SAFETY PRECAUTIONS FOR MILLING MACHINES• Wear approved safety goggles.

• See that the table is clean and dry before mounting holding devices for the work.

• Be sure that the bases of work-holding accessories or w/p are wiped clean before they are fastened to the table.

• Check to see that the w/p is mounted securely.

• Select and mount the proper cutter, and see that it revolves in the proper direction.

• Be sure that the arbor, cutter, and collars are clean before mounting them on the machine Use a rag to handle sharp cutters.

• Keep your fingers clear of the arbor hole when replacing the overarm support. Fasten the overarm and overarm support securely.

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securely.

• Use the proper spindle speed, feed, and depth of cut.

K l f th l i tt D t h th tt• Keep clear of the revolving cutter. Do not reach over the cutter.

• Stop the cuter to remove chips, and use a brush for chip removal.

• Release all automatic feed controls when the job is completed.

• Keep the floor around the machine free of chips and oil.Keep the floor around the machine free of chips and oil.

• When you are finished, remove and return all tools and accessories. Brush the m/c free of chips and wipe up all excess oil.

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MILLING MACHINES

cutters to shape the w/p.revolving# A milling m/c uses one or more

attached to a movable table. fixtureor vise # The w/p is usually held in a p y

the w/p against the revolving cutter. feeding# Cutting takes place by

TYPES OF MILLING MACHINESTYPES OF MILLING MACHINES

1 V i l illi /1. Vertical milling m/c

2. Horizontal milling m/cg

3. Milling m/c for special uses.

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Vertical Milling Machine: of End-milling cuttersvarious types and sizesvarious types and sizes are used .

OPERATIONS :1. horizontal surfaces,

2. vertical surfaces,

3. angular surfaces,

4. shoulders,

5. grooves,

6. fillets,

7 k7. keyways,

8. T -slots

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9. & dovetails

Horizontal Milling MachineH. milling m/c are made in two types: 1. Plain 2. Universal gPlain milling m/c have the table fixed at a right angle to the kneeknee.

The universal milling m/c table to be swiveled to whatever angle is needed .

The universal milling m/c is used widely by toolmakers & Maintenance machinists.

It i th t til f llIt is the most versatile of all types of milling m/c.

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Attachments extend the range of work that can be done on both plain & universal milling m/c.

HORIZONTAL MILLING MACHINEMET

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HORIZONTAL MILLING MACHINE

HORIZONTAL UNIVERSAL MILLIMG M/C

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HORIZONTAL UNIVERSAL MILLING M/C

• UNIVERSAL HORIZONTAL MILLING M/C CONSITS OF TABLE SWIVEL HOUSING WHICH IS LOCATED BETWEEN TABLE AND SADDLETABLE AND SADDLE.

• PERMITS TABLE TO BE SWIVELED 45 04 ON EITHERPERMITS TABLE TO BE SWIVELED 45 ON EITHER DIRECTION ON HORIZONTAL PLANE.

• USED FOR MILLING OF HELICAL GROOVES IN TWIST DRILLS, MILLING CUTTERS AND GEARS

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Milling Machine Attachments and Accessories

A wide variety of accessories are available to increase the versatility and productivity of a milling machine.

MILLING MACHINE ATTACHMENTS

:Vertical Milling Attachment. 1

V ti l tt h t bl thVertical attachments enable the horizontal milling m/c to be used for operations such as face millingsuch as face milling,end milling, drilling, boring, and T -slot milling.

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. Slotting Attachment2

It converts the rotary motion of the spindle into reciprocating motion for cutting keyways, splines, templates, and irregular-shaped surfaces.

VERTICAL ATTACHMENT SLOTTING ATTACHMENT

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HOLDING ACCESSORIES-CUTTER

Adapters, and Collets, Arbors

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L ENG INEER ING TECHNOLOGYMounting a milling cutter on an arbor for Fig : use on a horizontal milling machine

ARBOR………One end of the arbor isOne end of the arbor is held in the milling machine spindle while the outer end is supported by one or more arbor supports.

The cutter is position on the arbor by collars and is prevented fromis prevented from turning on the arbor by a square key .

COLLETS……

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HOLDING DEVICES FOR-WORKMILLING M/CMILLING M/C

1. Vise2 Chucks2. Chucks3. Rotating tables4. Angle plates5. Special fixturesp6. Universal dividing head7 Clamp work to table7. Clamp work to table8. V - Blocks

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A plain milling machine vise ROTARY TABLE

V-BLOCK

A universal vise permits compound angles to be machined

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MILLING CUTTERS & OPERATIONS….

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A SHELL MILL CUTTER

slot cutting with a milling cutter-Fig : (a) TMET

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g gg ( )

PLAIN MILLING CUTTER LIGHT DUTY PLIAN MILLING CUTTER

HEAVY DUTY PLAIN MILLING CUTTER

HIGH HELIX PLIAN MILLING CUTTER

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CUTTER

Type Helical Milling Cutters-Standard Shank

FACE MILLING CUTTERFACE MILLING CUTTER

SIDE MILLING CUTTER

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Types of Formed Cuttersyp

CONCAVE CUTTER CONVEX CUTTER GEAR TOOTH

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DEPTH OF CUT& FEED, CUTTING SPEED

• Type of work materialC tt t i l

CUTTING SPPED DEPENDS ON…..

• Cutter material• Diameter of the cutter• Surface finish required• Depth of cutp• Rigidity of the machine and work setup

INCH METRIC

4X CSDr / min =

320 X CSDr / min =

CS= Cutting speed (ft/min)

D= Dia of cutter ( inch)

CS= Cutting speed (m/min)

D= Dia of cutter ( mm)

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D= Dia of cutter ( inch)

Feed

Feed is the rate at which the work moves into the revolving cutter.

millimeters or inches per minuteIt is measured in either . per minute

INCH CALCULATIONS MERTIC CALCULATIONS

FEED INCH / min = N X c.p.t X r / min FEED mm/ min = N X c.p.t X r / min

N = NUMBER OF TEETH ON CUTTER

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c.p.t chip per tooth for a cutter & material

is the amount of material which should Chip per toothbe removed by each tooth of the cutter as it revolvesbe removed by each tooth of the cutter as it revolves and advances into the work.

D th f tDepth of cut

Where a smooth accurate finish is desired, it isWhere a smooth accurate finish is desired, it is considered good milling practice to take a roughing and finishing cut.

Roughing cuts should be deep, with a feed as heavy as the work and the machine will permit.

When a fine finish is required, the feed should be reduced rather than the cutter speeded up.

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reduced rather than the cutter speeded up.