Manufacturing Lecture

Manufacturing Technology I
ME 307
Chapter 22

2010 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 4/e
References:
Fundamentals of Modern Manufacturing:
materials, processes, and systems, 3nd Ed., by
Mikell P. Groover, JOHN WILEY & SONS, INC.,
2007. (Chapter 22, pages 523-530)

MACHINING OPERATIONS AND MACHINE
TOOLS
Turning and Related Operations
Drilling and Related Operations
Milling
Machining Centers and Turning Centers
Other Machining Operations
High Speed Machining

Machining Processes Used to Produce Various
Shapes: Milling, Broaching, Sawing, and
Filing; Gear Manufacturing
FIGURE 22.2 (d) plain milling, and (e) profile milling.
Generating shape in milling
Parts Made with Millining Processes
Figure 24.1 Typical parts and shapes that can be produced with the
machining processes described in this chapter.
Milling
Machining operation in which work is fed past a
rotating tool with multiple cutting edges (fly-
cutter with single cutting edge is rarely used)
Axis of tool rotation is perpendicular to feed
(parallel in drilling)
Creates a planar surface
Other geometries possible either by cutter
path or shape
Other factors and terms:
Interrupted cutting operation
Cutting tool called a milling cutter, cutting
edges called "teeth"
Machine tool called a milling machine
Figure 21.3 Two forms of milling: (a) peripheral milling, and (b)
face milling.
Two Forms of Milling
Peripheral Milling vs. Face Milling
Peripheral milling (plain milling)
Cutter axis parallel to surface being
machined
Cutting edges on outside periphery of cutter
Face milling
Cutter axis perpendicular to surface being
milled
Cutting edges on both the end and outside
periphery of the cutter
Milling Cutters and Milling Operations
Figure 24.2 Some basic types of milling cutters and milling operations. (a) Peripheral milling. (b)
Face milling. (c) End milling. (d) Ball-end mill with indexable coated-carbide inserts machining a
cavity in a die block. (e) Milling a sculptured surface with an end mill, using a five-axis numerical
control machine. Source: (d) Courtesy of Iscar. (e) Courtesy of The Ingersoll Milling Machine
Co.
Fig 22.18 Peripheral milling: (a) slab milling, (b) slotting, (c) side
milling, (d) straddle milling, and (e) form milling.
Basic form of peripheral milling in which the
cutter width extends beyond the workpiece
on both sides
Figure 22.18 (a) slab
milling
Slab Milling
Width of cutter is less than workpiece width,
creating a slot in the work
if the cutter is very thin, the operation can mill
narrow slots or cut workpart in two. (saw
milling)
Figure 22.18 (b) slotting
Slotting (Slot milling)
milling teeth have a special profile that
determines the shape of the slot
Form milling is therefore classified as a forming
operation
Figure 22.18 (e) form milling
Form milling
Fig 22.19 Two forms of milling with a 20-tooth cutter: (a) up milling,
and (b) down milling.
(a) up milling (conventional milling) the direction of motion of
the cutter teeth is opposite the feed direction. (milling against
the feed)
(b) Down milling (climb milling) the direction of cutter motion is
the same as the feed direction. (milling with the feed)
up milling and down milling
up milling down milling
the chip starts out very thin and increases
in thickness during the sweep of the
cutter.
the chip starts out thick and reduces in
thickness throughout the cut
The length of a chip is slightly large The length of a chip is less
The cutter is engaged in the work for
more time per volume of material cut.
The cutter is engaged in the work for less
time per volume of material cut,
this tends to reduce tool life this tends to increase tool life
tendency to lift the workpart as the cutter
teeth exit the material.
the cutter force direction is downward,
tending to hold the work against the
milling machine table.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R.
Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Cutters
Figure 24.11 Cutters for (a) straddle milling, (b) form
milling, (c) slotting, and (d) slitting with a milling cutter.
Schmid.
Milling Operations
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, t
c
; and workpiece speed, v.
(c) Schematic illustration of cutter travel distance, l
c
, to reach full depth-of-cut.
Figure 22.20 Face milling

Cutter overhangs work
on both sides
Figure 22.20 (a) conventional face milling
Conventional Face Milling
the cutter overhangs the
work on only one side
Figure 22.20 (b) conventional face milling
Partial Face Milling
High speed face
milling using
indexable inserts
(photo courtesy of
Kennametal Inc.).
Cutter diameter is
less than work
width, so a slot is
cut into part
Figure 22.20 (c) end milling
End Milling
Form of end milling
in which the
outside periphery
of a flat part is cut
Figure 22.20 (d) profile milling
Profile Milling
Another form of
end milling used
to mill shallow
pockets into flat
parts
Figure 22.20 (e) pocket
milling
Pocket Milling
Ball-nose cutter fed
back and forth
across work along a
curvilinear path at
close intervals to
create a three
dimensional surface
form
Figure 22.20 (f) surface
contouring
Surface Contouring
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.ISBN 0-13-
148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Face-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.
After Materials and
Processes in
Manufacturing. 8th
ed. By E. Paul
DeGarmo, J.T. Black,
Ronald A. Kohser.
1997 by Prentice-
Hall.
After G. Ghryssolouris. Manufacturing Systems. Theory and Practice. Springler-
Verlag New York, Inc., 1992. 419 p.
CUTTING CONDITIONS IN MILLING
The cutting speed is determined at the outside
diameter of a milling cutter.

The feed given as a feed per cutter tooth; (chip
load) it represents the size of the chip formed
by each cutting edge. The feed rate is:

where f
r
= feed rate,mm/min; N = spindle speed,
rev/min; n
t
= number of teeth on the cutter; and
f = chip load in mm/tooth.
CUTTING CONDITIONS IN MILLING
Material removal rate is determined using the
product of the crosssectional area of the cut
and the feed rate.
R
MR
= wd f
r

The feed given as a feed per cutter tooth; (chip
load) it represents the size of the chip formed
by each cutting edge. The feed rate is:

where f
r
= feed rate, mm/min; N = spindle speed,
rev/min; n
t
= number of teeth on the cutter; and
f = chip load in mm/tooth.
Time required for Milling (slab)
Fig 22.21 Slab (peripheral) milling showing entry of cutter into the workpiece
the approach distance

Time required to Mill
Time required for Milling (face centered)
FIGURE 22.22 Face milling showing approach and overtravel distances for: (a) when cutter is
centered over the workpiece

Time required for Milling (face offset)
FIGURE 22.22 Face milling showing approach and overtravel distances for: (b) when cutter is
offset to one side over the work.

Fig 22.22 Face milling showing approach and overtravel distances for two
cases: (a) when cutter is centered over the workpiece, and (b) when cutter
is offset to one side over the work
In all of the milling scenarios of the previous slides T
m
represents
the time the cutter teeth are engaged in the work, making chips.
Approach and overtravel distances are added at the beginning
and end of each cut to allow access to the work for loading and
unloading. Thus the actual duration is greater than T
m
.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
Position of Cutter and Insert in Face
Milling
Figure 24.9 (a) Relative position of the cutter and insert as it first engages the workpiece 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.
Schmid.
Ball Nose End
Mills
Figure 24.10 Ball nose end mills.
These cutters are able to produce
elaborate contours and are often used in
the machining of dies and molds. (See
also Fig. 24.2d.) Source: Courtesy of
Dijet, Inc.
Schmid.
T-Slot Cutting and Shell Mill
Figure 24.12 (a) T-slot cutting with a milling cutter. (b) A shell mill.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
Face-Milling Cutter with Indexable Inserts
Figure 24.5 A face-milling cutter with indexable inserts.
Source: Courtesy of Ingersoll Cutting Tool Company.
MILLING MACHINES
Milling machines must provide a rotating spindle
for the cutter and a table for fastening,
positioning, and feeding the workpart.
Classified on the base spindle orientation:
1. horizontal milling machine
2. vertical milling machine
Other types are
knee-and-column,
bed type,
planer type,
tracer mills, and
CNC milling machines.
Figure 22.23 Two basic types of knee-and-
column milling machine.

It is a versatile machine due to its capability for worktable feed
movement in any of the xyz axes.
The worktable can be moved in the x-direction, the saddle in the
y-direction, and the knee vertically to achieve the z-movement.
Schmid.
Column-and-Knee Type Milling 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.
Figure 22.23 (a) horizontal knee-and-column milling machine.
Horizontal Milling Machine
Figure 22.23 (b) vertical knee-and-column milling machine
Vertical Milling Machine
Figure 22.24 Special
types of knee-and-
column milling
machine: (a) universal
overarm, arbor, and
cutter omitted for clarity
Universal Milling Machine (knee & column type)
It has a table that can be swiveled in a horizontal plane (about a vertical
axis) to any specified angle. This facilitates the cutting of angular
shapes and helixes on workparts.
Figure 22.24 Special
types of knee-and-
column milling
machine: (b) ram type
Ram Mill (knee & column type)
The ram can be adjusted in and out over the worktable to locate the
cutter relative to the work. The tool head can also be swiveled to
achieve an angular orientation of the cutter with respect to the work.
Fig 22.25 Simplex bed-type milling machine horizontal spindle
Bed-type Milling Machine
Designed for high production.
Constructed with greater rigidity than knee-
and-column machines,
this permits them to achieve high material
removal rates by heavier
feed rates and
depths of cut

Bed-type Milling Machine
Simplex mills:
Single spindle bed machines are called simplex
mills, and are available in either
horizontal or
vertical models.
Duplex mills
use two spindle heads.
The heads are usually positioned
horizontally on opposite sides of the bed
to perform simultaneous operations during
one feeding pass of the work.
Triplex mills
add a third spindle mounted vertically over
the bed to further increase machining
capability.

Planer type Mills
Planer type mills are the largest milling
machines.
The general appearance and construction is
that of a large planer with the difference
milling is performed instead of planing.
One or more milling heads are substituted for the
single-point cutting tools used on planers, and
the motion of the work past the tool is a feed rate
motion rather than a cutting speed motion.
built to machine very large parts.
The worktable and bed of the machine are
heavy and relatively low to the ground, and
FIGURE 22.31 Open-side planer.
Tracer Mills
Also called a profiling mill, is designed to
reproduce an irregular part geometry that has
been created on a template.
Uses either
manual feed by a human operator or
automatic feed by the machine tool
a tracing probe is controlled to follow the
template while a milling head duplicates the
path
Tracer mills are of two types:
1. x-y tracing
2. x-y-z tracing
CNC Vertical-Spindle 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.
Five-Axis Profile Milling Machine
Figure 24.18 Schematic illustration of a five-axis profile milling machine. Note that there
are three principal linear and two angular movements of machine components.
After Manufacturing Technology. Metal Cuting & Machine Tools. By P N RAO. 2002 by
McGRAW-HILL.
Fig 25-6 Sketch of an arbor (two views) used on a horizontal
spindle milling machine
After Materials and Processes in Manufacturing. 8th ed. By E. Paul DeGarmo, J.T. Black,
Ronald A. Kohser. 1997 by Prentice-Hall.
After Manufacturing Technology. Metal Cuting & Machine Tools. By P N RAO. 2002
by McGRAW-HILL.

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Manufacturing Technology I

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