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    Milling is a machining process that uses a rotating cutting tool to remove material from the workpiece. There are several types of milling including peripheral, face, end, and straddle milling. Up milling and down milling refer to whether the milling cutter rotates in the same direction or opposite direction of the workpiece feed. Other machining processes discussed include turning, drilling, boring, reaming, and electrochemical and electrodischarge machining.

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    MP 2

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    Milling is a machining process that uses a rotating cutting tool to remove material from the workpiece. There are several types of milling including peripheral, face, end, and straddle milling. Up milling and down milling refer to whether the milling cutter rotates in the same direction or opposite direction of the workpiece feed. Other machining processes discussed include turning, drilling, boring, reaming, and electrochemical and electrodischarge machining.

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    Milling is a machining process that uses a rotating cutting tool to remove material from the workpiece. There are several types of milling including peripheral, face, end, and straddle milling. Up milling and down milling refer to whether the milling cutter rotates in the same direction or opposite direction of the workpiece feed. Other machining processes discussed include turning, drilling, boring, reaming, and electrochemical and electrodischarge machining.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    45 views3 pages

    MP 2

    Uploaded by

    kawsar_002
    Milling is a machining process that uses a rotating cutting tool to remove material from the workpiece. There are several types of milling including peripheral, face, end, and straddle milling. Up milling and down milling refer to whether the milling cutter rotates in the same direction or opposite direction of the workpiece feed. Other machining processes discussed include turning, drilling, boring, reaming, and electrochemical and electrodischarge machining.

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    Milling: Milling is a machining operation in which a workpiece is fed past a rotating cylindrical rotating tool with multiple cutting

    edges. The axis of rotation of the cutting tool is perpendicular to the direction of feed. This orientation between the tool axis and the feed direction is one feature that distinguishes milling from drilling. The cutting tool in milling is called milling cutter and the edges are called teeth. The machine tool that traditionally performs this operation is a milling machine. There are 2 basic types: 1. 2. Peripheral milling: If the tool axis is parallel to the surface being machined, then it is called peripheral milling. Face milling: If the axis of the cutter is perpendicular to the surface being machined, then it is called face milling. The other types are:
       

    Form milling : A milling operation that uses a mill with a unique shape to create that shape into the workpiece. Straddle Milling: A milling setup where two side milling cutters are spaced on an arbor to machine two parallel surfaces with a single cut. End milling : A milling operation that uses a narrower mill to create pockets and contours in a workpiece. Face milling: A milling operation in which the surface of the workpiece is perpendicular to the spindle axis. Face milling primarily is used to mill the top surface of the part. Conventional face milling: In which face miling, the dia of the cutter is greater than the w/p width. Partial face milling: In whichface milling the cutter overhangs the w/p on only one side. Slab milling: A milling operation that uses a cylindrical mill on an axis parallel to the worktable to create a flat surface. Slotting /slot milling/keyways milling: A milling operation that cuts a narrow ridge into the surface of a workpiece.

    i. ii.
     

    Up Milling: Up Milling is the operation when the milling tool is rotating in the opposite direction as the feed. This means that the teeth of the tool are pulling the chips out. It is scoo ping the metal starting at the bottom of the depth of cut scooping upwards. In up milling the chips start small and have a very low force at contact. This low force can cause a pull of the table, which can be dangerous if the work piece is not securely fas tened or if the force is great enough to pull the table off the ground. Down Milling: Down Milling is the operation when the tool is rotating the same direction as the feed. This means that the teeth of the tool are pushing down on the work piece. It scoo ps the metal starting at the top of the depth of cut and goes all the way to the bottom. The chips are generally bigger because of the high forces at contact. The high forces and high impact secure the work piece to the table. Up vs. Down Milling : Down Milling tends to be the safest choice because it secures the work piece to the table instead of trying to pull it off as in up milling. Also the chips in down milling are less likely to fly off and hit people while operating the mill. The down side to down milling is that is takes higher forces and impact which equate to higher energy which costs more money. For large manufacturers up milling is the choice, but for many small industrial operations safety in down milling is chosen most of the time. Drilling: The process of using a multi-point tool to penetrate the surface of a workpiece and make a round hole. Boring : The process of enlarging an existing hole with a s ingle-point tool. Reaming : The process of using a multi-point tool to smooth the interior surface of a hole. Turning:This operation is one of the most basic machining processes. That is, the part is rotated while a single point cutting tool is moved parallel to the axis of rotation.

    Facing is part of the turning process. It involves moving the cutting tool at right angles to the axis of rotation of the rotating workpiece. Knurling is a manufacturing process, typically conducted on a lathe, whereby a visually attractive diamond-shaped (criss-cross) pattern is cut or rolled into metal. Parting/cutoff : An operation performed on the lathe that uses a cutting tool to separate a part from the rest of the stock. Form turning: An operation performed on a lathe that feeds a tool into a workpiece in order to impart the tool's shape in the workpiece. Chuck : A device that holds a workpiece in place as it rotates. The chuck commonly has three or four jaws that can be adjusted to fit various sizes of parts. Clapper box: Clapper box of a shaper is hinged at its side allowing swing in only one direction from normal and it swings while ram is in return stroke and avoids tool from rubbing against the work and protects both. Taper turning: An operation performed on a lathe that feeds a tool at an angle to the length of the workpiece in order to create a conical shape. Threading: The process used to machine a long, spiraling ridge down the outer or inner surface of a workpiece. EDM(Electro-Discharge Machining): Some of the advantages of EDM include machining of:

    y y y y y y

    Complex shapes that would otherwise be difficult to produce with conventional cutting tools Extremely hard material to very close tolerances Very small work pieces where conventional cutting tools may damage the part from excess cutting tool pressure. There is no direct contact between tool and work piece. Therefore delicate sections and weak materials can be machined without any distortion. A good surface finish can be obtained. Very fine holes can be easily drilled.

    Some of the disadvantages of EDM include:

    y y y y y

    The slow rate of material removal. The additional time and cost used for creating electrodes for ram/sinker EDM. Power consumption is high. Excessive tool wear occurs during machining. Electrically non-conductive materials can be machined only with specific set-up of the process.

    Applications: 1. 2. 3. 4. Small hole drilling Prototype production Coinage die making Metal disintegration machining

    Electro Chemical Machining(ECM): Applications:

    1. 2. 3. 4.

    It can be used for Die-Sinking operations. Drilling a jet engine turbine blade. Multiple Hole drilling. Steam turbine blades can be machined within close limits.

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