SIDE MILLINGOPERATION ON MILLING MACHINE

SIDE MILLING DEFINED:

Milling with a side-milling cutter to machine one vertical surface.

This operation is the machining of vertical surfaces, or surfaces at right angles to the axis of the milling cutter.

SIDE MILLING

CUTTING TOOLS USED IN SIDE MILLINGSIDE AND FACE CUTTER

Side and face cutters are much narrower and usually a larger diameter than slab mills. They are designed also to cut on the side of the cutter and employ a side clearance .

Side and face cutters are used to machine vertical slots and faces (when used on a horizontal mill).

CUTTING TOOLS USED IN SIDE MILLING

SIDE AND FACE CUTTER

CUTTING TOOLS USED IN SIDE MILLING ENDMILLS

An end mill, like a side and face cutter can perform both peripheral and face milling.an end mill may be considered a side and face cutter of relatively small diameter with a high width to diameter ratio. Due to the shank the end mill may only cut on one end face. The end teeth of an end mill do not cut across the full diameter of the face therefore an end mill should not be fed axially into the workpiece.

CUTTING TOOLS USED IN SIDE MILLING

ENDMILL

CUTTING TOOLS USED IN SIDE MILLING

PARTS OF ENDMILL

SELECTING PROPER SPEED

The formula for calculating spindle speed in revolutions per minute is as follows:

RPM = CSx4/DWhere :RPM = Spindle speed (in revolutions

per minute).CS = cutting speed of milling cutter (in

SFPM)D = diameter of milling cutter (in

inches)

SELECTING PROPER SPEED

For example, the spindle speed for machining a piece of steel at a speed of 35 SFPM with a cutter 2 inches in diameter is calculated as follows:

RPM = CSx4/D= 35×4/2= 70 RPM

SPEED AND FEED RATE

SPEED AND FEED RATE

SPEED AND FEED RATE

COOLANTS

SELECTION OF COOLANTS

The major advantage of using a coolant or cutting oil is that it dissipates heat, giving longer life to the cutting edges of the teeth. The oil also lubricates the cutter face and flushes away the chips, consequently reducing the possibility of marring the finish.

TYPES OF COOLANTS

Water-Soluble OilsWater-soluble oils combine oil

with emulsifiers and performance additives to create an oil-based coolant concentrate designed to be diluted with water.

TYPES OF COOLANTS

WATER SOLUBLE OILThese coolants provide the

lubricity of straight oil with the cooling and flushing abilities of water. Water-soluble oils are compatible with virtually all types of metal and their unbeatable corrosion protection safeguards valuable parts and expensive machinery.

TYPES OF COOLANTS

LARD OILLard oil is the clear, colourless oil

pressed from pure lard after it has been crystallized, or grained, at 7° C (45° F). It is used as a lubricant, in cutting oils, and in soap manufacture. The solid residue, lard stearin, is used in shortenings and as a source of saturated fatty acids

TYPES OF COOLANTS

MINERAL OILMineral oil is used in a variety of

industrial/mechanical capacities as a non-conductive coolant or thermal fluid in electric components as it does not conduct electricity, while simultaneously functioning to displace air and water.

TYPES OF COOLANTS

MINERAL OILSome examples are in 

transformers where it is known as transformer oil, and in high voltage switchgear where mineral oil as an insulator and as a coolant to disperse switching arcs.  Thedielectric constant of mineral oil ranges from 2.3 at 50 °C to 2.3 at 200 °C.

SIDE MILLING WITH COOLANT