Milling Operations
Straddle Milling:
The straddle milling
is the operation of producing a flat vertical surface on both sides of a workpiece
by using two side milling cutters mounted on the same arbor. Distance between
the two cutters is adjusted by using suitable spacing collars. The straddle
milling is commonly used to design a square or hexagonal surface.
Angular Milling:
The angular milling is the operation of producing an angular
surface on a workpiece other than at right angles of the axis of the milling
machine spindle. The angular groove may be single or double angle and may be of
varying included angle according to the type and contour of the angular cutter
used. One simple example of angular milling is that the production of V-blocks.
Gang Milling:
The gang milling is
the operation of machining several surfaces of a workpiece simultaneously by
feeding the table against a number of cutters having the same or different
diameters mounted on the arbor of the machine. The method saves much of
machining time and is widely used in repetitive work. Cutting speed of a gang
of cutters is calculated from the cutter of the most important diameter.
Form Milling:
The form milling is that the operations of manufacturing the
irregular contour by using form cutters. The irregular shape may be convex,
concave, or of any other shape. After machining, the formed surface is
inspected by a template gauge. Cutting rate for form milling is 20% to 30% but
that of the plain milling.
Profile Milling:
The profile milling is the operation of reproduction an
outline of a template or complex shape of a master dies on a workpiece.
Different cutters are used for profile milling. An end mill is one among the
widely used milling cutters in profile milling work.
Saw Milling:
Saw-milling is the operation of producing narrow slots or
grooves on a workpiece by using a saw-milling cutter. The saw-milling also
performed for complete parting-off operation. The cutter and the workpiece are
set in a manner so that the cutter is directly placed over one of the T-slots
of the table.
Keyways and Grooves Milling:
T-slot-operation:
A dovetail slot or T-slot is manufactured by using special
sorts of cutters designed to offer the specified shape on the workpiece. The
second slot is cut at right angles to the first slot by feeding the work past
the cutter. A woodruff key is designed by using a woodruff key slot cutter.
Standard keyways are cut on the shaft by using side milling cutters or end
mills. The cutter is set exactly at the centre line of the workpiece and then
the cut is taken.
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