PROJECT

AIM:- ANALYSIS OF CHIPS FORMED IN PLANO MILLERS AND BORING MACHINES

IN BM-1BY SURAJ SINGH PATWAL

Number of axisTable Size Travel (a) X (b)Y (c)Z (d)W (e)U

P-5 P-4 HB-3 HB-11X,Y,Z,W,U X,Y,Z,W X,Y,Z,W X,Y,Z,W7500*2250 6000*3000 12500*3760 8300*37608200 6000 12500 120004600 3000 3000 35001000 1000 400 4002600 3000 1600 1600500 - - -

Spindle Diameter(mm)

275 250 200 200

Spindle rpm 10-1000 700 600 600

SPECIFICATIONS OF MACHINES

90 deg lead angle

75 deg lead angle

45 deg lead

angle

LEAD ANGLE90

4575

w/p w/pw/p

MILLING

CLIMB MILLING CONVENTIONAL MILLINGCUTTER ROTATES

IN ANTICLOC

KWISE DIRECTIO

N

FEEDFEED

CUTTER ROTATES

IN ANTICLOC

KWISE DIRECTIO

N

Action of

force applied to

work

Action of

force applied to

work

HB3

RPM=410FEED=200DOC=1,2,3

RPM=284FEED=300

DOC=.2

RPM=504FEED=129

DOC=.5

HB-3RPM=202FEED=4.5DOC=1.5

RPM=269FEED=200

DOC=1

RPM=222FEED=200

DOC=.3

RPM=240FEED=40DOC=.5

RPM=251FEED=150

DOC=.8

RPM=251FEED=150

DOC=.5

RPM=418FEED=80DOC=.3

RPM=448FEED=90DOC=.5

HB-3RPM=504FEED=129

DOC=.5

RPM=306FEED=125

DOC=.2

RPM=448FEED=166

DOC=.6

RPM=448FEED=90DOC=.5

RPM=299FEED=70DOC=.5

RPM=319FEED=100

DOC=.8

RPM=301FEED=150

DOC=.5

P-5RPM=187FEED=200

DOC=1

RPM=250/275FEED=400DOC=1.5

RPM=240FEED=40DOC=.5

RPM=800FEED=400DOC=.15

RPM=190FEED=210

DOC=1

RPM=205FEED=260DOC=.145

RPM=200FEED=280

DOC=.5

HB-11RPM=538FEED=40DOC=1

RPM=229FEED=200

DOC=1

RPM=241FEED=200

DOC=.5

RPM=270FEED=150

DOC=.8

RPM=270FEED=85DOC=.8

RPM=258FEED=250DOC=.21

RPM=244FEED=50DOC=2

RPM=231FEED=50DOC=1

HB-11RPM=182FEED=420DOC=1.5

RPM=182FEED=45DOC=3

RPM=182FEED=525

DOC=3

RPM=182FEED=340

DOC=3

P-4RPM=200FEED=250DOC=.25

RPM=200FEED=256DOC=.15

RPM=210FEED=196.6

DOC=.5

RPM=210FEED=280

DOC=.6

RPM=210FEED=210

DOC=.6

W/P

EFFECT OF DIAMETER OF CUTTER WRT WIDTH OF CUT

CUTTER IF CUTTER DIAMETER IS EQUAL TO

WIDTH OF CUT • THEN THE CHIP WILL BE FORMED AT THE ENTRY

AND EXIT OF THE CUT WILL BE VERY THIN

AND THE CHIPS CANNOT CARRY AWAY HEAT AS WELL AS THICKER CHIPS, THEREFORE HEAT IS

TRANSFER BACK INTO THE INSERT , CAUSING EDGE FAILURE.• WORK-HARDENING IS ALSO MORE LIKELY TO

OCCUR IN THE ENTRY AND EXIT AREAS.

25% of cutter body

DO’S AND DON’T

• AT 45DEG LEAD ANGLE , NEVER GIVE HIGH DEPTH OF CUT DOC<=4MM BUT CAN BE USED FOR HIGHER FEED RATE.

• FOR THIN WALL WORK PEACE (BOLSTER), WHEN PERPENTICULARITY REQUIRED AT THE EDGES OF PLATE THEN USE SOLDER CUTTER .

• 75 DEG CUTTER IS NOT USED FOR WEAK MACHINES/WORKPIECE/FIXTURES BECAUSE OF HIGHER VALUE OF RADIAL FORCE.

• ALWAYS USE CLIMB MILLING.• FOR BETTER TOOL LIFE , 25 % OF THE CUTTER BODY SHOULD BE OUTSIDE THE WORK PIECE.• CUTTING FLUID SHOULD BE USED WHEN RECOMMENDED.• NEVER GIVE HIGH VALUE OF DOC IN A THIN PLATE,IT WILL CAUSE VIBRATIONS.

OBSERVATION

• IN MILLING THICKNESS OF CHIPS DEPEND ON FEED AND WIDTH OF CHIPS DEPEND ON DOC.• CORRESPONDING TO THE LARGER FEED CHIP SIZES REDUCES,IF WE KEEP RPM AND DOC

CONSTANT.• AS WE INCREASES THE DOC FROM 1MM, 2MM,3MM, CHIPS COLOR VARIES FROM WHITE ,

GOLD AND BLUE, IT MEANS WITH INCREASE IN DOC,MORE HEAT IS RELEASED.• IF FEED INCREASES THEN VIBRATION INCREASES AND CHANCES OF BREAKING OF BITS

INCREASES.• LARGER IS THE DOC , HEAT REALSE MORE AND TOOL BITS BREAK AND ALSO PRODUCE

DAMAGE TO CUTTER.• IF VIBRATIONS ARE MORE THEN DISTORTED CHIPS ARE FORMED AND IT EFFECTS

MACHINING AS A RESULT DAMAGE OUR BITS AND CUTTER.