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Chapter

Chapter 24
24
Machining processes that produce
various shapes: Milling, Broaching,
Sawing, and Filing; Gear Manufacturing

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Various
Various Shaped
Shaped Parts
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
Milling Characteristics
Characteristics
Milling machine tools
z Wide variety of rotating cutters to
produce chips (slab, face, end milling)
z Tool may be vertical or horizontal
z Produces flats, slots, angles, pockets,
radii, and many other geometries
z

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Video
Video

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Milling
Milling Machines
Machines

Figure 24.15 Schematic illustration of (a) a horizontal-spindle column-andknee type milling machine and (b) vertical-spindle column-and-knee type
milling machine. Source: After G. Boothroyd.
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CNC
CNC Milling
Milling Machine
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 verticalspindle 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,
Slab, Face,
Face, and
and End
End Milling
Milling

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Face
Face Milling
Milling
Produces flat surfaces quickly
z Can produce stepped surfaces
z

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Face-Milling
Face-Milling Cutter
Cutter

Figure 24.7 Terminology for a face-milling cutter.


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Face-milling
Face-milling Cutter
Cutter (inserts)
(inserts)

Figure 24.5 A face-milling cutter with indexable inserts. Source:


Courtesy of Ingersoll Cutting Tool Company.

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Face-Milling
Face-Milling Operation
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
Cutter Position
Position in
in Face
Face Milling
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.
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Slab
Slab Milling
Milling

Figure 24.3 (a) Schematic illustration of conventional milling and climb milling. (b) labmilling 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
Slab Milling
Milling
z

Produces flat surfaces, contoured, or


shaped surfaces (grooves, gears, etc.)

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Slab
Slab Milling
Milling Cutters
Cutters

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Slab
Slab Milling
Milling Process
Process Settings
Settings

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End
End Milling
Milling Cutters
Cutters
Produces a wide variety of shapes
z Produces slots, angles, pockets, radii, and
many other geometries
z

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End
End Milling
Milling Geometries
Geometries

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End
End Milling
Milling Cutters
Cutters

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End
End Milling
Milling Process
Process Settings
Settings

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Milling
Milling Equations
Equations

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Equations,
Equations, 11

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Equations,
Equations, 22

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Equations,
Equations, 33

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Equations,
Equations, 44

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Equations,
Equations, 55

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Equations,
Equations, 66

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Equations,
Equations, 77

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Equations,
Equations, 88

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Milling
Milling Machined
Machined Surface
Surface

Figure 24.13 Machined surface features in face milling. See also Fig. 24.6.
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Insert
Insert Shape
Shape and
and Feed
Feed Marks
Marks

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Milling
Milling Machine
Machine Settings
Settings

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Example
Example 24.1
24.1 (from
(from textbook)
textbook)

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Cost
Cost Elements
Elements
Machine tool
z Setup time
z Load/unload time
z Cutting time
z Tool costs
z Direct labor cost
z Overhead
z

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Safety
Safety Factors
Factors
Rotating tool
z Hot and sharp chips
z Eye and skin irritation from cutting
fluids
z

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