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MANUFACTURING
MANUFACTURING
PROCESSES
PROCESSES
- - AMEM 201 AMEM 201
Lecture 8 Lecture 8: : Machining Processes Machining Processes
DR. SOTIRIS L. OMIROU
Milling Milling
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Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining - -- - - -- - Definition Definition Definition Definition Definition Definition Definition Definition
Milling is one of the basic machining processes
that allows large amounts of material to be
removed quickly.
Milling is a very versatile process capable of
producing simple two dimensional flat shapes to
complex three dimensional interlaced surface
configurations.
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Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining - -- - - -- - Definition Definition Definition Definition Definition Definition Definition Definition
At all types of milling machines, the cutting tool
performs a rotational motion, that is the cutting
motion. The rotation axis of the tool could be
horizontal or vertical, depending on machine-
tool version.
The feeding motion is achieved either by part
or tool, or both, usually on three perpendicular
directions.
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Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining - -- - - -- - Definition Definition Definition Definition Definition Definition Definition Definition
The Milling process
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Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining video 1 video 1 video 1 video 1 video 1 video 1 video 1 video 1
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Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining video 2 video 2 video 2 video 2 video 2 video 2 video 2 video 2
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Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining Milling Machining video 3 video 3 video 3 video 3 video 3 video 3 video 3 video 3
Main cutting motion
Feeding motion
Machined
Surface
Milling Tool
Part
Swarfs
In order to perform a
flat surface by milling
operation, a relative
motion has to be
between the milling
tool and part. In this
respect the milling
tool will have a
rotation motion, that
is the main cutting
motion, and either the
tool or part has to
perform a translation
motion, that is the
feeding motion.
In order to perform a
flat surface by milling
operation, a relative
motion has to be
between the milling
tool and part. In this
respect the milling
tool will have a
rotation motion, that
is the main cutting
motion, and either the
tool or part has to
perform a translation
motion, that is the
feeding motion.
Click here
for
animation
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Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools - -- - - -- - Types Types Types Types Types Types Types Types
Horizontal Milling Machine
Horizontal spindle - Designed for peripheral milling operations
X axis motion
Z axis motion
Y axis motion
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Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools - -- - - -- - Types Types Types Types Types Types Types Types
Vertical Milling Machine
Vertical spindle - Designed for face milling operations
X axis motion
Y axis motion
Z axis motion
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Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools - -- - - -- - Types Types Types Types Types Types Types Types
Vertical Milling Machining center
Tool Post
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Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools Milling Machine Tools - -- - - -- - Types Types Types Types Types Types Types Types
Automatic Tool Change on a Vertical Milling Machining center
Up milling
Also called Also called conventional milling conventional milling, ,
- - Wheel rotation opposite of the feed Wheel rotation opposite of the feed
- - The chip formed by each cutter tooth The chip formed by each cutter tooth
starts out very thin and increases its starts out very thin and increases its
thickness thickness
- - The length of the chip is relatively The length of the chip is relatively
longer longer
- - Tool life is relatively shorter Tool life is relatively shorter
- - Need more clamping force to hold Need more clamping force to hold
the work part still. the work part still.
Up Milling & Down Milling Up Milling & Down Milling Up Milling & Down Milling Up Milling & Down Milling Up Milling & Down Milling Up Milling & Down Milling Up Milling & Down Milling Up Milling & Down Milling
Down milling
Also called Also called climb milling climb milling, ,
- - Wheel rotation is parallel to the feed Wheel rotation is parallel to the feed
- - The chip formed by each cutter tooth The chip formed by each cutter tooth
starts out thick and leaves out thin starts out thick and leaves out thin
- - The length of the chip is relatively The length of the chip is relatively
short short
- - Tool life is relatively longer Tool life is relatively longer
- - Need less clamping force to hold the Need less clamping force to hold the
work part still. work part still.
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Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine
Slab milling: Slab milling:
Cutter width extends beyond the work piece on both sides Cutter width extends beyond the work piece on both sides
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Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine
Slotting (Slot milling): Slotting (Slot milling):
Cutter width is less than the work piece width, creating a slot. Cutter width is less than the work piece width, creating a slot. If If
the cutter is very thin, it can be used to cut a work part into the cutter is very thin, it can be used to cut a work part into two, two,
called called saw milling saw milling. .
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Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine
Side milling: Side milling:
Cutter, machines the side of the work piece. Cutter, machines the side of the work piece.
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Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine
Straddle milling: Straddle milling:
Similar to side milling, but cutting takes on both sides of the Similar to side milling, but cutting takes on both sides of the
work part simultaneously. work part simultaneously.
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Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine
Form Form milling: milling:
The cutter has the desired form of the part The cutter has the desired form of the part
Milling of a concave half circle Milling of a concave half circle
Milling of a gear Milling of a gear
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Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Vertical Vertical Vertical Vertical Vertical Vertical Vertical Vertical Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine
Face Face milling: milling:
The cutter with a relatively large diameter removes a layer fro The cutter with a relatively large diameter removes a layer from m
the upper side of the part the upper side of the part
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Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Vertical Vertical Vertical Vertical Vertical Vertical Vertical Vertical Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine
End End milling: milling:
Cutters diameter is less than the work parts width Cutters diameter is less than the work parts width
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Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Vertical Vertical Vertical Vertical Vertical Vertical Vertical Vertical Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine
Profile Profile milling milling (also contouring or shaping) (also contouring or shaping): :
Outside periphery of flat part is cut Outside periphery of flat part is cut
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Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Vertical Vertical Vertical Vertical Vertical Vertical Vertical Vertical Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine
Pocket Pocket milling: milling:
The cutter removes material creating a cavity (rectangular, The cutter removes material creating a cavity (rectangular,
circular etc.) circular etc.)
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Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Vertical Vertical Vertical Vertical Vertical Vertical Vertical Vertical Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine
3 3- -Dimensinal Dimensinal surface surface milling: milling:
The cutter (ball end mill) removes material, moving in 3 The cutter (ball end mill) removes material, moving in 3
directions simultaneously.) directions simultaneously.)
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Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Vertical Vertical Vertical Vertical Vertical Vertical Vertical Vertical Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine
3 3- -Dimensinal Dimensinal surface surface milling: milling:
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Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Vertical Vertical Vertical Vertical Vertical Vertical Vertical Vertical Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine
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Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Milling Operations on a Vertical Vertical Vertical Vertical Vertical Vertical Vertical Vertical Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine
Slot Slot milling milling T T- -Slot Slot milling milling
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Horizontal
flat surface
Vertical
flat surface
Profile
surface
Surface Machining on a Surface Machining on a Surface Machining on a Surface Machining on a Surface Machining on a Surface Machining on a Surface Machining on a Surface Machining on a Vertical Vertical Vertical Vertical Vertical Vertical Vertical Vertical Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine Milling Machine
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Milling Tools Milling Tools Milling Tools Milling Tools Milling Tools Milling Tools Milling Tools Milling Tools - -- - - -- - End Mills End Mills End Mills End Mills End Mills End Mills End Mills End Mills
The most common cutting tool used with a vertical mill is an
end-mill, which looks like a stubby twist drill with a flattened
end.
An end mill can cut into a workpiece either vertically, like a drill, or
horizontally using the side of the end mill to do the cutting. This
horizontal cutting operation imposes heavy lateral forces on the
tool and the mill, so both must be rigidly constructed
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Ball-end mills make rounded pockets
or spherical pockets; also fillets
Corner-rounders form rounded corners!
Conical end-mill for chamfers
Milling Tools Milling Tools Milling Tools Milling Tools Milling Tools Milling Tools Milling Tools Milling Tools - -- - - -- - End Mills End Mills End Mills End Mills End Mills End Mills End Mills End Mills
Flat end-mills for::
pockets
slots
edge trim
facing
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standard drill: will flex/walk, follow pilot
stub drill for less walk/greater rigidity
reamers (straight or spiral)
finish off hole (last several thousandths)
precise hole diameter
for insertion of dowel pins, bearings, etc.
plunge while spinning, extract still
countersink: for screw heads & deburring hole
center drill establishes hole position with no walk
Milling Tools Milling Tools Milling Tools Milling Tools Milling Tools Milling Tools Milling Tools Milling Tools - -- - - -- - Drills and Reamers Drills and Reamers Drills and Reamers Drills and Reamers Drills and Reamers Drills and Reamers Drills and Reamers Drills and Reamers
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Work Work Work Work Work Work Work Work- -- - - -- -holding holding holding holding holding holding holding holding for milling operations for milling operations for milling operations for milling operations for milling operations for milling operations for milling operations for milling operations
Several types of fixtures are commonly used to hold parts Several types of fixtures are commonly used to hold parts
while milling them. The most common is a while milling them. The most common is a vise vise. .
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Work Work Work Work Work Work Work Work- -- - - -- -holding holding holding holding holding holding holding holding for milling operations for milling operations for milling operations for milling operations for milling operations for milling operations for milling operations for milling operations
Another common alternative is to clamp the part directly to Another common alternative is to clamp the part directly to
the machine table using clamps. Therefore all milling the machine table using clamps. Therefore all milling
machine tables have machine tables have T T- -slots slots along the length to allow along the length to allow
placement of placement of the clamps the clamps. .
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Work Work Work Work Work Work Work Work- -- - - -- -holding holding holding holding holding holding holding holding for milling operations for milling operations for milling operations for milling operations for milling operations for milling operations for milling operations for milling operations
Another common work Another common work- -holding method is an holding method is an indexed indexed vise vise, ,
which allows the part to be rotated so as to expose a which allows the part to be rotated so as to expose a
different surface to the milling tool quickly. different surface to the milling tool quickly.
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I If the machine tool needs to access different facets of the f the machine tool needs to access different facets of the
part to cut some shapes, then the part may need to be part to cut some shapes, then the part may need to be
released and re released and re- -fixtured fixtured. . Each fixed position is called a Each fixed position is called a
setup setup. In one . In one setup setup, multiple tools can be used to cut , multiple tools can be used to cut
different shapes, or features on the part. When the different shapes, or features on the part. When the setup setup
or tool is changed, the machinist must locate the part or tool is changed, the machinist must locate the part
that that is, the coordinates of the part with respect to the tool is, the coordinates of the part with respect to the tool
must must be determined. Each machine table gives feedback be determined. Each machine table gives feedback
about the relative motion of the table along each axis (X, about the relative motion of the table along each axis (X,
Y, and Z). Y, and Z). A primary goal in every machining process is to A primary goal in every machining process is to
limit to minimum the number of required part setups. limit to minimum the number of required part setups.
Work Work Work Work Work Work Work Work- -- - - -- -holding holding holding holding holding holding holding holding for milling operations for milling operations for milling operations for milling operations for milling operations for milling operations for milling operations for milling operations
Definition of part Setup Definition of part Setup