ME364_machining_milling - Valery Marinov, Manufacturing...

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Milling 103 Valery Marinov, Manufacturing Technology 6.2 MILLING Introduction Milling is a process of producing Fat and complex shapes with the use of multi-tooth cutting tool, which is called a milling cutter and the cutting edges are called teeth . The axis of rotation of the cutting tool is perpendicular to the direction of feed, either parallel or perpendicular to the machined surface. The machine tool that traditionally performs this operation is a milling machine . Milling is an interrupted cutting operation: the teeth of the milling cutter enter and exit the work during each revolution. This interrupted cutting action subjects the teeth to a cycle of impact force and thermal shock on every rotation. The tool material and cutter geometry must be designed to withstand these conditions. Cutting Fuids are essential for most milling operations. Milling operation. The cutter is lifted to show the chips, and the work, transient, and machined surfaces. Cutting conditions in milling In milling, each tooth on a tool removes part of the stock in the form of a chip. The basic interface between tool and workpart is pictured below. This shows a only a few teeth of a peripheral milling cutter: Basics of a peripheral (slab) milling operation.
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Milling 104 Valery Marinov, Manufacturing Technology Cutting velocity V is the peripheral speed of the cutter is deFned by V = π DN where D is the cutter outer diameter, and N is the rotational speed of the cutter. As in the case of turning, cutting speed V is Frst calculated or selected from appropriate reference sources (see Section 5.10 Selection of Cutting Conditions) , and then the rotational speed of the cutter N, which is used to adjust milling machine controls is calculated. Cutting speeds are usually in the range of 0.1~4 m/s, lower for difFcult-to-cut materials and for rough cuts, and higher for non-ferrous easy-to-cut materials like aluminum and for Fnishing cuts. Three types of feed in milling can be identiFed: ± feed per tooth f z : the basic parameter in milling equivalent to the feed in turning. ±eed per tooth is selected with regard to the surface Fnish and dimensional accuracy required (see Section 5.10 Selection of Cutting Conditions). ±eeds per tooth are in the range of 0.05~0.5 mm/tooth, lower feeds are for Fnishing cuts; ² feed per revolution f r : it determines the amount of material cut per one full revolution of the milling cutter. ±eed per revolution is calculated as f r = f z z z being the number of the cutter’s teeth; ³ feed per minute f m : ±eed per minute is calculated taking into account the rotational speed N and number of the cutter’s teeth z, f m = f z zN = f r N ±eed per minute is used to adjust the feed change gears. Types of milling
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This note was uploaded on 12/11/2010 for the course MECH 364 at Cornell.

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ME364_machining_milling - Valery Marinov, Manufacturing...

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