Milling

Question 1

Milling

Answer 1

Is a machining process by which a surface is generated by progressive chip removal using a rotating cutting tool. The workpiece is fed into a rotating cutting tool.

Question 2

The axis of rotation

Answer 2

Is perpendicular to the direction of feed.

Question 3

Material removal is achieved by

Answer 3

Interrupted cutting during which teeth (cutting edges) of the cutting tool intermittently engage and machine the workpiece during each revolution.

Question 4

Peripheral milling

Answer 4

The surface is generated by teeth located on the periphery of the cutter body; The surface is parallel with the axis of rotation of the cutter (also called plain milling).

Question 5

Face milling

Answer 5

The surface is generated is at a right angle to the cutter axis; Material is removed by the peripheral teeth and the face portion providing finishing action (also called end milling).

Question 6

Slab milling (Peripheral)

Answer 6

Cutter width extends beyond the workpiece on both sides.

Question 7

Slot milling (Peripheral)

Answer 7

Width of the cutter is less than the workpiece width.

Question 8

Side milling (Peripheral)

Answer 8

Cutter machines one side of the workpiece only. (One side of the workpiece face).

Question 9

Straddle milling (Peripheral)

Answer 9

Similar to side milling but cutting both side of the work.

Question 10

Conventional face milling

Answer 10

Cutter diameter is greater than the workpiece width.

Question 11

Partial face milling

Answer 11

Cutter overhangs the workpiece on one side. (One side of the workpiece face).

Question 12

End milling

Answer 12

Cutter diameter is less than workpiece width creating a slot.

Question 13

Profile milling

Answer 13

Is a form of end milling in which the outside periphery of a flat part is cut. (Cuts out perimeter of a shape by moving in the horizontal plane). CNC.

Question 14

Pocket milling

Answer 14

Is a form of end milling used to mill shallow pockets. (Cuts out pockets and internal dimensions by moving in the horizontal plane.) CNC.

Question 15

Surface contouring

Answer 15

A ball-nose cutter is fed back and forth along a curvilinear path to create a 3D surface form. (Can create a surface with varying heights by moving in up and down. Also moves in horizontal plane). CNC.

Question 16

Up milling

Answer 16

The direction of motion of the cutter teeth is opposite the feed direction when the teeth cut into the workpiece (conventional milling). “against the feed”.

Question 17

Down milling

Answer 17

The direction of cutter motion is the same as the feed direction when the teeth cut into the workpiece (climb milling). “with the feed”.

Question 18

Up milling chip formation

Answer 18

Chip at the beginning is very thin increasing to maximum thickness when the tooth leaves the workpiece (abrupt exit). Cutter tends to push the workpiece along and lift it upward from the table. Greater clamping forces are required.

Question 19

Down milling chip formation

Answer 19

Maximum chip thickness is at the point of tooth contact with the workpiece; dulling the teeth more quickly especially for hard surfaces. Workpiece is pulled into the cutter.