Drilling and Milling Machine Operation

Drilling and Milling
Machine Operation
Contents:
• Drilling operation
• Twist drill geometry
• Radial drilling machine jigs and fixtures
• Drill jig-locating devices
• Milling Operation
• Milling classification column and knee type milling machine
• Milling cutter and classification fundamentals
DRILLING OPERATION
Drilling Machine
One of the most popular machine tools in a workshop is the drilling
machine. It was created to drill a cylindrical hole in metal workpieces
with the appropriate diameter and depth.
The drill is a cutting instrument that is attached to the drilling
machine's spindle. Spindle is a rotating axis of the machine, which
often has a shaft at its heart. A center punch is used to make an
indentation mark at the appropriate spot. The spinning drill is inserted
into the job after being pressed into position. The hole can be dug to a
specific depth.
Twist Drill Geometry
Twist Drill Geometry
The twist drill is one of the most geometrically complex metal cutting
tools in use. It has an internal structure that resembles a cone, with a
narrow top or web and a gradually increasing thickness to the shank.
This structure adds strength and rigidity to the design. The chisel edge,
which is the line that runs across the point, the cutting lips, which are
the leading sharp knife edges on a drill point, and the heels, which are
the drill point's trailing edge, are all located at the tip of the drill bit.
The chisel edge, cutting lips, and heels are the areas on a drill bit that
can be re-sharpened. Twist drills are named after the helical flutes or
grooves that wind around the body of the drill from the point to the
neck.
Radial Drilling Machine
Radial Drilling Machine
The radial drilling machine is designed to drill medium- to large-sized
and heavy-duty workpieces. It has a large base with a heavy round
column. The table is supported by a radial arm that can be raised or
lowered to accommodate workpieces of various heights.
The arm with the drill head on it can be swung around in any direction.
It is possible to make the drill head slide on the radial arm. Because of
this, the machine is given that name. Base, column, radial arm, drill
head, and driving mechanism are among the components.
Jigs Fixtures
Jigs Fixtures
• Jigs are the work holding device • Fixtures are the work holding
which holds, supports and locate device which holds, supports and
the workpiece and guides tools to locate the workpiece but not guides
perform a specific operation. the cutting tool to perform a
• Its main purpose is to provide specific operation.
repeatability, accuracy, and • The fixtures are only the work
interchangeability in the holding device that holds,
manufacturing of products. supports, and locate the workpiece
in the desired position to perform
• They are not fixed to the machine any operation.
table until a big operation is not
required to perform. • Fixtures are fixed to the machine
table.
Drill Jig-Locating Devices
Locating elements position the workpiece accurately with respect to
tool guiding elements in the jig. One of the most important
requirements of a successful jig design is that when workpiece is
machined and removed from the jig, the operator should be able to put
another workpiece quickly into jig, clamp it and machine it to the
dimensions with given tolerance.
The location system should allow for simple and fast loading and
unloading of workpieces with the fewest possible movements.
MILLING OPERATION
Milling Machine
Milling is a metal cutting operation in which a rotating multipoint
cutting tool called a milling cutter is used to extract excess material
from the work piece. A milling machine is a machine that extracts
metal by feeding it via a rotating multipoint cutter. With the aid of
several cutting edges, the milling cutter rotates at a high speed and cuts
metal at a rapid pace.
On the milling machine, one or more cutters may be placed at the same
time. It is for this purpose that a milling machine is widely used in
manufacturing. Flat surfaces, contoured surfaces, external and internal
threads are all machinable with this tool.
Column and Knee Type Milling Machine
Column and Knee Type
For general shop work, it is the most widely used milling machine. The
table is supported by the knee, which is in turn supported by the main
column's vertical slides.
The column's knee is vertically adjustable, allowing the table to be
rotated up and down to accommodate different heights of work.
Classification of Column and Knee Type Milling Machine:
• Hand milling
• Horizontal milling
• Universal milling
• Vertical milling
Hand Milling Machine
• It is the simplest and
smallest machine, with only
a hand feed for the table and
power spindle rotation.
• It is used for small jobs such
as slotting, keyways, and
grooves.
• The tool is held by a
horizontal arbor, and the
table usually has three
movements.
Horizontal Milling Machine
• The spindle of the horizontal
milling machine is parallel to the
shop floor, and the overarm
extends over the workpiece.
• The arbor, which holds the
milling cutter, is supported by
the overarm.
• The arbor is the part of the
horizontal mill that rotates the
milling cutter.
Universal Milling Machine
• The cutter can be rotated both
vertically and horizontally.
• It has more versatility and can be
used for a variety of purposes.
Milling cutters, spur, helical,
spiral, level gears, twist drills,
reamers, and other milling
operations can all be machined.
• It's possible to swivel the table
horizontally and feed it at an
angle.
Vertical Milling Machine
• The spindle is oriented vertically.
• Phase milling is possible due to
the small axial spindle
movement.
• The most popular cutters are end
mill cutters and face mill cutters.
Grooves, holes, and flat surfaces
are all made with them.
• Drilling and boring are examples
of auxiliary operations.
Milling Cutters and
Classification Fundamentals
The most common types of milling cutters are:

End Mill Cutter
• End mills are used in milling,
profiling, contouring, slotting,
counterboring, drilling, and
reaming applications to create
shapes and holes in a workpiece.
• They have cutting teeth on the
face and edge of the body and
can cut a variety of materials in a
variety of directions.
Face Mill Cutter
• Face milling creates a surface
that is perpendicular to the
rotation axis. It's typically used
on large, flat surfaces.
• Most of the metal cutting is done
by the teeth's periphery.
• As a result, it must always cut in
a horizontal direction at a
specific depth when approaching
the stock from the outside.
Ball End Mill Cutter
• Ball end mills are used for drilling
shallow holes, slotting a channel
where a flat bottom is not required or
most used to produce multi-
dimensional contours in molds or
dies.
• A ball end mill will produce a radius
one half the diameter of the tool used.
• They are ideal for machining 3-
dimensional contoured shapes in
machining centers, for example in
molds and dies.
Slab Mill Cutter
• Slab mills are used to rapidly
machine wide broad surfaces,
either alone or in gang milling
operations on manual horizontal
or universal milling machines.
• Cemented carbide-tipped face
mills, which are then used in
vertical mills or machining
centers, have surpassed them.
Side-and-face Mill Cutter
• The side-and-face cutter has
cutting teeth on both sides and
around the circumference.
• The side teeth allow side and
face cutters to make unbalanced
cuts (cutting on only one side)
without deflecting the cutter as a
slitting saw or slot cutter would
(no side teeth).
Involute Gear Mill Cutter
• Milling gears need specialized
cutting equipment.
• To cut the teeth to fit a unique
gear shape known as an involute
type.
• Built as machine tool arbor
mounted cutters, it can be used
in a wide range of ferrous and
non-ferrous materials.
Fly Mill Cutter
• A single-point cutting instrument,
like a lathe tool fixed in a special
holder, is known as a fly cutter.
• Fly cutters are rotary tools that
surface planes with one or more
single point tools.
• Fly cutters come in a variety of
shapes and sizes, with the most
basic being the Point Cutter,
Rotary Carving Tool, and Rotary
Cutting Tool.
Hollow Mill Cutter
• A milling cutter that encircles and
revolves around a cylindrical workpiece
with three or more cutting edges.
• While conventional high-speed steel and
carbide-tipped blades are still used, more
modern hollow mills use indexable
carbide inserts for cutting.
• Since it can conduct several operations,
hollow milling has an advantage over
other cutting methods.
• In a single pass, a hollow mill can reduce
the diameter of a component while also
performing facing, centering, and
chamfering.
Shell Mill Cutter
• A shell mill is any of many
milling cutters (typically a face
mill or endmill) whose
construction is modular, with the
shank (arbor) made separately
from the cutter body.
• Which is called a "shell" and
attaches to the shank/arbor using
one of several uniform joining
methods.
Roughing End Mill Cutter
• During heavier operations,
roughing end mills, also known
as hog mills, are used to rapidly
extract large quantities of
material.
• The tooth architecture reduces
vibration to a minimum but
leaves a rougher finish. Where a
particular radius size is needed,
corner radius end mills with a
rounded cutting edge are used.
Dovetail Mill Cutter
• O-ring grooves in fluid and
pressure instruments, industrial
slides, and thorough undercutting
work are all done with dovetails.
• The trapezoidal shape of dovetail
cutters is like that of a dove's
tail.
• Undercut or deburr features in a
workpiece with general purpose
dovetails.
Woodruff Mill Cutter
• Woodruff cutters are used to cut
the keyway for a woodruff key.
• Woodruff cutters are slightly
hollow ground on the sides for
relief and the teeth are not side
cutting.
• The teeth come in both straight
and staggered varieties.
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Drilling and Milling

The most common types of milling cutters are:

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