O - Milling to Bandsaws Flashcards
vital to modern subtractive manufacturing, available in manual and CNC variants, can cut virtually any machinable shape when combined with TURNING.
VERTICAL MILLING
The 3 different names for the manual version of VERTICAL MILLING
- vertical mill
- knee mill
- bridgeport
Used primarily for machines that are more compact in size and therefore suitable for smaller workshops where footprint and ceiling height are limited. Another name for a vertical milling machine.
KNEE MILL
A pioneering manufacturer of full-size machines founded in Bridgeport, Connecticut. Another name for a vertical milling machine.
BRIDGEPORT
In what way does a VERTICAL MILLING MACHINE resemble a DRILL PRESS?
since it has a single, driven vertical spindle that moves up and down
“Beefier” version of a press and has an x-y-z indexable table for work holding and positioning
MILL
Although it is possible to attach a drill to the spindle of a MILL (via a COLLET CHUCK), the tool bit of choice is the _______ ______.
MILLING CUTTER
The most common type of milling cutter, usually made of HSS, can be single, double, or triple-coated, usually have 3 or more blades, and can produce a fairly good surface finish.
END MILL
An END MILL with only 2 blades available, used to remove material quickly (rough cutting/roughing).
SLOT MILL
The ____ _____ is first used to rapidly remove material, followed by a tool swap to a 3+ bladed ___ ____ for a lighter finish cut with a superior surface finish.
SLOT MILL; END MILL
What can MILLING CUTTERS do that Shapers could not?
PLUNGE into the workpiece, changing path direction (L-shaped slot)
What must the MILLING CUTTER be capable of in order to plunge into the workpiece?
cutting all the way to the center of its face.
Characteristics of CENTER CUTTING
- one or more cutting edges at the tip
- allows cutter to plunge, drill, or ramp
- greater variety of applications
Characteristics of NONCENTER CUTTING
- used for side cuts of contouring an exterior surface
- used where plunging is not necessary
Many modern tool bits, including INDEXABLE END MILLS, use the convenience of _______ _______.
CUTTING INSERTS
Unlike those used for single-point lathe tools, these are designed to cut along 2 edges at the same time.
CUTTING INSERTS
Another common milling operation used to quickly reduce the thickness of a workpiece.
FACE MILLING
Large discs with teeth on the periphery of the face, and are rarely ground from the solid material, use a ring of INSERTS.
FACE MILLS
A special type of groove often cut into machine tool tables or lathe face plates. They are milled in a 2-stage operation.
T-SLOTS
What are the 2 stages of malling a T-SLOT?
- multiple passes using a slender end mill to progressively cut the vertical groove
- use a special T-SLOT CUTTER to create the lower horizontal portion
A milling operation achieved with a single bit similar to the appearance of the T-SLOT cutter.
KEYWAY CUTTING
Has a shank with a curved reduction adjacent to the bladed end.
KEYWAY/KEYSEAT CUTTER
What is an advantage to KEYWAY CUTTERS?
They can cut the D-shaped seating groove needed for WOODRUFF KEYS
What kinds of odd shapes are MILLING CUTTERS available for special applications?
- BALL END MILLS to cut round-bottomed grooves
- DOVETAIL MILLS to make dovetail grooves
- CHAMFERING MILLS to put a chamfer on an edge
- CORNER ROUNDING MILLS to soften edges with a curve
What is the issue with VERTICAL MILLING that is addressed with the HORIZONTAL MILLING MACHINE?
the cutting tools on a vertical milling machine are only held at one end, which limits the depth of cut without tool breakage, and flexing can create poor accuracy
Are HORIZONTAL MILLING MACHINES available in CNC and manual varients?
YES
driven around and supported at both ends; cutting tools in a HORIZONTAL MILLING MACHINE are attached to this
an ARBOR
6 types of HORIZONTAL MILLING operations
- straddle milling
- form milling
- slotting
- slitting
- gang milling
- slab milling
A manual machine with all the motion inputs handled by servos or stepper motors
CNC MILL (computer numerical control)
The software language used in CNC MILLS, can be written directly by a skilled programmer generated as the output from a CAD/CAM package.
G-CODE
How are instruction files input into the CNC MILL?
USB or downloaded from a network.
An operator manually inputs parameters via a keyboard on the controller
CONVERSATIONAL PROGRAMMING
safer to use than manual ones because the machining takes place in an enclosed space.
CNC MILLS
CNC MILLS have at least _ ______ machines
3 AXIS (X, Y, and Z)
Why is the W-AXIS not strictly necessary in a CNC MILL?
because the same motion can be achieved through coordination of the Z and X
Nowadays it is common to see a ___ ____ combined with a ___ _____.
CNC MILL; CNC LATHE
Multi-axis machines are expensive so they are limited to _-____ (X, Y, Z, A) or _-____(X, Y, Z, A, B) systems.
4-AXIS; 5-AXIS
tool storage and automatic changing system in CNC MILLS and CNC MACHINE CENTERS
MAGAZINE or CAROUSEL (turret)
Each tool in the MAGAZINE/CAROUSEL is fitted into a tapered (non-locking) holder and held in the spindle by a _________ _______.
pneumatic DRAWBAR
Process used to manufacture simple external straight-cut gears
GEAR SHAPING
a cylindrical BROACH configuration with teeth running down inside the bore
POT BROACHING
A form of milling for gear cutting
GEAR MILLING
for spiral or helical cut gears, it is necessary to use a gear-generating machine and this cutting tool
GEAR HOB
A HAND TOOL made of hardened steel with a rough surface and comes in various cross-sections, used for deburring operations
FILES
The course variant of the FILE.
BASTARD FILES
Very small files for doing detailed work
NEEDLE FILES (US) OR SWISS FILES (UK)
FILES are prone to getting clogged with chips stuck between the fine teeth when cutting soft metal like aluminum
LOADING
Why is it recommended that FILES be coated in CHALK prior to and during use?
to prevent chips from sticking and loading
A powered alternative to the FILE, a small handheld power tool that makes simple tasks like deburring or engraving effortless
ROTARY FILE or DREMEL TOOL
Removing sharp edges and attached metal flakes left after machining operations
DEBURRING
Rotary device that runs at a very high speed and makes a sound like a “dentist’s drill”
DREMEL TOOL
Cutting tool bits that substitute for filing
BURRS/BURS or ROTARY FILES
Very difficult to control when handheld and have the tendency to suddenly rip across the workpiece surface causing superficial damage
ROTARY TOOLS
The body of the ROTARY TOOL stays on a solid surface away from the workpiece, while the cutter is securely held, but easily manipulated, like a pen
FLEXIBLE DRIVE SHAFT ATTACHMENT
Common way of cutting material used a lot in carpentry (woodworking)
SAWING
A hand tool that uses a removable blade that is always installed with the teeth angled towards the front, cutting only occurs on the forward stroke.
HACKSAW
Compact configuration of the HACKSAW.
JUNIOR/MINI HACKSAW
A metal sawing tool that uses a continuous loop blade that is driven between 2 pulleys
BANDSAW
The portable and powered version of the BANDSAW
PORTA-BAND
BANDSAW machine tool configuration good for cutting a sheet or plate, and can follow a curved path if desired
VERTICAL BANDSAW
BANDSAW machine tool configuration designed specifically for cutting long bar stock or pipe/tube into manageable lengths.
HORIZONTAL BANDSAW
