Study Guide O: Milling (Bandsaws)

Question 1

What is also vital to modern subtractive manufacturing aside from TURNING?

Answer 1

VERTICAL MILLING

Question 2

What are the manual version names of VERTICAL MILLING?

Answer 2

VERTICAL MILL, KNEE MILL or BRIDGEPORT

Question 3

What do the names KNEE MILL and BRIDGEPORT mean about the VERTICAL MILLING MACHINE?

Answer 3

KNEE MACHINE means that the machine is small and compact. BRIDGEPORT refers to the full size machines.

Question 4

A VERTICAL MILLING MACHINE is very similar to a DRILL PRESS, but how is it different?

Answer 4

Its “beefier” has an x-y-z indexable table for work holding and positioning.

Question 5

What is the tool bit of choice for a MILL, and what are its features?

Answer 5

MILLING CUTTER and it has a sharp side on both the face and sides

Question 6

What is the most common MILLING CUTTER?

Answer 6

END MILL, they are generally made of HSS and can be single,double, or triple coated.

Question 7

What is the 2 blade version of the END MILL called, and what is it mainly used for?

Answer 7

SLOT DRILL and is mainly used to remove material quickly as “ROUGH CUTTING” OR “ROUGHING” which leaves poor surface finish

Question 8

What is the process of using both a SLOT DRILL and END MILL?

Answer 8

First use the SLOT DRILL and rapidly cut material then use a 3+ bladed END MILL and do a lighter finish cut with a superior finish cut.

Question 9

What are the characteristics of a MILLING CUTTER and how is it different from a SHAPER?

Answer 9

It has cutting blades on the face and sides, can also “plunge” into the workpiece and change path direction

Question 10

What are the 2 types of END MILLS?

Answer 10

CENTER CUTTING and NON CENTER CUTTING

Question 11

What are the characteristics of CENTER CUTTING END MILL?

Answer 11

One or more cutting edges at the tip, allows cutter to plunge, drill or ramp, and is expensive.

Question 12

What are the charecteristics of a NON CENTER CUTTING END MILL?

Answer 12

Cheaper, clear chips better, are easier to resharpen, used for side cuts of contouring an exterior surface, and are used when plunging is not necessary.

Question 13

What modern tool bit uses a special type of INSERT?

Answer 13

INDEXABLE END MILLS and the INSERTS are designed to cut along two edges at the same time, not just the corner.

Question 14

What is another common milling operation which is used to quickly reduce the thickness of the workpiece?

Answer 14

FACE MILLING and this operation has no need to plunge.

Question 15

Why use FACE MILLING vs END MILLING?

Answer 15

FACE MILLING can remove large amounts material that would require a END MILL to do many passes to do.

Question 16

What is the tool used for FACE MILLING and what is its characteristics?

Answer 16

The tool is a FACE MILL and they are large discs with teeth on the periphery of the face, and are rarely ground from solid material. Most FACE MILLS nowadays use a ring of INSERTS.

Question 17

What is other common cutting operation?

Answer 17

T SLOTS and KEYWAYS (staright or Woodruff)

Question 18

What are T SLOTS?

Answer 18

T SLOTS are a special type of groove often cut into machine tool tables ro lathe face plates, shaped like an inverted T and are used in conjunction with SQUARE HEADED BOLTS to clamp a workpiece securely during a cutting operation.

Question 19

How are T SLOTS milled?

Answer 19

T SLOTS are milled in a two-stage operation involving first - multiple passes using a slender end mill to progressively cut a groove, folowed by a T SLOT CUTTER to create a lower horizontal portion/

Question 20

Can you comine the two operations to create a T SLOT?

Answer 20

NO

Question 21

What is the specialized tool to create a T SLOT and how is it used?

Answer 21

The tool is a T SLOT CUTTER and it is used in an operation that must be done in a single pass to create the bottom of the T groove.

Question 22

What is the tool used in KEYWAY CUTTING and its special features?

Answer 22

Its called a KEYWAY ( or KEYSEAT) CUTTER and it has a shank with a curved reduction adjacent to the blade end.

Question 23

Why use a KEYWAY ( or KEYSEAT) CUTTER instead of a END MILL?

Answer 23

It is used to cut staright external KEYWAYS along shafts, it has a sturdy construciton that allows a much faster operation with fewer passes and can cut D-shaped seating groove for WOODRUFF.

Question 24

What are other types of MILLING CUTTERS that are used for special applications?

Answer 24

BALL END MILLS, DOVETAIL MILLS, CHAMFERING MILLS, and CONER ROUNDING MILLS

Question 25

What does a BALL END MILL do?

Answer 25

It can cut round-bottomed grooves

Question 26

What does a DOVETAIL MILL do?

Answer 26

It can cut dovetailed grooves

Question 27

What does a CHAMFERING MILL do?

Answer 27

It puts a chamfer on an edge

Question 28

What does a CORNER ROUNDING MILL do?

Answer 28

It softens edges with a curve