
2. Knee: supports the work table. It has all the linear movements: X, Y
& Z.
Machine types:
1. VERTICAL MACHINE
2. HORIZONTAL MACHINE
3. UNIVERSAL MACHINE
MACHINE TYPES
Z
X
Y
Conventional milling machines
Column and knee type (turret type)
by Endika Gandarias
VIDEO
17. 17
Conventional milling machines
MACHINE TYPES
Cutter is directly mounted in the spindle.
Typical for face and end milling operations.
Arbor supports the cutter and an overarm
the arbor.
Typical for side or peripheral milling
operations.
1 2
Column and knee type (turret type)
VERTICAL MILLING MACHINE HORIZONTAL MILLING MACHINE
by Endika Gandarias
18. 18
It is a vertical and horizontal milling machine at the same time.
Types:
MACHINE TYPES
Conventional milling machines
3
Vertical & horizontal
spindle
Hure spindle:
It has a swiveling spindle that allows to swivel the
spindle at different angles. Vertical milling
attachment
Column and knee type (turret type)
UNIVERSAL MILLING MACHINE
by Endika Gandarias
VIDEOVIDEO
19. 19
The tool has the perpendicular movement.
The worktable has the X & Y movements.
Greater rigidity. Used for voluminous and
heavy parts.
A special machine type:
» It has a roughing spindle and a
finishing spindle.
Conventional milling machines
Bed type
Z
MACHINE TYPES
ROTARY TABLE TYPE
by Endika Gandarias
Z
20. 20
A stylus follows the profile of a template and guides the
cutter movement synchronizing with the table movement,
to produce a similar profile as on the template.
The movement of the stylus is controlled through
electronic or hydraulic systems.
It is used for engraving small and height profiles,
producing cams, dies,…
Machining time: important.
Idle time: small.
Set-up time: important.
Series: Unitary or medium.
Precision: IT7/8, Ra ~ 1.6 µm.
MACHINE TYPES
Conventional milling machines
Copy or Traced Controlled milling machine
by Endika Gandarias
22. 22
Automatic movements execution.
Manual tool change.
Manual part change.
Usually, it is not needed any special workholding
device.
Machining time: less than in an universal milling.
Idle time: very short
Set-up time: slightly important (programming)
Series: 10 to 1000 parts, or more.
Precision: IT7/8, Ra ~ 0.8 ÷1.6 µm.
MACHINE TYPES
CNC machines
CNC Milling machine
by Endika Gandarias
23. 23
The part has the longitudinal axis movement.
Spindle carriers are mounted on cross-rails (bridge structure).
Large size milling machines.
Suitable for flat surfaces of heavy components.
May use several spindle heads (vertical or horizontal).
Bed type
MACHINE TYPES
1
CNC machines
BRIDGE TYPE OR PLANER MILLING MACHINE
by Endika Gandarias
Y
X
Z
VIDEO
24. 24
Similar to the bridge type machine, but
the workpiece has no movement at all.
Typically used for large size parts.
The part has no movement at all.
Bed type
MACHINE TYPES
2 3
CNC machines
GANTRY MILLING MACHINE TRAVELLING COLUMN MILLING MACHINE
by Endika Gandarias
Y
Z
X
X
Z
Y
VIDEO VIDEO
25. 25
It is a CNC milling machine equipped by an
automatic tool changer.
Automatic tool changer using tool magazine or
carousel.
Automatic part changer using pallets (optional).
Machining time: similar to CNC Milling machines.
Idle time: smaller than in CNC Milling machines.
Set-up time: slightly important (programming &
setting-up)
Series: 10 to 1000 parts, or more
Precision: IT7/8, Ra ~ 0.8 ÷1.6 µm.
MACHINE TYPES
CNC machines
Machining Centre
tool magazine tool carousel
tool magazine CNC
by Endika Gandarias
26. 26
Automatic tool changer
Automatic part changer
(pallets)
(optional)
MACHINE TYPES
CNC machines
Machining Centre
by Endika Gandarias
VIDEO
VIDEO
27. 27
MACHINE TYPES
CNC machines
Machining Centre
Machine has CNC controlled
X,Y & Z linear movements.
Machine has CNC controlled X,Y & Z linear movements
+ 1 rotational movement.
a) Horizontal rotary table
b) Vertical rotary table
c) Rotary spindle
To obtain surfaces with a cylindrical pattern (e.g. gears,
polygonal geometries,…).
3 AXIS
4 AXIS
Integrated vertical rotary table
(C axis)
Horizontal rotary table (A axis)
by Endika Gandarias
VIDEO VIDEO
28. 28
MACHINE TYPES
CNC machines
Machining Centre
Machine has CNC controlled X,Y & Z linear movements
+ 2 rotational movements.
Types:
Trunnion table
Vertical machine Horizontal machine
Combination type
Swiveling head
Heavier parts can be machined.
Shorter tools are needed.
A larger working volume.
More powerful spindle Heavier removal
rates.
Bigger rotational movement capability.
1
2
3
5 AXIS
by Endika Gandarias
Higher versatility (part can be clamped
on the rotary table or out of it).
VIDEO
VIDEO
29. 29
• Several technologies are integrated into one machine:
turning, milling, drilling,…
• It has evolved from turning machines.
• The heart of the machine is the tool spindle (B
spindle), which even can be tilted. It provides milling,
drilling and tapping capability along with turning,
facing, grooving and threading.
• This spindle is serviced by an automatic tool changer
that resides outside the cutting zone.
• It may have a double spindle and one/two tool turrets.
• Application: very complex parts.
VIDEO
MACHINE TYPES
CNC machines
Machining Centre MULTITASKING MACHINE – HORIZONTAL (I)
by Endika Gandarias
31. 31
• Parts normally larger in diameter than for a horizontal
multi-task machine.
• Does not require support via a steady rest, tailstock or
sub-spindle.
• It has evolved from 5 axis machining centers:
a) High rpm capability of the C axis (turning table).
b) Adopting the spindle for stationary operations.
MACHINE TYPES
CNC machines
Machining Centre MULTITASKING MACHINE – VERTICAL
by Endika Gandarias
Trunnion table
Combination type
VIDEO
33. 33
WORKHOLDINGDEVICES
Vise
Clamps
Modular fixturing system
Indexer / Rotary table
Magnetic chuck
Vacuum chuck
Freeze chuck
Dedicated fixture
Features of a workholding device:
Proper part immobilization.
Accesibility to the machining area.
Ability to absorb machining efforts.
Minimum part deformation.
Short part clamping & unclamping time.
by Endika Gandarias
WORKHOLDING DEVICES
VIDEO
34. 34
Vise
The most common type of workholding
device for small parts.
Part is hold by pressure driven:
Mechanically
Pneumatically
Hydraulically
Types based on the degree of freedom:
Plain vise
Plain vise with swivel base
Universal vise with swivel base
Plain vise Plain vise with swivel base Universal vise
by Endika Gandarias
WORKHOLDING DEVICES
HYDRAULIC VISEPNEUMATIC VISE
MECHANICAL VISE VIDEO
35. 35
Clamps
Used for big size or irregular parts.
Part is hold using clamps, t-slot bolts, screws, washers, nuts, parallels, step blocks,…
It is important to keep in mind the efforts/deformations produced on the part.
by Endika Gandarias
WORKHOLDING DEVICES
Step block
Toe mold clamp
Angle plate
Cam clamp
Washer
C clamp V blockSwing clamp
T-nut
T-slot bolt
VIDEO
36. 36
Modular fixturing system
Based on a drilled and/or grooved baseplate.
It offers flexibility or versatility.
It allows to build different workholding systems from a set of standard
components (clamps, positioners,…).
by Endika Gandarias
WORKHOLDING DEVICES
VIDEOVIDEO
37. 37
Commonly used for machining angularly equidistant surfaces.
The chuck allows to hold and rotate the part working at different
angles.
Similar clamping possibilities to the turning process:
Jaw chuck
Between chuck and center
Between centers
Indexing head / Rotary table
by Endika Gandarias
WORKHOLDING DEVICES
MOTOR DRIVEN
MANUALLY OPERATED
VIDEO
VIDEO
VIDEO
38. 38
Magnetic Chuck
WORKHOLDING DEVICES
Ideal for ferromagnetic parts.
Powerful workholding system.
Usually electronically activated.
Part centering may be time consuming.
by Endika Gandarias
VIDEO
39. 39
Vacuum Chuck
WORKHOLDING DEVICES
Ideal for thin and flat metal sheets, non-porous surfaces.
Hold down forces are not extremely high.
Uniform holding pressure on the entire workpiece surface.
Coolant can be used without affecting the chuck’s performance.
by Endika Gandarias
VIDEO
40. 40
Freeze Chuck
WORKHOLDING DEVICES
To clamp small workpieces.
No tension builds up within the workpiece.
Clamping time +/- 90 seconds.
Holding precision ± 3μm
by Endika Gandarias
VIDEO
41. 41
Dedicated fixture
WORKHOLDING DEVICES
It is a custom-designed fixture.
Capital investment must be absorbed by the job.
It is used for medium to big-batch production runs.
by Endika Gandarias
Dedicated fixture Modular fixture
VS.
43. 43
TOOLHOLDING DEVICES
TOOLHOLDINGDEVICES TOOLHOLDER
Weldon / Whistle Notch
ER Collet chuck
Power chuck
Hydraulic chuck
Shrink fit (Thermal)
Save lock
Polygonal clamping
SPINDLE TYPE
ISO / SK / BT
HSK
Capto
BIG PLUS
KM
EXTENSION ADAPTOR
by Endika Gandarias
44. 44
Whistle NotchWeldon
ER Collet chuck
TOOLHOLDING DEVICES
Weldon / Whistle Notch
Power chuck Shrink fit (thermal)Hydraulic chuck
Toolholder
by Endika Gandarias
VIDEOVIDEO
VIDEOVIDEO
VIDEO
45. 45
Safe Lock
Pull out protection
Polygonal clamping
TOOLHOLDING DEVICES
Toolholder
by Endika Gandarias
VIDEO
Clamping steps
VIDEO
46. 46
HSKISO / SK / BT Capto
KM
Spindle type
TOOLHOLDING DEVICES
VIDEO
BIG PLUS
ISO / SK / BTBIG PLUS
by Endika Gandarias
54. 54
SIDE AND FACE MILLING
MACHINING OPERATIONS
Slot Milling
2
TOOLING
VIDEO
Horizontal milling
machine
Vertical milling
machine
Commonly used on
components that cannot
be rotated.
by Endika Gandarias
55. 55
MACHINING OPERATIONS
Helical Slot Milling
It requires a previous slot milling operation of width
bigger than the T-shape tool shank.
The use of air flow is highly recommended in order
to evacuate the chip continuously.
T-shape Slot Milling
by Endika Gandarias
It requires a coordination between the rotational
speed (N) and the feed per revolution (fn).
VIDEOVIDEO
57. 57
MACHINING OPERATIONS
Dovetail Milling Form Milling
Two or more milling cutters mounted on the same
arbor.
Displacing the cutters half a pitch in relation to
each other assists in avoiding vibration.
High productivity, high removal rate.
Medium/big series.
The use of a fly-wheel reduces torsional vibrations.
Gang Milling
by Endika Gandarias
VIDEO VIDEO
60. 60
MACHINING OPERATIONS
Gear Milling
Hobbing (productivity ↑)Disc cutting
TYPE OF GEARS
TOOLING
External & Internal gears Splines Bevel gears and pinions
by Endika Gandarias
VIDEOVIDEO VIDEOVIDEO
61. 61
A curved surface is milled while rotating
the workpiece around its centre point.
MACHINING OPERATIONS
Periphery turn milling – 3/4 axesFace turn milling – 4/5 axes
Main method for external machining. Used mainly for internal features.
Same principle as for circular milling /
ramping, but with component rotating.
2 METHODS:
Turn Milling
by Endika Gandarias
VIDEO
62. 62
VIDEO
MACHINING OPERATIONS
Boring
Excellent dimensional
tolerances and surface
roughnesses.
ROUGHING FINISHING
VIDEO
by Endika Gandarias
a a a >a
BORE FACE GROOVING
It is a productive alternative way to produce
circular grooves.
Increased productivity.
Diameters from 47mm to 1275mm.
It can be done in vertical or horizontal machines.
64. 64
MACHINING OPERATIONS
Thread Milling
by Endika Gandarias
TAPPING1
Synchronization of the feed movement and rotational movement is a must.
If the machine spindle is not prepared for direct threading, a special
toolholder needs to be used.
VIDEOVIDEO
65. 65
THREAD MILLING2
Internal threading
External threading
MACHINING OPERATIONS
by Endika Gandarias
A B
A B VIDEO
CNC thread generator: http://vargen.vargus.com/VargusGenWeb/Pages/ThreadSelection.aspx
66. 66
a) Manual reamers: long entry (A)
and length (L)
b) Milling reamers: short entry (A)
and length (L)
c) Reamer with no shank or
separated shank.
VIDEO
MACHINING OPERATIONS
The reamer never should be
spinned counterclockwise.
Reaming
Straight flute
Axial coolant supply
For blind holes
Spiral flute
Lateral coolant supply
For through holes
by Endika Gandarias
RIGHT WRONG
Objective: To achive a good surface roughness and good
dimensional tolerances (H7) in a pre-drilled hole.
High penetration rates and small depths of cut.
The tool is called “reamer”.
VIDEO
70. 70
BIOMEDICAL APPLICATIONS
VIDEOVIDEO
by Endika Gandarias
MONOBLOCK PROSTHESIS –
Titanium
BONE PLATE –
Titanium
MOULD FOR PILLS –
Steel
DENTAL BRIDGE PROSTHESIS –
Titanium
IMPLANTABLE MEDICAL PORT
OR DRUG DELIVERY SYSTEM
– Titanium
77. 77
OPERATION OVERVIEW
1. Face milling
2. Boring
3. Back facing
4. Drilling
5. Thread milling
GEARBOX HOUSING
Cast iron
WIND POWER APPLICATIONS
by Endika Gandarias
OPERATION OVERVIEW
1. Face Milling
2. Shoulder Milling
3. Helical or Circular Interpolation
4. Finish Boring
5. Back Facing
6. Drilling
7. Threading
8. Chamfering
HUB
Cast iron
78. 78
OPERATION OVERVIEW
1. Face and shoulder milling
2. Contouring
3. Fine boring
4. Drilling
5. Face milling
MAIN FRAME
Cast iron
WIND POWER APPLICATIONS
by Endika Gandarias
80. 80
GLOSSARY
by Endika Gandarias
ENGLISH SPANISH BASQUE
Angle plate Placa angular Plaka angeluar
Arbor Mandril Mandril
Bed type Bancada fija Bankada finkoa
Between centers Entre puntos Puntuen artean
Between chuck and center Plato de garras y punto Atzapardun playera eta puntuaren artean
Bevel gears Engranes cónicos Engranai konikoak
Blade Álabe Alabe
Blood Sangre Odol
Bone Hueso Hazur
Boring Mandrinado Mandrinaketa
Bridge type Tipo puente Zubi erakoa
Cam Leva Espeka
Cast iron Fundición Fundizio
Chamfering Achaflanado Alakaketa
Clamp Brida Brida
Collet chuck Portaherramientas de pinzas Pintza etxea
Coolant Refrigerante Hozkarria
Copy or tracer mill Copiadora Kopiagailua
Counterclockwise Giro antihorario Erloju orratzen aurkako biraketa
Cutting depth Profundidad de pasada axial Sakontze sakonera
Cutting speed Velocidad de corte Ebaketa abiadura
Cylinder head Culata Kulata
Dedicated fixture Utillaje específico Tresneria espezifikoa
Dovetail Cola de milano Mirubuztan
Drilling Taladrado Zulaketa
Drug Droga Droga
Ear muff / Ear plug Orejera de casco Entzumen kaskoak
Face milling Planeado Planeaketa / Lauketa
81. 81
GLOSSARY
by Endika Gandarias
ENGLISH SPANISH BASQUE
Feed per revolution Avance por vuelta Aitzinamendua birako
Feed rate Avance por minuto Aitzinamendua minutuko
Finishing Acabado Akabera
Flute Estría Ildaska
Fly-wheel Soporte Euskarri
Freeze chuck Amarre por congelación Hozte bidezko lotzea
Gang milling Fresado en grupo / Arbol de fresas Multzokako fresaketa
Gantry type Tipo pórtico Portiko erakoa
Gearbox housing Carcasa de caja de engranes Engranai kutxako karkasa
Gloves Guantes Eskularruak
Goggles Gafas de seguridad Segurtasun betaurrekoak
Hobbing Tallado Tailaketa
Hub Cubo Kubo
Hydraulic chuck Portaherramientas hidraúlico Erraminta etxe hidraulikoa
Idle time Tiempos no productivos Denbora ez produktiboa
Indexer / Rotary table Plato divisor Plater zatitzailea
Insert Plaquita intercambiable Plakatxo trukagarria
Jaw chuck Plato de garras Atzapardun platera
Knee Ménsula Mentsula
Machining centre Centro de mecanizado Mekanizazio zentrua
Machining time Tiempo de mecanizado Mekanizazio denbora
Main frame Bastidor principal Bastidore nagusia
Milling Fresado Fresaketa
Modular fixturing system Utillaje modular Tresneria modularra
Multitasking machine Máquina multitarea Ataza anitzeko makina
Numerical control Control numérico Zenbakizko kontrola
Overarm Carnero Ahari
Overhang Voladizo Hegalkina
82. 82
GLOSSARY
by Endika Gandarias
ENGLISH SPANISH BASQUE
Pallet Palet Paleta
Parallel Calzo paralelo Altxagarria
Pill Pildora Pilula
Pitch Paso Neurri
Planer Planeadora Gainazal leunak mekanizatzeko makina
Plate Placa Plaka
Power chuck Portapinzas de alto apriete Estutze haundiko pintza etxea
Reamer Escariador Otxabua
Reaming Escariado Otxabuketa
Rib Costilla Saihets
Rotary table Plato rotatorio Plater birakaria
Roughing Desbaste Arbastaketa
Safe lock Portaherramientas de amarre de seguridad Lotze ziurrezko erraminta etxea
Safety guidelines Normas de seguridad Segurtasun arauak
Set-up time Tiempo de puesta a punto Prestaketa denbora
Shoulder milling Escuadrado Eskuairaketa
Shrink fit Portaherramientas térmico Erraminta etxe termikoa
Slot milling Ranurado Artekaketa
Spindle Cabezal Burua
Spindle speed Velocidad de giro Biraketa abiadura
Stainless steel Acero inoxidable Altzairu erdoilgaitza
Stamping die Molde de estampación Estanpazio moldea
Steering knucle Portamanguetas Mangeta etxea
Step block Calzo escalonado Altxagarri mailakatua
Swing clamp Brida oscilante Brida kulunkari
Swivel base Base giratoria Oinarri birakorra
Swiveling head Cabezal giratorio Buru birakaria
Tail Cola Buztan
83. 83
GLOSSARY
by Endika Gandarias
ENGLISH SPANISH BASQUE
Tap Macho de roscar Hariztatzeko ardatza
Tapping Roscado con macho Ardatzarekin egindako hariztaketa
Thread milling Roscado con fresas Fresekin egindako hariztaketa
Tool magazine / carousel Cambiador de herramienta Erraminta aldagailua
Tool shank Mango de la herramienta Erramintaren kirtena
Toolholder Portaherramientas Erraminta etxea
Toolhonding device Sistema de amarrar herramientas Erramintak lotzeko sistemak
Travelling column Columna movil Zutabe mugikorra
T-shpe slot Ranura en T T erako arteka
Turbo charger Turbocompresor Turbokonpresore
Turn milling Torneado fresado Torneaketa fresaketa
Vaccum chuck Amarre por vacío Huts bidezko lotzea
Vise Mordaza Baraila
Washer Arandela Zirrindola
Wing Ala Hego
Workholding device Sistema de amarrar piezas Piezak lotzeko sistemak