Study Guide O: Milling (Bandsaws) Flashcards
What is also vital to modern subtractive manufacturing aside from TURNING?
VERTICAL MILLING
What are the manual version names of VERTICAL MILLING?
VERTICAL MILL, KNEE MILL or BRIDGEPORT
What do the names KNEE MILL and BRIDGEPORT mean about the VERTICAL MILLING MACHINE?
KNEE MACHINE means that the machine is small and compact. BRIDGEPORT refers to the full size machines.
A VERTICAL MILLING MACHINE is very similar to a DRILL PRESS, but how is it different?
Its “beefier” has an x-y-z indexable table for work holding and positioning.
What is the tool bit of choice for a MILL, and what are its features?
MILLING CUTTER and it has a sharp side on both the face and sides
What is the most common MILLING CUTTER?
END MILL, they are generally made of HSS and can be single,double, or triple coated.
What is the 2 blade version of the END MILL called, and what is it mainly used for?
SLOT DRILL and is mainly used to remove material quickly as “ROUGH CUTTING” OR “ROUGHING” which leaves poor surface finish
What is the process of using both a SLOT DRILL and END MILL?
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.
What are the characteristics of a MILLING CUTTER and how is it different from a SHAPER?
It has cutting blades on the face and sides, can also “plunge” into the workpiece and change path direction
What are the 2 types of END MILLS?
CENTER CUTTING and NON CENTER CUTTING
What are the characteristics of CENTER CUTTING END MILL?
One or more cutting edges at the tip, allows cutter to plunge, drill or ramp, and is expensive.
What are the charecteristics of a NON CENTER CUTTING END MILL?
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.
What modern tool bit uses a special type of INSERT?
INDEXABLE END MILLS and the INSERTS are designed to cut along two edges at the same time, not just the corner.
What is another common milling operation which is used to quickly reduce the thickness of the workpiece?
FACE MILLING and this operation has no need to plunge.
Why use FACE MILLING vs END MILLING?
FACE MILLING can remove large amounts material that would require a END MILL to do many passes to do.
What is the tool used for FACE MILLING and what is its characteristics?
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.
What is other common cutting operation?
T SLOTS and KEYWAYS (staright or Woodruff)
What are T SLOTS?
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.
How are T SLOTS milled?
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/
Can you comine the two operations to create a T SLOT?
NO
What is the specialized tool to create a T SLOT and how is it used?
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.
What is the tool used in KEYWAY CUTTING and its special features?
Its called a KEYWAY ( or KEYSEAT) CUTTER and it has a shank with a curved reduction adjacent to the blade end.
Why use a KEYWAY ( or KEYSEAT) CUTTER instead of a END MILL?
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.
What are other types of MILLING CUTTERS that are used for special applications?
BALL END MILLS, DOVETAIL MILLS, CHAMFERING MILLS, and CONER ROUNDING MILLS
