milling operation

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Brief study of milling operation

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HASMUKH GOSWAMI COLLEGE OF ENGINEERING SUBJECT : MANUFACTURING PROCESS - I Presentation on : MILLING OPERATIONS GUIDED BY : Prof. PARESH PATEL

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PRESENTED BY Panchal Poorvang -130240119071 Panchal Prashant - 130240119072 Panchal Nitin -130240119069 Panchal Vedant -130240119075

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CONTENT Introduction Milling and Milling Operation Face Milling 2. Plain or Slab Milling 3. T-Slot Milling 4. Keyway Milling

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Introduction Milling & Milling Operation Milling is the process of machining flat, curved, or irregular surfaces by feeding the workpiece against a rotating cutter containing a number of cutting edges. The milling machine consists basically of a motor driven spindle, which mounts and revolves the milling cutter, and a reciprocating adjustable worktable, which mounts and feeds the workpiece .   

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Milling operations are the operations which are performed on milling machine using different types of cutting tools.

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Face Milling Face milling is the milling of surfaces that are perpendicular to the cutter axis, as shown in fig . Face milling produces flat surfaces and machines work to the required length. In face milling , the feed can be either horizontal or vertical.

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Arrangement : When face milling , the workpiece may be clamped to the table or angle plate or supported in a vise, fixture, or jig. Large surfaces are generally face milled on a vertical milling machine with the workpiece clamped directly to the milling machine table to simplify handling and clamping operations.

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Facing Partial facing End milling Profiling Pocketing Surface contouring Fig. Face Milling Operations

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Depth Of Cut : When setting the depth of cut, the workpiece should be brought up to just touch the revolving cutter. After a cut has been made from this setting, measurement of the workpiece is taken. At this point, the graduated dial on the traverse feed is locked and used as a guide in determining the depth of cut. When starting the cut, the workpiece should be moved so that the cutter is nearly in contact with its edge, after which the automatic feed may be engaged.

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Fig. Depth Of Cut

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Plain Milling Definition : Plain Milling , also called Surface Milling or Slab Milling , is milling flat surfaces with the milling cutter axis parallel to the surface being milled.

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Arrangement : Generally, plain milling is done with the workpiece surface mounted parallel to the surface of the milling machine table and the milling cutter mounted on a standard milling machine arbor. The arbor is well supported in a horizontal plane between the milling machine spindle and one or more arbor supports.

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Fig. Arrangement of Plain Milling

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Selection Of Milling Cutter A careful study of the drawing must be made to determine what cutter is best suited for the job. Flat surfaces may be milled with a plain milling cutter mounted on an arbor. Deeper cuts may generally be taken when using narrow cutters than with wide cutters. The choice of milling cutters should be based on the size and shape of the workpiece. If a wide area is to be milled, fewer traverses will be required using a wide cutter.

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T-Slot Milling Definition : T-slot milling is the operation of producing T-slot in workpiece. Cutting T-slots in a workpiece holding device is a typical milling operation. The size of the T-slots depends upon the size of the T- slot bolts which will be used.

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Fig. Arrangement of T-slot Milling

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Selection Of Milling Cutters Two milling cutters are required for milling T-slots , a T-slot milling cutter and either a side milling cutter or an end milling cutter . The side milling cutter (preferably of the staggered tooth type) or the end milling cutter is used to cut a slot in the workpiece equal in width to the throat width of the T-slot and equal in depth to slightly less than the head space depth plus the throat depth.

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Keyway Milling Definition : Keyways are grooves of different shapes cut along the axis of the cylindrical surface of shafts, into which keys are fitted to provide a positive method of locating and driving members on the shafts. A keyway is also machined in the mounted member to receive the key.

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The type of key and corresponding keyway to be used depends upon the class of work for which it is intended. The most commonly used types of keys are the Woodruff key , the square-ends machine key , and the round-end machine key

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Arrangement : When milling keyways. the shaft may be supported in the vise or chuck, mounted between centers. or clamped to the milling machine table. The cutter must be set centrally with the axis of the workpiece.

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Woodruff Keyway : The Woodruff keys are semi cylindrical in shape and are manufactured in various diameters and widths. The circular side of the key is seated into a keyway which is milled in the shaft. The upper portion fits into a slot in a mating part, such as a pulley or gear. The Woodruff key slot milling cutter must have the same diameter as that of the key

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Woodruff key sizes are designated by a code number in which the last two digits indicate the diameter of the key in eights of an inch, and the digits preceding the last two digits give the width of the key would be 4/8 or ½ inch in diameter and 2/32 or 1/16 inch wide, while a number 1012 Woodruff key would be 12/8 or 1 ½ inches in diameter and 10/32 or 5/16 inch wide. Fig. Woodruff Key slot

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Selection Of Milling Cutter : Shaft keyways for Woodruff keys are milled with Woodruff keyslot milling cutters. The Woodruff keyslot milling cutters are numbered by the same system employed for identifying Woodruff keys, Thus, a number 204 Woodruff keyslot cutter has the proper diameter and width for milling a keyway to fit a number 204 Woodruff key .     

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Square-end keyways can be cut with a plain milling cutter or side milling cutter of the proper width for the , key. Round-end keyways must be milled with end milling cutters so that the rounded end or ends of the key may fit the ends of the keyway. The cutter should be equal in diameter to the width of the key.

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