08 Milling Full Slides

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Chapter 24

Chapter 24Machining processes that produce

various shapes: Milling, Broaching,Sawing, and Filing; Gear Manufacturing


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Various Shaped Parts

Various Shaped Parts

Figure 24.1 Typical parts and shapes that can be produced with the

machining processes described in this chapter.


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Milling Characteristics

Milling Characteristics

Milling machine tools

Wide variety of rotating cutters toproduce chips (slab, face, end milling)

Tool may be vertical or horizontal

Produces flats, slots, angles, pockets,

radii, and many other geometries


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VideoVideo


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Milling MachinesMilling Machines

Figure 24.15 Schematic illustration of (a) a horizontal-spindle column-and-

knee type milling machine and (b) vertical-spindle column-and-knee type

milling machine. Source: After G. Boothroyd.


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CNC Milling MachineCNC Milling Machine

Figure 24.17 A computer numerical-control (CNC) vertical-spindle milling machine.

This machine is one of the most versatile machine tools. The original vertical-

spindle milling machine iused in job shops is still referred to as a “Bridgeport”, after

its manufacturer in Bridgeport, Connecticut. Source: Courtesy of Bridgeport

Machines Dibision, Textron Inc.


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Slab, Face, and End MillingSlab, Face, and End Milling


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Face MillingFace Milling

Produces flat surfaces quickly

Can produce stepped surfaces


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Face-Milling CutterFace-Milling Cutter

Figure 24.7 Terminology for a face-milling cutter.


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Face-milling Cutter (inserts)Face-milling Cutter (inserts)

Figure 24.5 A face-milling cutter with indexable inserts. Source:

Courtesy of Ingersoll Cutting Tool Company.


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Face-Milling OperationFace-Milling Operation

Figure 24.4 Face-milling operation showing (a) action of an insert in face

milling; (b) climb milling; (c) conventional milling; (d) dimensions in face milling.

The width of cut, w, is not necessarily the same as the cutter radius.


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Cutter Position in Face MillingCutter Position in Face Milling

Figure 24.9 (a) Relative position of the cutter and insert as it first engages theworkpiece in face milling. (b) Insert positions towards the end of cut. (c) Examples of

exit angles of insert, showing desirable (positive or negative angle) and undesirable

(zero angle) positions. In all figures, the cutter spindle is perpendicular to the page and

rotates clockwise.


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Slab MillingSlab Milling

Figure 24.3 (a) Schematic illustration of conventional milling and climb milling. (b) lab-

milling operation showing depth-of-cut, d; feed per tooth, f ; chip depth-of-cut, tc; and

workpiece speed, v. (c) Schematic illustration of cutter travel distance, lc, to reach full

depth-of-cut.


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Slab MillingSlab Milling

Produces flat surfaces, contoured, or

shaped surfaces (grooves, gears, etc.)


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Slab Milling CuttersSlab Milling Cutters


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Slab Milling Process SettingsSlab Milling Process Settings


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End Milling CuttersEnd Milling Cutters

Produces a wide variety of shapes

Produces slots, angles, pockets, radii, andmany other geometries


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End Milling GeometriesEnd Milling Geometries


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End Milling CuttersEnd Milling Cutters


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End Milling Process SettingsEnd Milling Process Settings


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Milling EquationsMilling Equations


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Equations, 1Equations, 1


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Milling Machined SurfaceMilling Machined Surface

Figure 24.13 Machined surface features in face milling. See also Fig. 24.6.


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Cost ElementsCost Elements

Machine tool

Setup time Load/unload time

Cutting time

Tool costs Direct labor cost

Overhead


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Safety FactorsSafety Factors

Rotating tool

Hot and sharp chips Eye and skin irritation from cutting

fluids

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