Vertical and Horizontal Mills

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Vertical and Horizontal Mills
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Vertical Mill
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Parts

• Base and Column
• Knee
• Saddle
• Table
• Ram
• Tool Head
• Quill Feed

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Cutter Holding

• No more overhang than is necessary
• R8 Taper
• Solid Collet (most rigid)
• Split Collet

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Vertical Milling Cutters
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End mills

• 2 or more flutes
• single or double end
• straight or helix flute
• roughing end mills

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Geometry Forming cutters

• dovetail - 45 or 60 degree
• t-slot
• woodruff key
• shell end mills
• three flute tapered - used for mold making, die
  work, patterns

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Misc cutters

• Fly cutters - single point tool often consisting
  of high speed or carbide tool
• take light face cuts from large surface areas
• Indexible tooling - many cutter types and shapes
• eliminate resharpening
• Face mills - flat surfaces

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Horizontal Mill
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Parts

• Base and Column
• Knee
• Saddle
• Table
• Spindle
• Overarm

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Universal Horizontal Mill

• similar to plain except it has has an additional
  housing that supports the table and allows table
  to swivel 45 deg in either direction in horiz
  plane
• used to machine helical slots or grooves in mill
  cutters and twist drills, otherwise they are the
  same as the plain machines

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Types of spindles, arbors, and adapters

• front end of spindle nose has a tapered socket in
  a standard milling machine taper. This taper
  aligns the milling machine adapter or cutter
  arbor
• driving force is provided by two keys located on
  the spindle nose
• these engage slots on the adaptor or arbor

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Milling machine spindle nose tapers

• 30, 40, 50 (most common), 60

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Cutters may be attached

• a. directly to the spindle nose
• b. on a taper shank arbor (our application)

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Taper shank arbor assembly

• arbor itself
• spacing collars - take up space between cutter
  and end of arbor
• bearing collar - rides in arbor support bearing
• arbor support bearing - supports outer end of the
  arbor

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Horizontal Milling Cutters
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Arbor driven cutters (most common)
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Plain arbor driven cutters - for removing
material across entire surface (most common
operation) - 3 types

• 1. light duty - more teeth
• 2. heavy duty - less / heavier teeth
• Note any width 3/4 and less will have straight
  teeth more chatter

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Side milling cutters - for machining steps or
grooves

• stagger tooth
• inserted tooth (indexable)
• 1/2 side

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Slitting saws - for slotting and cut-off

• stagger tooth
• inserted tooth (indexable)
• side

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Geometry forming

• single angle - 45 and 60 most common
• double angle - 45, 60 and 90 most common
• concave - go by the cutter shape not by the
  geometry created
• convex
• corner rounding
• gear cutters

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Misc. Horizontal Milling setups

• 1. straddle milling
• 2. gang milling - to machine special shapes and
  contours on workpiece
• cutter rpm calculated for largest dia cutter in
  gang

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Day 2
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Work holding methods
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1.) Vise (most common)

• plain vise
• swivel vise
• universal vise -swivels 90 deg in vert and 360 in
  horiz plain

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Vise operation

• manual
• air
• hydraulic

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Use a lead or rubber hammer to strike handle to
tighten
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Keep work piece as far into vise as possible
without danger of hitting vise
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Proper part orientation in vise for cutting
pressures

• pressure against solid jaw (best)
• pressure against movable jaw
• pressure parallel to jaws (worst)

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Soft jaws
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2.) Mounting directly to the table

• strap clamps, T-bolts, and step blocks
• protect work piece surface with shims when
  necessary
• use parallels or shims under work piece as needed
• work piece distorted or damaged with excessive
  pressures

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3.) Pallets
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Work edge locating

• offset edge finder (accurate)
• dial indicator (accurate)
• touch off method (less accurate)
• paper shim (less accurate)

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Hole center locating
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Climb (down) vs. Conventional Milling (up)
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Selection depends on

• is there backlash compensation
• required surface finish
• type of material being cut

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Climb milling

• results in good surface finish - chips not swept
  back through cut
• avoid unless backlash is compensated for

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Conventional milling (normally used)

• surface finish not as good

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Vertical Milling Depth of cut - End mills

• Roughing cuts with standard end mills in steel -
  dont exceed 1/2 dia. cutter dia.
• Finish cuts - .005 - .010

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Horizontal Milling Depth of cut - Arbor driven
cutters

• roughing cuts .100 to 200
• finish cuts .015 to .030
• no less than .015

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Squaring vise and machine head
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Vertical Mill

• Head squared to table
• Vise squared to table

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Horizontal Mill

• Table squared by mounting indicator on table
  (Never the column)
• Vise squared to table with indicator mounted on
  overarm