Presentation is loading. Please wait.

Presentation is loading. Please wait.

Dr. Salah Gasim Ahmed MET 103 1 MET 103 Module 5 Milling Machines.

Similar presentations


Presentation on theme: "Dr. Salah Gasim Ahmed MET 103 1 MET 103 Module 5 Milling Machines."— Presentation transcript:

1 Dr. Salah Gasim Ahmed MET 103 1 MET 103 Module 5 Milling Machines

2 2 What is milling Milling is the process of machining flat,curved, or irregular surfaces by feeding the workpiece against a rotating cutter containing a number of cutting edges. A milling machine uses on or more revolving cutters to shape a work piece.

3 Dr. Salah Gasim Ahmed MET 103 3 Types of milling machines:  Vertical milling machines –Turret (head can be tilted or swiveled) –Fixed head (head can not be tilted or swiveled)  Horizontal milling machines –Plain horizontal milling machines (table is fixed at right angle to the knee) –Universal milling machines (the table can be pivoted in a horizontal plane)  Milling machines for special purposes

4 Vertical Milling machine Base Spindle Milling head Ram Column Table Knee Saddle

5 Base Saddle Table Spindle Milling head Ram Column Knee

6 Dr. Salah Gasim Ahmed MET 103 6 Horizontal milling machine Base Column Ram Spindle Arbor Support Saddle Knee Table

7 Column Saddle Table Spindle Arbor support Base Ram (or over arm) Knee

8 Universal Milling machine Vertical milling attachment

9 Dr. Salah Gasim Ahmed MET 103 9 Milling machine attachment and accessories There are three classes of accessories: 1. Those which increase the versatility of the milling machine e.g.: –Vertical milling attachment –Slotting attachment 2. Those which holds the cutter 3. Those which holds the work piece

10 Dr. Salah Gasim Ahmed MET 103 10 Cutter holding devices: Arbor Used for mounting the cutterUsed for mounting the cutter It is held in the main spindle by a draw boltIt is held in the main spindle by a draw bolt The outer end is supported by the arbor supportThe outer end is supported by the arbor support The cutter is positioned on the arbor by collarsThe cutter is positioned on the arbor by collars Collet adaptor It is held in the spindle the same manner as the arborIt is held in the spindle the same manner as the arbor It is used for mounting tools with taper shankIt is used for mounting tools with taper shank Quick change adaptor Used for holding wide range of cutting toolsUsed for holding wide range of cutting tools

11 Arbor installation

12 Spring collet

13 Quick-change adaptor and tool holder chuck Collet chuck

14 14 The most common types are: 1.Vises 2.V-blocks Mainly used for round works 3.Angle plates They are used for large works or special shapes 4.Fixtures They are made to hold a particular work piece 5.Indexing head (dividing head) It permits the cutting of gears, ratchets, bolt heads 6.Clamps Work holding devices:

15 Vises 1.Plain vise Jaws parallel or at right angle to the spindle axis 2.Swivel base vise it can swivel in a horizontal plane 3.Universal vise it can swivel in a horizontal plane,360 0, and can be tilted 0 – 90 0 in a vertical plane

16 Clamps When work can not be held in a vise or a fixture it is clamped on the table. Here are some types of clamps: –Straight clamp –Finger clamp –Double finger clamp –Screw clamp –U-clamp –Goose neck clamp –Universal clamp

17 Indexing head

18 Milling cutters There many types of milling cutter. Here are some examples:  Plain milling cutter  Plain slitting cutter  Shell milling cutter  Side milling cutter  End milling cutter  Gear milling cutter  T-slotting cutter  Dove-tail slotting cutter

19 Cutting speeds, feeds and depth of cut: Factors for determining speed (rpm)  Type of work material  Cutter material  Diameter of cutter  Surface finish  Depth of cut  Rigidity of machine and work setup

20 The spindle speed  (inch)  (metric) The Value of CS is taken from table(1) Material High speed steel cutter Carbide cutter ft/minm/minft/minm/min Machine steel 802520060 Tool steel 651916050 Cast iron 702016050 Bronze903030090 Aluminium7502251500225 Table (1) Milling Machine Cutting Speeds

21 Milling feed  Feed = N x cpt x rpm  Where, –N: Number of teeth in milling cutter –cpt: chip per teeth for particular cutter, see table (2). –rpm revolution per minute of the cutter Material Side mill End mills Plain helical mills Inches Millimet er Inch Inches Machine steel.0070.18.0060.15.0100.25 Tool steel.0050.13.0040.10.0070.18 Cast iron.0070.18.0070.18.0100.18 Bronze.0080.20.0090.23.0110.28 Aluminium.0130.33.0110.28.0180.46 Table (2) Recommended Feed Per Tooth (High-Speed Steel Cutters)

22 Table (1) Milling Machine Cutting Speeds Material High speed steel cutter Carbide cutter ft/minm/minft/minm/min Machine steel 802520060 Tool steel 651916050 Cast iron 702016050 Bronze903030090 Aluminium7502251500225 Table (2) Recommended Feed Per Tooth (HSS Cutters Table (2) Recommended Feed Per Tooth (HSS Cutters)Material Side mill End mills Plain helical mills InchesMillimeterInchMillimeterInchesMillimeter Machine steel.0070.18.0060.15.0100.25 Tool steel.0050.13.0040.10.0070.18 Cast iron.0070.18.0070.18.0100.18 Bronze.0080.20.0090.23.0110.28 Aluminium.0130.33.0110.28.0180.46

23 Material High speed steel cutter Carbide cutter ft/minm/minft/minm/min Machine steel 802520060 Tool steel 651916050 Cast iron 702016050 Bronze903030090 Aluminium7502251500225

24 Dr. Salah Gasim Ahmed MET 103 24Material High speed steel cutter Carbide cutter ft/minm/minft/minm/min Machine steel 802520060 Tool steel 651916050 Cast iron 702016050 Bronze903030090 Aluminium7502251500225 Material Side mill End mills Plain helical mills InchesMillimeterInchMillimeterInchesMillimeter Machine steel.0070.18.0060.15.0100.25 Tool steel.0050.13.0040.10.0070.18 Cast iron.0070.18.0070.18.0100.18 Bronze.0080.20.0090.23.0110.28 Aluminium.0130.33.0110.28.0180.46

25 Safety precautions for milling machines 25 1.Wear safety goggles 2.Clean and dry the table before mounting the work holding device 3.Clean and dry the holding device and work piece 4.Mount the work piece securely 5.Select and mount the proper cutter to revolve in the proper direction 6.Clean and dry arbor cutter and collars 7.Use only correctly fitting wrenches on the machine 8.Tighten or loosen the arbor nut only with the arbor support in place (otherwise the arbor may bend) 9.Use the proper spindle speed, feed and depth of cut

26 10. Make certain that the table holding device and work piece will clear the arbor and its support during the cut. 11. Disengage the manual feed hand wheel when automatic feed is to be used. 12. Make sure that unauthorized persons are outside the safety zone of the machine when it is started. 13. Keep clear of the revolving cutter 14. Stop the cutter to remove chips and use a brush for chip removal 15. Release the automatic feed control when the job is completed. 16. Keep floor free of chips, oil and grease 17. When you finish working return all tools, accessories and brush the machine free of chips.

27 Dr. Salah Gasim Ahmed MET 103 27 Thank You


Download ppt "Dr. Salah Gasim Ahmed MET 103 1 MET 103 Module 5 Milling Machines."

Similar presentations


Ads by Google