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1.2 Introduction
Milling is a cutting operation with a geometrically specified cutting edge in which the tool makes the rotating main movement, and the feed as well as the infeed movement are generally made by the work part. Milling operations are classified according to the position of the milling axis towards the work part, i.e. between face milling and peripheral milling. In case of face milling, the milling axis is located vertically to the machining. The work part surface is machined by the main cutting edges. Also, the work part surface is further finished with auxiliary cutting edges
synchronous and conventional milling (Figure 1.4 and 1.5) are differentiated.
Due to the cutting path comma-form chips are cut with a changing chip thickness
The design of the CNC machine specifies the definition of the respective coordinate system. Correspondingly, the Z axis is specified as the working spindle (tool carrier) in CNC milling machines (Figure 1.13), whereby the positive Z direction runs from the work part upwards to the tool. The X axis and the Y axis are usually parallel to the clamping plane of the work part. When standing in front of the machine, the positive X direction runs to the right and the Y axis is away from the viewer. The zero point of the coordinate system is recommended to be placed on the outer edge of the work part.
c) Reference Point R
A machine tool with an incremental travel path measuring system needs a calibration point which also serves for controlling the tool and work part movements. This calibration point is called the reference point R. Its location is set exactly by a limit switch on each travel axis. The coordinates of the reference point, with reference to the machine zero point, always have the same value. This value has a set adjustment in the CNC control.
Figure 1.14 : Location Of The Zero And Reference Point For Milling
* Blocks
Each NC-program consists of a number of so-called blocks, which contain the commands to be executed. The blocks are consecutively numbered; each block number consisting of a letter "N" plus a (e.g. three-digit) numeral. Block numbers appear at the beginning of each program line * Words Address, Value As a rule an NC block is comprised of several words. Each word consists of an address (letter) and a value or code (numerals).
A numeral can either represent a code (e.g. G01: Linear feed motion) or a real value (e.g. X+60 : Approaching the target coordinate X=60). Example of part program:
N110 F95 S850 M03 N115 G00 X+25 Y+30 N120 G01 Z-8 N125 X+105 N130 Y+80
Explanation:
Block-No.
N110 A feed rate of 95 mm/min and a spindle speed of 850 U/min is programmed. N115 The tool is moved in the rapid traverse motion from its current position to the starting point (X+25 Y+30)t N120 Infeed in the Z-axis at the programmed feed rate (G01) N125 Because G01 is a modal command, the tool will continue to move at the programmed feed rate on a straight line to the target position X=105 N130 The tool moves in the Y-axis to the target position Y=80. The technology data programmed in block N110 (feed rate, speed and sense of cutter rotation) will be retentive and take effect through blocks N120 to N130.
b) List Of G Codes
G00 Rapid move G0 X# Y# Z# up to 6 axis or G0 Z# X# G01 Linear feedrate move G1 X# Y# Z# up to 6 axis or G1 Z# X# G02 Clockwise move G03 Counter clockwise move G04 Dwell time G08 Spline smoothing on, optional L# number of blocks to buffer G09 Exact stop check, spline smoothing Off G10 Linear feedrate move with decelerated stop G11 Controlled Decel stop G17 X Y Plane G18 X Z Plane G19 Y Z Plane G28 move to position relative to machine zero G53 Cancel fixture coordinate offsets G54-G59 fixture coordinate offsets 1 through 6
Cont
G70 Inch mode G71 Millimeter mode G80 Cancels canned cycles and modal cycles G81 Drill cycle G82 Dwell cycle G83 Peck cycle G84 Tapping cycle G85 Boring cycle 1 bore down, feed out G86 Boring cycle 2 bore down, dwell, feed out G88 Boring cycle 3 bore down, spindle stop, dwell, feed out G89 Boring cycle 4 bore down, spindle stop, dwell, rapid out G90 Absolute mode G91 Incremental mode G92 Home coordinate reset G93 cancel home offsets G98 - G199 User-definable G codes
Feed Rate, F The feed rate is programmed in millimeters per minute (mm/min). Example: F080.000; Here the programmed feed rate is 80 millimeters per minute. Spindle Speed, S The spindle speed is programmed in revolutions per minute (RPM). Example: S500; Here the programmed spindle speed is 500 revolutions per minute. Tool Change, T A tool change is programmed by a four-digit number at the address T. The first two positions of that number indicate the tool position in the magazine; the last two positions indicate the tool compensation storage. Example: T0808; This command effect the loading of the tool to position No.8 of the current tool magazine and the reading-in of the corresponding compensation value storage No.8.
Cont In the CNC Simulator there is a maximum of 99 magazine positions available, as well as 99 compensation value registers. This provides the opportunity, for example, to assign the compensation value register No. 36 to the tool in the magazine position No. 12). The applicable NC-command would then be programmed as follows: T1236
Shallow clamps are used for flat work parts whose surfaces need to be kept free for machining.
Machine Vises Machine vises are easy to use and reliable. They are used for clamping smaller work parts. Alignment is achieved with a measuring gauge.
Universal machine vises can be horizontally as well as vertically turned. Furthermore, there are also vises that pneumatically generate clamping power.
The cutting speed of a cutting tool depends on the number of the rotations. The direction constantly changes however during cutting operation.
The calculation of the feed speed Vf is based on the feed fz , i.e. the feed path per milling tooth. Under consideration on the number of rotations n and the number or teeth z the formula is as follows:
Vf= fz * n * z in mm / min
The feed speed can be expressed with the following formula as well with reference to the feed per milling rotation.
Vf = f * n in mm / min
Calculation Examples
Example 1.1
Calculate the cutting speed for milling if the milling tool diameter, d = 50 mm and the number of rotations, n = 520 1/min
Example 1.2
Calculate the number of rotations, n of an end mill with a diameter of d = 12 mm and cutting speed of Vc = 120m/min.
Example 1.3
In plain milling with a face milling cutter a cutting speed of Vc = 180 m/min has been scheduled and the number of rotations should not exceed 400 1/min. What is the maximum diameter, d of the face milling cutter so that these values are not exceeded?