Milling Machines & Milling Operations: The Fundamentals of Conventional and CNC Milling

This ebook aims to provide basic backgrounds of different types of milling machining processes and highlights on an understanding of important parameters which affects machining of metals. Mechanics of machining is introduced for the calculation of power used in metal machining operation; defects occurring in the machining processes will be discussed with its solutions. Significant factors influencing economics of machining will also be included to give the optimum machining efficiency.

1) Milling Machines and Operations (Précis)

·Introduction

·Types of Milling Operations

·The Milling Process

·Work-holding mechanisms

2a) Introduction to CNC Technology (Instructional)

I. CNC Milling

II. CNC Programming

III. CNC Vertical Mill Installation

b) Standard Operating Procedures for Manual Milling Machines (Lecture)

I. SAFETY RULES

II. USING THE MACHINE

III. GENERAL SHOP SAFETY

3a) Measuring and Gauging (Pamphlet)

b) Optimizing Milling Operations (Article)

· Chip-Breaking Predictive Model for Three-Dimensiona Grooved Inserts

· Experiment-based Predictive Model of Chip-Breaking Limit

· Static Stiffness Analysis of High-Frequency Milling Spindle

· Analysis of Milling Machine chatter vibration reduction

· Cutting Strategies for Casting Die Manufacturing on CNC Milling Machine

· Using Pulsed jet minimum quantity lubrication system in machining

· Virtual training environment for a 3-axis CNC Milling machine

Appendix A Speeds and Feeds

Appendix B Milling Formulas

Appendix C Sample Chip-Breaking Charts of Three-dimensional Grooved Inserts

Machining is operated by selectively removing the metal from the workpiece: turning of metal to produce the required shape. Removal of metal parts is accomplished by straining a local region of the workpiece to fracture by the relative motion of the tool and the workpiece. Conventional methods require mainly mechanical energy. More advanced metal-removal processes involve chemical, electrical or thermal energy.

Due to the amount of material covered, we have divided this dissertation into a Précis and 4 segments. While covering each segment, we continually emphasize the safety precautions that must be observed when operating milling machines.

LEARNING OBJECTIVES After studying this ebook, you will be able to:

Describe how milling machines operate.

Set up and safely operate horizontal and vertical milling machines.

Perform various cutting, drilling, and boring operations on a milling machine.

Point out safety precautions that must be observed when operating a milling machine. (Machine-manual dissertation)