Cutting by Milling − Course: Techniques for Machining of Material.

Instruction Examples for Practical Vocational Training

 Table of Contents
Cutting by Milling − Course: Techniques for Machining of Material. Instruction Examples for
Practical Vocational Training..........................................................................................................................1
Introduction.............................................................................................................................................1
Instruction example 6.1.: Backing material.............................................................................................2
Instruction example 6.2.: Measuring point..............................................................................................6
Instruction example 6.3.: Fixing bush.....................................................................................................9
Instruction example 6.4.: Segment.......................................................................................................14

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Cutting by Milling − Course: Techniques for Machining of Material.
Instruction Examples for Practical Vocational Training
Institut für berufliche Entwicklung e. V.
Berlin

Original title:
Lehrbeispiele für die berufspraktische Ausbildung
"Trennfräsen"

Author: Dieter Frank

First edition © IBE

Institut für berufliche Entwicklung e.V.

Parkstraße 23
13187 Berlin

Order No.: 90−33−3306/2

Introduction

The present material includes four selected instruction examples which are intended to help practising and
consolidating the knowledge and skills acquired in the technique of cutting by milling.

To facilitate the preparation and realization of the work for each instruction example the necessary materials,
tools, measuring and testing means as well as the auxiliaries are named, With the material specification the
marking of the raw material is made according to the value of its strength (tensile or compressive strength) in
the unit of "Megapascal" (MPa).

The specified technological sequence of operations guarantees a quality true manufacturing of the
appropriate workpieces. For this reason, the sequence of operations has to be followed by all means.

For the whole operation the correct selection of the cutting values (calculation or selection from a nomogram)
is presupposed.

The hints on the required previous knowledge are a recommendation. This basic knowledge is necessary and
should be repeated before starting with the work.

To each instruction example a working drawing is enclosed from where you can draw out the required sizes
and forms of the work−pieces.

Necessary explanations on the working drawings are placed in front of the technological process (sequence of
operations) of the instruction examples.

The admissible deviations for sizes with no indication of tolerances may be taken from the table below.

Nominal size Admissible deviation in mm

0.5 − 6 ± 0.1

6−30 ± 0.2

30 − 120 ± 0.3

120 − 315 ± 0.5

The admissible surface roughness Rz is given in µm (0.001 mm).

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Instruction example 6.1.: Backing material

A cuboid−shaped bar stock (bar steel) with a length of 850 mm has to be cut by means of a metal slitting saw
blade into several one−off parts by cutting by milling.

Material

St 38 (structural steel, tensile strength 380 − 500 MPa)

Dimensions

40 x 40 x 80 mm (finishing sizes)

Milling machine

Horizontal milling machine

Tools

Metal slitting saw blade (Ø 180 − 200 mm x 2.5 − 3 mm), cutter arbor (long), machine vice, lock screws, keys,
flat file

Measuring and testing means

Vernier caliper, bevelled edge square, dial gauge, steel square

Auxiliaries

Separating jaws for a machine vice, stop bar for the separating jaws, chip brush, hand broom, cleaning rag,
T−slot cleaner, tongues for the machine vice

Required previous knowledge

To read a drawing, to measure and to test, to set−up and to operate horizontal and vertical milling machines,
to mill front surfaces

Explanations to the working drawing

? 0,10 The maximum deviation from angularity is 0.10 mm

Sequence of operations Remarks

1. Batch−quantity (number of the Comparison with the specifications of the work accompanying data
bars) and length control (size 850 sheets

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mm)

2. Functional test and lubrication Lubrication and oil−level check according to the lubrication schedule
of the milling machine

3. Fixing and adjusting the Adjustment, localization by means of tongues and steel squares
machine vice (along the machine
table)

4. Placing the separating jaws into Separating jaw should always be used batchwise (in pairs).
the machine vice

5. Fixing the cutter arbor and Do not forget the feather key! Place the end support as near as
fasten the metal slitting saw blade possible to the metal slitting saw blade.

6. Setting−up the coolant and the

milling safety systems

7. Clamping in the workpiece (bar The length feed stop results from fixing a parallel part/strip into the
stock) after having fixed the length premanufactured slots of the clamping jaws.
feed stop

8. Fixing the cutting values The values should be taken from the nomogram or a table.

9. Position the milling table into Mechanically with the rapid traverse or with manual adjustment
working position (X−Y−Z−direction).

10. Start cutting with the rotating The length size (80 mm) should be fixed as precise as possible
metal slitting saw blade by manual according to the marking on the workpiece and after the first cut
adjustment of the milling table correspondingly corrected.

11. Cutting by milling of the first Observation of the cutting process is necessary! At a "standstill" of the
workpiece after a possible metal slitting saw blade switch off the machine immediately! Take back
correction of the length size the milling table manually and clamp the metal slitting saw blade tighter
by "fastening" the arbor nut.

12. Declamp, deburr and clean the Control of the dimensional accuracy, parallelism and surface finish
workpiece, make a quality control.

13. Going on with the cutting by In case of an impaired surface finish you have to change the metal
milling at a permanent control of slitting saw blade!
the quality requirements

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 Backing material

Instruction example 6.2.: Measuring point

A strip shaped bar stock at a length of 550 mm has to be cut with a metal slitting saw blade into one−off parts
by cutting by milling.

Material

St 60 (structural steel, tensile strength 600 − 750 MPa)

Dimensions

20 x 24 x 50 mm (finishing sizes)

Milling machine

Horizontal milling machine

Tools

End face mill (Ø 100 mm), metal slitting saw blade (Ø 125 − 160 mm x 2.5 − 3 mm), cutter arbors (short and
long), machine vice, chucking screws, flat file, keys

Measuring and testing means

Vernier caliper, bevelled edge square, steel square

Auxiliaries

Separating jaws for the machine vice, stop bar for the separating jaws, chip brush, hand broom, cleaning rag,
T−slot cleaner, tongues for the machine vies

Required previous knowledge

To read a drawing, to measure and to test, to set−up and to operate horizontal and vertical milling machines,
face milling

Sequence of operations Remarks

1. Batch−quantity (number of the bars) and Comparison with the specifications of the work
length control accompanying data sheets

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2. Functional test and lubrication of the Lubrication and oil−level check according to the lubrication
milling machine schedule

3. Fixing and adjusting the machine vice Adjustment, localization by means of tongues and steel
(along the machine table) square

4. Clamping in the cutter arbor (short) and The short arbor and the end face mill are provided for face
fastening of an end face mill (about Ø 100 milling of one side of the bar stock.
mm)

5. Setting−up the coolant and the milling

protective systems

6. Clamping in the bar stock in multi−piece The workpieces should be clamped in so that they stand out
clamping (2−4 bars) from the vice only short.

7. Fixing the cutting values for face milling The values should be taken from the nomogram or a table.

8. Position the milling table into working

position

9. Scratch marking at rotating mill and "To mill clean" does mean that the cut is as low as possible.
"clean milling" of the end faces

10. Declamp the workpieces, deburr, clean Use proper files only − otherwise there is an injury hazard!
and control of the angularity and surface
finish

11. Changing the cutter arbor and the milling Clamping in the cutter arbor (long) and fastening the metal
tool − fixing the coolant and the milling slitting saw blade.
protective systems

12. Placing the separating jaws into the Separating jaws should only be used batchwise.
machine vice

13. Clamping in two bars for cutting by When clamping in the work−pieces, they should be arranged
milling after having fixed a length feed stop with the milled end face to the length feed stop.

14. Fixing the cutting values for cutting by The values should be taken from the nomogram or a table.
milling

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15. Position the milling table into the working To be positioned into the X−Y−Z−direction
position

16. Start cutting with the rotating metal Make a dimensional inspection and a possible correction
slitting saw blade by manual adjustment of after having started cutting (length size 50 mm).
the milling table

17. Cutting by milling of the first workpiece The rotating metal slitting saw blade should be observed
after a possible correction of the length size permanently and in case of disturbances (e.g. "standstill") the
machine should be switched off.

18. Declamp, deburr, and clean the Control of the dimensional accuracy angularity, parallelism
workpiece and do a quality control. and surface finish

19. Continuation of the cutting by milling at a With a large number of pieces a timely changing of the metal
permanent control of the quality slitting saw blade is recommended.
requirements

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 Measuring point

Instruction example 6.3.: Fixing bush

A bush−shaped workpiece made of grey cast iron has to be separated (slotted) with a metal slitting saw blade
half way of its bore.

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Material

GGL 25 (grey cast iron with laminated graphite, tensile strength 250 MPa, compressive strength 1000 MPa)

Dimensions

Ø 40 x Ø 80 x 120 mm

Milling machine

Horizontal milling machine

Tools

Metal slitting saw blade (Ø 125 − 150 x 2.5 mm), long cutter arbor, machine vice, clamping intake, chucking
screws, keys

Measuring and testing means

Vernier caliper, steel square

Auxiliaries

Stop rack, chip brush, hand broom, cleaning rag, T−slot cleaner, tongues for the machine vice

Required previous knowledge

To read a drawing, to measure and to test, to set−up and to operate horizontal milling machines

Sequence of operations Remarks

1. Batch−quantity and visual control of Comparison with the specifications of the work accompanying
the supplied workpieces data sheets

2. Functional test and lubrication of the Lubrication and oil−level check according to the lubrication
milling machine schedule

3. Fixing and adjusting the machine vice The adjustment and localization is done by means of the
(along the machine table) tongues and steel squares

4. Fastening the cutter arbor (long) and Do not forget the feather key!
fixing the metal slitting saw blade

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5. Setting−up the milling protective Pay attention to the space between the milling protective device
system and the upper edge of the workpiece!

6. Clamping in and adjusting the The adjustment should be carried out with a steel square on a
workpiece according to the marking slightly fastened workpiece. A side stop secures the
(separating slot) concentricity of the separating slot.

7. Fixing the cutting values

8. Position the milling table into the Place the metal slitting saw blade manually on the marking of
working position the separation slot.

9. Cutting by milling of the fixing bush Observation of the metal slitting saw blade during cutting by
(semi−sided cutting) milling on "standstill".

10. Declamp and clean the work−piece The clamping out of the workpiece should be carried out before
the return stroke of the milling table.

11. Visual control of the work−piece Control if the separating slot is situated at the marked point
(marking).

12. Continuation of cutting by milling until With a large number of pieces the metal slitting saw blade
all fixing bushes are slotted should be changed in time.

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 Fixing bush

Instruction example 6.4.: Segment

A collar−shaped workpiece has to be separated with a metal slitting saw blade into uniform segments (1 ring −
6 segments − 6 x 60°).

Material

C 35 (tempered steel, tensile strength 650 − 800 MPa)

Dimensions

Ø 160 x Ø 240 x 24 mm

Milling machine

Horizontal milling machine

Tools

Metal slitting saw blade (Ø 200 x 3 mm), cutter arbor (long), clamp iron, chucking screws, keys (spanner or
ring spanner), marking gauge, flat file

Measuring and testing means

Vernier caliper, universal bevel protractor

Auxiliaries

Chuck flange, chip brush, hand broom, cleaning rag, T−slot cleaner

Required previous knowledge

To read a drawing, to measure and to test, to set−up and to operate horizontal milling machines

Sequence of operations Remarks

1. Batch−quantity and visual control (number of Comparison with the specifications of the work
collars) accompanying data sheets

2. Functional test and lubrication of the milling Lubrication and oil−level check according to the lubrication
machine schedule

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3. Fastening of the workpiece (collar) directly The adjustment and localization are done with a marking
onto the machine table, adjustment according gauge, the marking should be above a slot of the milling
to the marking table! The clamping and positional stability are done by
means of a clamp iron and lock screws.

4. Fixing the cutter arbor (long) and fastening Do not forget the feather key at the right place, use chuck
the metal slitting saw blade flanges!

5. Position the milling table into the working Place the metal slitting saw blade manually on the
position marking.

6. Fixing the cutting values Use the nomogram or a table.

7. Setting−up the coolant and the milling

protective systems

8. Cutting by milling after marking, cleaning, Visual control, marking, surface finish, dimensional
deburring, visual and quality control inspection, angle control

9. Continuation of the cutting by milling until all Carry out permanent dimensional, angle and visual
collars are separated into segments inspection.

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Segment

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