Milling and Broaching

Question 1

Milling Process

Answer 1

Workpart is fed against rotating cylindrical tool (milling cutter) with multiple cutting edges

Question 2

types of milling

Answer 2

face milling
end milling
peripheral milling

Question 3

peripheral (plain) milling

Answer 3

axis of milling cutter parallel to workpiece surface

Question 4

different types of plain milling

Answer 4

Slab (whole surface –> cutter is bigger than width of cut)
Slot (only a slot)
Side ( only on the side)
straddle milling

Question 5

Up vs Down milling

Answer 5

Up Milling:
- milling against the feed
-long chips (start thin gets thick at the end)
-lower initial cutting force
-wavy surface
Down Milling:
- milling with the feed
- shorter chips (start thick end thin)
-higher initial cutting force
-better surface quality
-can be dangerous on a manual mill due to gear backlash

Question 6

Face Milling

Answer 6

cutter mounted on a spindle with axis of rotation perpendicular to workpiece
leaves feed marks on surface
works on top of workpiece

Question 7

Up or Down Milling?

Answer 7

CNC: Down milling –> longer tool life –> better surface finish
Manual milling: up milling

Question 8

Difference drill and Mill

Answer 8

drill: up and down
mill: also in X and Y direction

Question 9

Parts of milling machine

Answer 9

• worktable
• saddle: supports worktable
• knee: supports the saddle
• over arm: only horizontal machines
• head: contains spindle

Question 10

Horizontal machining center (disadv/adv)

Answer 10

Advantages:
- chips drop out and do not need to be removed manually
- good line of sight control
- exchange mechanism easy to reach and control
Disadvantages:
- difficult to load large workpieces
- more costly
- High thrust must be absorbed by tombstones

Question 11

Vertical Machining cener (disadv/adv)

Answer 11

Advantages:
- Thrust get absorbed directly by working table
-ideal for large flat workpieces
- less costly
Disadvantages:
- the bigger the workpiece the more difficult to look into cut
- chips has to be removed manually
- not suitable for large boxy parts

Question 12

what is probing?

Answer 12

measuring workpiece –> calculation

Question 13

broaching process

Answer 13

cutting operations where accurate sizing and finishing of a surface or shape is produced of a multi point cutter

Question 14

other broaching process

Answer 14

internal broach