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What is milling?
Milling is the machining process of using rotary
cutters to remove material
A milling cutter is spun about an axis while a
workpiece is advanced through it in such a way
that the blades of the cutter are able to shave
chips of material with each pass
Milling is one of the most commonly used
processes in industry and machine shops today
for machining parts to precise sizes and shapes
Milling machine
History of milling
1810s-1830s first milling machines in use
1860s xyz coordinates in use
1910s-1940s accuracy of 0.0001 inches
1950s first automated milling machines
1980s onward Computers and CNC machine
tools continue to develop rapidly
Revolution marks
As material passes through the cutting area of
a milling machine, the blades of the cutter
take bits of material at regular intervals
This means that no surface cut by a milling
machine will ever be completely smooth
Thus revolution marks can be seen on milled
surface
Milling Forces
Milling forces affect
- amount of power required
- vibration propensity
- durability of cutter
Tangential force
Radial force
Axial force
Tooling
There is a high degree of standardization of the tooling used
with CNC milling machines, and a lesser degree with manual
milling machines.
To ease up the organization of the tooling in CNC production,
many companies use a tool management solution.
For manual milling machines, there is less standardization,
because a greater plurality of formerly competing standards
exist.
CNC milling machines nearly always use SK (or ISO), CAT, BT or
HSK tooling
SK tooling is the most common in Europe.
SK and HSK tooling, sometimes called "Hollow Shank Tooling", is
much more common in Europe where it was invented than it
is in the United States.
The holding mechanism for HSK tooling is placed within the
(hollow) body of the tool and, as spindle speed increases, it
expands, gripping the tool more tightly with increasing spindle
speed.
Tools:
Grinding parts of these tools
are made of high speed steel,
which is very hard material.
http://www.youtube.com/watch?v=Wk2VYwCIcZE
Milling machines
There is two basic types of mills, vertical and
horizontal. Generally these contains just two
axis, when only the spindle or the table can be
moved sideways or upright directions. Then
there is more valuable models, which are
made for very sharp working where mills can
have even 5- or 6-axis. Then the spindle and
the table can spin around their axis. Both of
these basic types can have many
subcategories.
Vertical Mills
In the vertical mills the
spindle axis is vertically
oriented. Where the work
tool, spindle, is above of a
table. Spindle or table can
be raised and lowered. And
it can also move sideways
directions. These are
classified two
subcategories, the turret
mills and the bed mills.
Horizontal Mills
Horizontal mill has same idea
than vertical mills, but the
spindle is mounted
horizontal arbor across the
table. And it has also same
possibilities to move the
table or the spindle sideways
and upright directions.