08 milling full slides
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Chapter 24
Chapter 24Machining processes that produce
various shapes: Milling, Broaching,Sawing, and Filing; Gear Manufacturing
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Various Shaped Parts
Various Shaped Parts
Figure 24.1 Typical parts and shapes that can be produced with the
machining processes described in this chapter.
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Milling Characteristics
Milling Characteristics
Milling machine tools
Wide variety of rotating cutters toproduce chips (slab, face, end milling)
Tool may be vertical or horizontal
Produces flats, slots, angles, pockets,
radii, and many other geometries
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VideoVideo
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Milling MachinesMilling Machines
Figure 24.15 Schematic illustration of (a) a horizontal-spindle column-and-
knee type milling machine and (b) vertical-spindle column-and-knee type
milling machine. Source: After G. Boothroyd.
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CNC Milling MachineCNC Milling Machine
Figure 24.17 A computer numerical-control (CNC) vertical-spindle milling machine.
This machine is one of the most versatile machine tools. The original vertical-
spindle milling machine iused in job shops is still referred to as a “Bridgeport”, after
its manufacturer in Bridgeport, Connecticut. Source: Courtesy of Bridgeport
Machines Dibision, Textron Inc.
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Slab, Face, and End MillingSlab, Face, and End Milling
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Face MillingFace Milling
Produces flat surfaces quickly
Can produce stepped surfaces
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Face-Milling CutterFace-Milling Cutter
Figure 24.7 Terminology for a face-milling cutter.
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Face-milling Cutter (inserts)Face-milling Cutter (inserts)
Figure 24.5 A face-milling cutter with indexable inserts. Source:
Courtesy of Ingersoll Cutting Tool Company.
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Face-Milling OperationFace-Milling Operation
Figure 24.4 Face-milling operation showing (a) action of an insert in face
milling; (b) climb milling; (c) conventional milling; (d) dimensions in face milling.
The width of cut, w, is not necessarily the same as the cutter radius.
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Cutter Position in Face MillingCutter Position in Face Milling
Figure 24.9 (a) Relative position of the cutter and insert as it first engages theworkpiece in face milling. (b) Insert positions towards the end of cut. (c) Examples of
exit angles of insert, showing desirable (positive or negative angle) and undesirable
(zero angle) positions. In all figures, the cutter spindle is perpendicular to the page and
rotates clockwise.
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Slab MillingSlab Milling
Figure 24.3 (a) Schematic illustration of conventional milling and climb milling. (b) lab-
milling operation showing depth-of-cut, d; feed per tooth, f ; chip depth-of-cut, tc; and
workpiece speed, v. (c) Schematic illustration of cutter travel distance, lc, to reach full
depth-of-cut.
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Slab MillingSlab Milling
Produces flat surfaces, contoured, or
shaped surfaces (grooves, gears, etc.)
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Slab Milling CuttersSlab Milling Cutters
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Slab Milling Process SettingsSlab Milling Process Settings
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End Milling CuttersEnd Milling Cutters
Produces a wide variety of shapes
Produces slots, angles, pockets, radii, andmany other geometries
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End Milling GeometriesEnd Milling Geometries
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End Milling CuttersEnd Milling Cutters
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End Milling Process SettingsEnd Milling Process Settings
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Milling EquationsMilling Equations
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Equations, 1Equations, 1
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Equations, 2Equations, 2
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Equations, 3Equations, 3
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Equations, 4Equations, 4
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Equations, 5Equations, 5
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Equations, 6Equations, 6
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Equations, 7Equations, 7
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Equations, 8Equations, 8
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Milling Machined SurfaceMilling Machined Surface
Figure 24.13 Machined surface features in face milling. See also Fig. 24.6.
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Insert Shape and Feed MarksInsert Shape and Feed Marks
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Milling Machine SettingsMilling Machine Settings
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Example 24.1 (from textbook)Example 24.1 (from textbook)
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Cost ElementsCost Elements
Machine tool
Setup time Load/unload time
Cutting time
Tool costs Direct labor cost
Overhead
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Safety FactorsSafety Factors
Rotating tool
Hot and sharp chips Eye and skin irritation from cutting
fluids