SUBJECT:MANUFACTURING PROCESS-1

SEM:3DEPARTMENT OF MECH.

ITM UNIVERSE

NAME:JUNAID BAGHDADI SHEIKHDIVYESH RAJPUTRAHUL SONERAHARDIK MISTRY

ENROLLMENT NO:140950119079140950119065140950119082140950119086

Milling and Milling MachinesMilling operations

• Milling: a process in which a rotating multi-tooth cutter removes material while traveling along various axes with respect to the workpiece.

• Figure 1: basic types of milling cutters & milling operations• In peripheral milling (also called plain milling), the axis of

cutter rotation is parallel to the workpiece surface. When the cutter is longer than the width of the cut, the process is called slab milling

Milling Cutters and Milling Operations

Figure .1 Some basic types of milling cutters and milling operations. (a) Peripheral milling. (b) Face milling. (c) End milling. (d) Ball-end mill with indexable coated-carbide inserts machining a cavity in a die block. (e) Milling a sculptured surface with an end mill, using a five-axis numerical control machine. Source: (d) Courtesy of Iscar. (e) Courtesy of The Ingersoll Milling Machine Co.

Milling Operations

Figure 2 (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.

Peripheral Milling vs. Face Milling• Peripheral milling

• Cutter axis is parallel to surface being machined• Cutting edges on outside periphery of cutter

• Face milling• Cutter axis is perpendicular to surface being milled• Cutting edges on both the end and outside periphery of the cutter

Slab MillingThe basic form of peripheral milling in which the cutter

width extends beyond the workpiece on both sides

(a) slab milling

Slotting • Width of cutter is less than workpiece width, creating a

slot in the work

(b) Slotting

Conventional Face Milling

Cutter overhangs work on both sides

(a) conventional face milling

End Milling Cutter diameter is

less than work width, so a slot is cut into part

(c) end milling

Profile Milling Form of end

milling in which the outside periphery of a flat part is cut

(d) profile milling

Pocket Milling Another form of

end milling used to mill shallow pockets into flat parts

(e) pocket milling

Surface Contouring Ball nose cutter is fed ‑

back and forth across the work along a curvilinear path at close intervals to create a three dimensional surface form

(f) surface contouring

(a) horizontal knee-and-column milling machine

(b) vertical knee‑and‑column milling machine

Machining CentersHighly automated machine tool capable of

performing multiple machining operations under CNC control in one setup with minimal human attention

• Typical operations are milling and drilling• Three, four, or five axes

• Other features: • Automatic tool changing ‑• Pallet shuttles • Automatic workpart positioning

MACHINE COORDINATES

X

Y

Z X - Primary Feed axisZ - Spindle axisY - Remaining axisA - Rotational axis about XB - Rotation axis around YC - Rotation axis around Z

Universal machining center (Haas CNC); highly automated, capable of multiple machining operations under computer control in one setup with

minimal human attention

5 axis trunnion machining center

CNC 4‑axis turning center

Mill-Turn Centers Highly automated machine tool that can perform turning, milling, and

drilling operations on a workpart• General configuration of a turning center• Can position a cylindrical workpart at a specified angle so a rotating

cutting tool (e.g., milling cutter) can machine features into outside surface of part

• A conventional turning center cannot stop workpart at a defined angular position and does not possess rotating tool spindles

Operation of a mill turn center: (a) example part with turned, milled, and ‑drilled surfaces; and (b) sequence of operations on a mill turn center: ‑

(1) turn second diameter, (2) mill flat with part in programmed angular position, (3) drill hole with

part in same programmed position, and (4) cutoff

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