Metrology & Workshop

Practice
Components:
Milling
Turning
Grinding
Group Project
(4 students/group) : Mini Vice
Individual project : Turning

Assessment
Tests :20%
Assignment :40%
Final Project :40%
 Milling Machines
Types of Milling Machines

Vertical milling machine. Tools are mounted directly
into the spindle, which is normally vertical. The
vertical spindle may be set at an angle for complex
machining.

Horizontal milling .Tools may be mounted directly
into the spindle, which is horizontal, or mounted on
a spindle extension called arbor.

Universal milling. Vertical spindle and the table can
be swiveled for complex or helical milling.
 Milling

Milling is a process of generating machined
surfaces by progressively removing a
predetermined amount of material or stock
from the workpiece at a relatively slow rate of
movement or feed by a milling cutter rotating
at a comparatively high speed. The
characteristic feature of the milling process is
that each milling cutter tooth removes its
share of the stock in the form of small
individual chips.
 Milling Machine Construction

Type of Machine Construction

Knee and Column-Milling machine having
only the three mutually perpendicular table
motion are called column and knee type.
Most popular

Bed type- The table is mounted directly on
the bed and has only one longitudinal motion.
On some machine vertical motion of the
spindle during each cycle
 TYPE OF MILLING OPERATION

The three basic milling operations are as

shown :
(A) peripheral milling,
(B) face milling,
(C) end milling.
TYPE OF MILLING OPERATION (cont.)
 TYPE OF MILLING OPERATION (cont.)

In peripheral milling (also called as slab milling), the axis of cutter

rotation is parallel to the workpiece surface to be machined. The
cutter has a number of teeth along its circumference, each tooth
acts like a single-point cutting tool called a plain mill. Cutters
used in peripheral milling may have straight or helical teeth
generating an orthogonal or oblique cutting action.

In face milling, the cutter is mounted on a spindle with an axis of
rotation perpendicular to the workpiece surface.

For end milling, the cutter generally rotates on an axis vertical to
the workpiece. It can be tilted to machine tapered surfaces.
Cutting teeth are located on both the end face of the cutter and
the periphery of the cutter body.
Milling Cutter
Cutting Tool Material
High Speed Steel Material

HSS- High Speed steel

HSSV- Vanadium High Speed Steel

HSCo-Cobalt High Speed Steel

HSSXS1-Non Cobalt Powder Metallurgy

Steel

HSCoXP-Sintered Cobalt High Speed Steel

CS- Chromium Steel

 Carbide Material

HM- Carbide Material (or Hard Material)
Carbide materials are often characterised by
high compression strength, high harness and
therefore high wear resistance
Surface coating

TiN - Titanium Nitride Coating

TiCN - Titanium Carbide Nitride Coating

TiAIN - Titanium Aluminium Nitride Coating

SELECTING THE END MIIL AND THE MILLING
PARAMETERS

Before any milling job is attempted, several

decisions must be made to determine:

the most appropriate end mill to be used

the correct cutting speed and feed rate to
provide good balance between rapid metal
removal and long tool life.
 SELECTING THE END MIIL AND THE
MILLING PARAMETERS (cont.)
Determining the most appropriate end mill:

identify the type of the end milling to be carried out:-
1. type of end mill
2. type of centre.

consider the condition and the age of the machine
tool.

select the best end mill dimensions in order to
minimize the deflection and bending stress:-
1. the highest rigidity
2. the largest mill diameter
3. avoid excessive overhang of tool from tool holder.
 SELECTING THE END MIIL AND THE
MILLING PARAMETERS (cont.)

Choose the number of flutes

1. more flutes - decreased space for chips -
increased rigidity - allows faster table
feed
2. less flutes - increased space for chips -
decreased rigidity - easy chip ejection.
SELECTING THE END MIIL AND THE
MILLING PARAMETERS (cont.)

Determining the correct cutting speed and

feed rate can only be done when the
following factors are known:

type of material to be machined

end mill material

power available at the spindle

type of finish
 FEATURES OF THE END MILL
- END CUTTING EDGES

End cutting edges are divided into:

1. Centre cutting type

Allows drilling and plunging operations.

Two edges reach the centre in the case of an even number

of flutes (i.e. 2-4-6,)etc

Only one edge in the case of an odd number (i.e. 3-5, etc).

2. Non centre Cutting Type

Used only for profiling and open slotting

Allows the regrinding between centres.

 FEATURES OF THE END MILL - CHOOSING THE
NUMBER OF FLUTES
Number of flutes should be determined by:

Milled material

Dimension of workpiece

Milling conditions.
2 Flutes

Large chip space.

Easy chip ejection.

Good for slot milling.

Good for heavy duty milling.

Less rigidity due to small section area.

Lower quality surface finish
 FEATURES OF THE END MILL - CHOOSING THE
NUMBER OF FLUTES (cont.)

3 Flutes

Chip space almost as two flutes

Larger section area - higher rigidity than 2 flutes.

Improved surface finish.
4 Flutes (or multiflutes)

Highest rigidity.

Largest section area - small chip space.

Gives best surface finish

Recommended for profiling, side milling and shallow
slotting
FEATURES OF THE END MILL - HELIX ANGLE

Increasing the number of flutes makes the

load on the single tooth more homogeneous
and consequently, this allows for a better
finish. But with a high helix angle, the load
(FV) along the cutter axis is increased too. A
high FV can give:

Load problems on the bearings

Cutter movement along the spindle axis. To avoid
this problem it is necessary to use Weldon or
screwed shanks
FEATURES OF THE END MILL - HELIX ANGLE

FT
 DIRECTION OF USE OF THE CUTTER

We can split the range of the cutters in

relationship to the possible working directions
to the workpiece surface. There are three
different types:

3 Directions (x, y, z)

2 Directions (x, y)

1 Direction (x)

Important: The axial direction is possible only
with centre cutting end mills.
Nomenclature

End Mill
Cutting tool selection decision
Input

Workmaterial

Type of cut-roughing or finishing

Part geometry

Lot size

Machinability data-tool life

Quality/capability needed

Past experience of decision maker

Avaibility of materials: composition,

properties application size etc.
Output

Selected tool specific tool material, grade,

shape and geometry.

Cutting parameters: speed feed depth of cut
Cutting fluid
Constraint

Manufacturing process-continous or
interrupted

Condition and capability of available machine

Geometry, finish, accuracy and surface

integrity requirements

Workholding devices-rigidity

Precessing time(time schedule)

 Material Removal Removal

We can calculate material removal rate, Q as
the volume of material removed divided by
the time taken to cut. The volume removed is
the initial volume of the workpiece minus the
final volume. The cutting time is the time
needed for the tool to move through the
length of the workpiece. This parameter
strongly influences the finishing grade of the
workpiece.
Material removal rate
The cutting time

Tm= (L + LA + Lo)/f min.

(where f feed rate mm 3 /min)

The material removal

MRR= Volume/ Tm = f x W x d /min
3
mm

(d=depth of cut)

Lo=LA= W ( D W ) for W<D/2

Lo=LA = D/2 for
D
W
2
 MRR
The MRR and the applications are strongly related.
For each different application we have a different MRR
that increases with the engagement section of the
cutter on the workpiece.

Side Milling - The radial depth of cut should be less
than 0.25 of the diameter of the end mill.

Face Milling - The radial depth of cut should be no
more than 0.9 of the diameter,axial depth of cut less
than 0.1 of the diameter.

Slot Milling - Machining of a slot for keyways. The
radial depth of cut is equal to the diameter on the end
mill.
Milling

Side Milling Face Milling Slot Milling Plunge Milling Ramping

 TOOL MOVEMENT

UP-MILLING The cutting action occurs
either by conventional milling or climb milling.

In conventional milling, also called up milling,
the maximum chip thickness is at the end of
the cut. The feed movement is opposite to
the tool rotation
TOOL MOVEMENT (cont.)
 TOOL MOVEMENT (cont.)
Pros:

Tooth engagement is not a function of workpiece surface
characteristics.

Contamination or scale on the surface does not affect tool life.

The cutting process is smooth, provided that the cutter teeth are sharp.
Cons:

The tool has the tendency to chatter.

The workpiece has the tendency to be pulled up, thus proper clamping
is important.

Faster wear on tool than climb milling.

Chips fall in front of the cutter - chip disposal difficult.

Upward force tends to lift up workpiece.

More power required due to increased friction caused by the chip
beginning at the minimum width.

Surface finish marred due to the chips being carried upward by tooth.
 TOOL MOVEMENT (cont.)
CLIMB MILLING

In climb milling, also called down milling,
cutting starts with the chip at its thickest
location. The feed movement and the tool
rotation have the same direction.
TOOL MOVEMENT (cont.)
TOOL MOVEMENT (cont.)
Pros:

The downward component of cutting forces holds the workpiece in
place, particularly for slender parts.

Easier chip disposal - chips removed behind cutter.

less wear - increases tool life up to 50%.

Improved surface finish - chips less likely to be carried by the tooth.

less power required - cutter with high rake angle can be used.

Climb milling exerts a downward force on workpiece - fixtures simple
and less costly.
Cons:

Because of the resulting high impact forces when the teeth engage the
workpiece, this operation must have a rigid setup, and backlash must
be eliminated in the table feed mechanism.

Climb milling is not suitable for machining workpieces having surface
scale, such as hot-worked metals, forgings and castings. The scale is
hard and abrasive and causes excessive wear and damage to the
cutter teeth, thus reducing tool life.
 CUTTING VELOCITY AND SPEEDS

The optimum speed of the tool in each case

depends on the cutter material, workpiece material
and the workpiece diameter. The speed can be
based on long experience, without calculation.
However, it is better to calculate the speed from the
cutting velocity given in the tables.

Exceeding the recommended cutting speed
substantially shortens the tool life.

Determining the cutting velocity:
The manufacturer's catalog or table book is used to
determine the optimum cutting velocity initially.
CUTTING VELOCITY AND SPEEDS (cont.)

Vc = 80 - 150 m/min
CUTTING VELOCITY AND SPEEDS (cont.)

The mean value Vc = 115 m/min is selected

This cutting velocity and the known tool
diameter is used to compute the speed n.
The formula

vc 1000
n=
d
CUTTING VELOCITY AND SPEEDS (cont.)

d1 = 40mm d2 = 63mm

115 1000
115 1000 n2 =
n1 = 63
40
1
n1 = 900
1 n2 = 580
mm mm
CUTTING VELOCITY AND SPEEDS (cont.)

For the tool to start cutting, this cutting

velocity or speed must be assigned a tool
feed rate.Like the cutting velocity, the value
for the federate per tooth is taken from the
table book, the manufacturer documentation
or from experience.
CUTTING VELOCITY AND SPEEDS (cont.)

f z = 0.1 0.2mm
CUTTING VELOCITY AND SPEEDS (cont.)

Select the average

f z = 0.15mm

The federate per tooth, the number of teeth and the
known speed is used to compute the feedrate using
the formula

vf = f z n
CUTTING VELOCITY AND SPEEDS (cont.)

Diameter = 63mm, z = 4 Diameter = 63mm, z = 9

vf1 = 580 0.15 4 vf 2 = 580 0.15 9
mm
vf1 = 348 mm
min vf 1 = 783
min
 TOOL HOLDERS
A device that acts as an interchangeable interface between a machine
tool spindle and a cutting tool such that the efficiency of either element
is not diminished.

To hold with this definition, four separate elements are essential:

1. Concentricity - The rotational axis of the machine spindle and of the
cutting tool must be maintained concentrically.
2. Holding Strength - The cutting tool must be held securely to
withstand rotation within the tool holder.
3. Gauges - The tool holder must be consistent. The application of
proper gauges assures consistency from holder to holder.
4. Balancing - Tool holders must be balanced as finely as the spindles
in which they are installed.
 TYPES OF TAPER

Steep Taper (CAT, BT,TC, ISO)

HSK (Hollow Shank Taper). For more information please see the
HSM (High Speed Machining)

Floating holders (only for tapping and reaming)

Other (Morse Taper, Automotive Shank, Cylindrical 1835 A,
Cylindrical B+E, ABS,Wohlhaupter)

Large manual machines and CNC machines use tool holders that
have been precisely ground with a male taper that mate with the
machine's specific female taper. There is also a way to secure
the tool holder in place with a pull stud or a draw bar thread. With
CNC machines, the pull stud is more popular because it allows
for easier automatic tool changing.
 Tool holder-components

A tool holder consists of five basic

components

Pull Stud

Tapered Shank

Flange

Adapter

Opposed Slot
Tool holder-components (cont.)