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Practical No. 13 milling

All feature of end milling

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Muhammad Abdullah
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61 views

Practical No. 13 milling

All feature of end milling

Uploaded by

Muhammad Abdullah
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Practical No.

13
Title:
Performing different operations on Vertical Milling Machine
Objective:
To Demonstrate Students How To Perform Different Operations (Face Milling, Side Milling,
Drilling, Counter Sinking, Counter Boring) On Vertical Milling Machine
Equipment\Material:
Milling Machine, Milling Tools, Work Piece, Vernier Caliper, Vice etc.
Milling Machine:
The milling machine is a type of machine which removes the material from the work piece
by feeding the work past a rotating multipoint cutter. The metal removal rate is higher very high
as the cutter has a high speed and many cutting edges. It is the most important machine in the
tool room as nearly all the operations can be performed on it with high accuracy. Following are
different operations performed on vertical milling machine:
1. Face milling:
It is a method of producing a flat surface at right angles to the axis of the cutter. Face milling
is a machining process in which the milling cutting is placed perpendicular to the workpiece. The
milling cutting is essentially positioned “face down” towards the top of the workpiece. When
engaged, the top of the milling cutting grinds away at the top of the workpiece to remove some
of its material as shown in Figure 13.1.

Figure 13.1. Face milling


2. Side milling:
The side milling is the production of a flat vertical surface on the side of a work piece by
using a side-milling cutter. The depth of cut is adjusted by rotating vertical feed screw of table.

Figure 13.2. Side milling


3. Drilling:
The milling machine may be used effectively for drilling, since the accurate location of the
hole may be secured utilizing the feed screw graduations. Twist drills may be supported in drill
chucks fastened in the milling machine spindle or mounted directly in milling machine collets or
adapters. The work piece to be drilled is fastened to the milling machine table by clamps, vises,
or angle plates as shown in Figure 13.3.

Figure 13.3. Drilling on milling machine


4. Counter sinking:
Countersinking is a process that creates a V-shaped edge near the surface of a hole. It is often
used to deburr a drilled or tapped hole, or to allow the head of a countersunk-head screw to sit
flush or below a surface. Countersinking is usually done to make a cone-shaped enlargement at
the end of the hole. The included angle of the conical surface may e º to 90º as in Figure 13.4.

Figure 13.4. Counter sinking


5. Counter boring:
In the counter boring, the end of the hole is enlarged cylindrically. A counter bore works as a
tool in the counter boring. The counter bore consists of cutting edges. These cutting edges may
be straight or spiral. The cutting speed in the counter boring process is usually slow. Typically,
this cutting speed is 25% smaller than that of the speed in the drilling as shown in Figure 13.5.

Figure 13.5. Counter boring


Procedure for face and side milling:
 Check the serviceability of the milling machine and lubricate it according to the
maintenance schedule.
 Select speed and rate of feed and set them accordingly. Turn the machine table to
working position.
 Clamp the work piece so that the material to be removed always projects above the
highest point of the work-holding fixture. Thus, work-holding fixture and milling tool are
protected against damage.
 Then, "scratching" is done, i.e. the milling cutter with running speed is brought close to
the work piece surface so that it face the highest points of the surface not yet machined.
 Following, the required depth of cut is adjusted (1mm) and the surface is roughly milled.
 Same process is repeated for side milling but the work piece are fixed and aligned in the
same way as for face milling.
 Setting-up of cutting values on the milling machine is followed by the so-called
"scratching", by adjusting the depth of cut and the first milling operation (rough milling).
After having finished the first size control, the required finish-size is set and the second
milling operation is conducted (finish-milling).

Procedure for drilling (countersinking and counter boring):

 Select the proper drill bit according to the size needed.


 Select an appropriate size twist drill.
 Select a cutting fluid.
 Properly secure the work piece to the table.
 Select the correct RPM for the drill bit. Take into account: size of bit, material, and depth
of hole to be drilled.
 For countersinking a conical cutting tool is used to produce this chamfer.
 When countersinking, the cutter must be properly aligned with the existing hole, and
should be rotated about 1/3 the cutting speed of the drilling operation for the hole.
 For counter boring a cutter which is similar to a drill bit is used, but instead of a point, it
has a smaller diameter pilot portion.
 The pilot fits into a pre-drilled hole, and guides the counter bore.
 Therefore the counter bore must be aligned with the original hole, so the pilot will follow
the hole properly...

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