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Millwright Level 1 > Milling > Flashcards

Milling Flashcards

1
Q

Use paper towel when handling_____?

A

Cutters

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2
Q

What is the most time consuming but the most crucial part of milling?

A

Set up

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3
Q

What are the four types of knee and column milling machines?

A

Plain Horizontal

Universal horizontal

Standard vertical

Ram type vertical

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4
Q

What are the characteristics of a plain horizontal milling machine?

A
  • most basic
  • can do most milling jobs
  • main spindle is horizontal
  • table moves at right angles
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5
Q

What are the characteristics of a universal horizontal milling machine?

A
  • same a plain milling machine but table can swivel.
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6
Q

What are the characteristics of a standard verticals milling machine?

A
  • vertical spindle
  • spindle can be fed in and out like a drill press
  • vertical spindle allows for use of endmills, drills, and other chuck mounted cutting tools.

-more versatile then horizontal but not as rigid.

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7
Q

How are knee type milling machines sized?

A

Range of movement

Horsepower

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8
Q

What are the parts of a knee column milling machine?

A

Base - supports column

Column - provides support for the horizontal spindle

Overarm - supports the arbour

Saddle - houses table feed mechanism

Knee - houses the saddle and knee feed mechanisms

Table - rides in dovetail ways on top of the saddle supports work pieces

Backlash eliminator - used when climb milling to prevent workpiece from being pulled into the cutter.

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9
Q

When should a backlash eliminator be used?

A

Before climb milling

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10
Q

What drives the cutter?

A

Spindle

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11
Q

How is spindle speed controlled?

A

Gear box

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12
Q

When a part cannot be taken apart easily what milling machine is best suited?

A

Portable key seat mill.

Can be taken to the shaft and used to cut on shaft diameters from .5” to 24”

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13
Q

Arbour mounted cutters are for?

A

Horizontal type milling machines

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14
Q

Shank mounted cutters are for?

A

Vertical milling machines

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15
Q

What are 4 shank styles of endmill cutters?

A

Straight style - light machining

Weldon shank - light machining

Threaded shank - heavy duty cuts

Double ended - less costly

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16
Q

How many cutting edges can a endmill have?

A

2- large chip space, ideal for cutting soft materials

3/4 - higher feed rates, typically not for plunge cutting unless teeth extend to the centre of the bit

All end mills can cut sideways through a workpiece. Centre cutting end mills can cut straight down. If cutting edges extend to the centre it can be used for plunge cutting.

Greater number of teeth permits higher feed rate.

Most three of four flute cutters are NOT for end cutting.

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17
Q

When do you use a fly cutter?

A

When very flat surface with a good finish is desired.

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18
Q

What is an arbour?

A

The long or short bar that holds the milling cutter in place

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19
Q

Describe a collet?

A

Hardened steel bushings with a series of slits cut into them. Used to grip the shank of the cutting tool

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20
Q

When should a backlash eliminator be used?

A

Before climb milling

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21
Q

What drives the cutter?

A

Spindle

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22
Q

How is spindle speed controlled?

A

Gear box

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23
Q

When a part cannot be taken apart easily what milling machine is best suited?

A

Portable key seat mill.

Can be taken to the shaft and used to cut on shaft diameters from .5” to 24”

24
Q

Arbour mounted cutters are for?

A

Horizontal type milling machines

25
Q

Shank mounted cutters are for?

A

Vertical milling machines

26
Q

What are 4 shank styles?

A

Straight style - light machining

Weldon shank - light machining

Threaded shank - heavy duty cuts

Double ended - less costly

27
Q

How many cutting edges can a endmill have?

A

2- large chip space, ideal for cutting soft materials

3/4 - higher feed rates, typically not for plunge cutting unless teeth extend to the centre of the bit

28
Q

When do you use a fly cutter?

A

When very flat surface with a good finish is desired.

29
Q

What is an arbour?

A

The long or short bar that holds the milling cutter in place

30
Q

What is a jacobs taper adapter?

What is a Morse tape adapter?

A

Makes it possible to fit a drill chuck to the spindle of the milling machine

Makes it possible to fit a large drill having a Morse taper shank into the spindle of the milling machine.

31
Q

What are the characteristics of a good holding device?

A

Easy to set up
Grip the workpiece
Allow coolant to cool the cutter

32
Q

What is the best way to clamp large or awkward pieces to the milling machine?

A

Clamp straight to the table

33
Q

Chip load x spindle speed x number of teeth =

A

Feed rate

34
Q

Work piece fed against the rotation of the cutter?

A

Conventional milling
- set up must be ridged as cutter tends to lift material off the table
- use conventional milling with ever there is no backlash eliminator in the machining table

35
Q

Workpiece feeds the rotation of the cutter?

A

Climb milling
- leaves good surface finish
- not suitable for castings or other workpieces with hard scale on the surface. Cutter dulls quickly

36
Q

Length of key seat does not include____?

A

Any runout or radius left.

37
Q

When changing spindle speed (gear box) it is important to?

Adjusting variable speed wheel it is important to adjust while ?

A

Shut machine down before changing.

Machine is running

38
Q

To use a friction collet you:

A

1: determine the diameter of the cutter shank
2: choose the corresponding collet from the set
3: clean all grit from the collet, cutting tool shank, chuck body and nut
4: snap the collet into the chuck nut using the palm of your hand
5: turn the chuck/nut assembly onto the thread of the chuck body but do not tighten it.
6: slide shank of cutter into the collet
7: use chuck wrench to tighten the chuck nut.

39
Q

Heavy duty collet chuck parts

A
40
Q

Each time a vertical head is installed it must be dialled in to ensure the vertical spindle is perpendicular to the surface of the table. Remember these points:

A
  • loosen vertical head slightly to allow for adjustments
  • dial indicator extensions are set up in the spindle. With the dial on the table surface. Rotate the dial by hand and adjust the head in small increments. Rechecking many times
  • a total runout of .001 - .002 “ is required for good machining performance.
41
Q

Best tool to find prick punch centre on milling machine?

A

Cone point edge finder is best

Wiggler works to

42
Q

Dialling in a vice on the milling machine.

A

1: set vice on table making sure table and bottom of vice are clean
2: clean jaws of vice and clamp a parallel extending past the top of the vice.
3: set base of dial indicator on a flat part of the milling machine. (Usually the column) adjust indicator to ride either on the front or back side of the parallel.
4: tighten one of the hold down bolts with a wrench. Leave the second bolt hand tight.
5: move the table so the indicator is positioned with the tight-end bolt and zero dial.
6: move table so the parallel runs across the indicator stopping at the opposite end.
7: use the change in dial reading to determine which way the vice is out and strike the vice with a soft faced hammer to knock the vise closer to true alignment.
8: repeat steps 5, 6 and 7 until dial shows no run run out.
9: tighten second bolt and double check runout.

43
Q

Setting up for face milling consists of?

A

1: choose a face mill slightly wider than the face to me machined. Check condition of cutter.
2: mount cutter
3: secure workpiece to the table using clamps or vice. IF CLAMPING FLAME CUT WORK PIECE TO TABLE MAKE SURE TO CLAMP OVER KEYSTOCK TO PREVENT DAMAGE TO TABLE.
4: set spindle and feed rate
5: start spindle and raise table until the cutter just touches the workpiece.
6: move workpiece away from cutter and raise table just enough to clean the face around .050”
7: engage feed and take a cut. When cut is finished use rapid feed to return table to the start of cut
8: stop spindle measure work piece and determine how much material needs to be cut away
9: take one or more cuts to finish workpiece to size.

44
Q

When cutting keyseats entire length of shaft what cutter is best?

A

Side milling cutter

45
Q

When keyseats run up to a feature what tool is needed to cut the key seat?

A

End mill.

End mills tend to deflect so they can take much longer to cut the keyseats

46
Q

Wood ruff key cutting is down with what tools?

A

Using standard cutters and fit with readily available keys having standard sizes

47
Q

Depth of keyseat is always measure from ?

A

The flat

48
Q

What are the two ways to set the cutter to depth when milling keyseats?

A

1: raise the workpiece until it just touches the cutter. Carefully raise the table further until the cutter appears to be cutting to its full width. Set the knee dial to zero then raise the table to the amount equal to the depth of keayseat. Not the best but good enough

2: consult a reference (machinery’s handbook) for the depth of the keyseat measured from the outside of the shaft rather the. The flat.

49
Q

When cutting the length of a keyseat and the plans call for 1 1/4 length how do you measure the length?

A

Length is measure by the straight portion of the cut and not taking the radius measurement into account.

50
Q

Centring the shaft under the cutter steps:

A

1: test off a strip of paper 6” long
2: hold paper between the rotating cutter and workpiece. Hold paper loosely so it slips out of fingers easily.
3: move workpiece toward the cutter until cutter grabs the paper. Zero dial.
4: lower work piece so it clears the cutter and move it to a distance equal to half the diameter of the cutter plus half the diameter of the work piece

51
Q

When finding centre of the shaft with the cutter what is the formula for endmill?

A

Cutter D/2 + shaft D/2

Cutter diameter
Shaft diameter

52
Q

When using a milling machine why do you not want to use a unusually slow feed?

A

Dulls the cutting bit

53
Q

Why should you never stop a cutter while in contact with a work piece?

A

Will chip the cutting edges

54
Q

Max cut for endmill is?

A

1/2 diameter of the cutter.

I would do less than that though

55
Q

Why is cleaning and oiling machines very important?

A

Prevents rusting which results in loss of accuracy

56
Q

Feed rate equals?

Original spindle speed formula
CS x 12/ 3.14 x diameter of cutter

A

Chip load x spindle speed x number of teeth

Inches per minute

57
Q

Why must cutter tools be stored to not make contact?

A

Protects their cutting edges from chips and wear

Millwright Level 1 (24 decks)

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