5. 5
The author would like to thank all the bibliographic references and videos that
have contributed to the elaboration of these presentations.
For bibliographic references, please refer to:
• http://www.slideshare.net/endika55/bibliography-71763364 (PDF file)
• http://www.slideshare.net/endika55/bibliography-71763366 (PPT file)
For videos, please refer to:
• www.symbaloo.com/mix/manufacturingtechnology
BIBLIOGRAPHY
by Endika Gandarias
7. 7
MILLING TECHNOLOGY
INTRODUCTION
BASIC MOVEMENTS:
– Mc Cutting movement (regarding the tool)
– Ma Feed movement (regarding the part or tool)
– Mp Cutting depth movement (regarding the
part or tool)
by Endika Gandarias
Mc
Mp
Ma
8. 8
Eli Whitney milling machine
1818
Middletown milling machine
1818
Nasmyth milling machine
1829
Lincoln miller
1870
Universal milling machine
Brown-and-Sharpe
1861
Horizontal milling machine
Cincinnati
early 1900s
INTRODUCTION
by Endika Gandarias
9. 9
N
N
F
DC
ae
ap
A milling cutting tool is similar to the
turning cutting tool, but many tools called
“teeth” integrate it.
• The tool is spinning (Mc).
• One or more linear movements
(Mp & Ma) may have the tool or the
part.
INTRODUCTION
by Endika Gandarias
N Spindle speed (rpm)
Vc Cutting speed (m/min)
Dc Tool diameter (mm)
F Feed rate (mm/min)
ap Axial cutting depth (mm)
ae Radial cutting depth (mm)
11. 11
Face Milling
Shoulder Milling
(Face & Side Milling)
Side or Peripheral
Milling
• Cutting depth in axial
direction.
• It uses mainly the cutting edges
on the periphery of the tool.
• Surface roughness created by
face teeth.
• Cutting depth in axial and
radial direction.
• It uses the cutting edges on the
face and periphery of the tool.
• Surface roughness created by
face and side teeth.
• Cutting depth in radial
direction.
• It uses mainly the cutting edges
on the periphery of the tool.
• Surface roughness created by
side teeth.
INTRODUCTION: MILLING TYPES
Mc:
Cutting mov.
Ma:
Feed mov.
by Endika Gandarias
Mc:
Cutting mov.
Ma:
Feed mov.
Mc:
Cutting mov.
Ma:
Feed mov.
13. 13
Horizontal and Vertical Milling machines
According to their main rotational axis…
MACHINE TYPES
Rotational axis
direction
Rotational axis
direction
by Endika Gandarias
Horizontal Milling MachineVertical Milling Machine
14. 14
Mc: Cutting
movement
Ma: Feed
movement
Mp: Cutting depth
movement
Mc: Cutting
movement
Ma: Feed
movement
Mp: Cutting depth
movement
Horizontal and Vertical Milling machines
According to their main rotational axis…
MACHINE TYPES
by Endika Gandarias
Horizontal Milling MachineVertical Milling Machine
15. 15
MACHINE TYPES
MILLINGMACHINES
Conventional machines
Column and knee type
Vertical
Horizontal
Universal
Bed type
Copy or tracer mill
CNC machines
CNC Milling machine
Bed type
Bridge type or planer
Gantry
Travelling column
Machining centre
3 axis
4 axis
5 axis
Multitasking machine
by Endika Gandarias
16. 16
Manual movements execution.
Manual tool and part change.
Machine may have or not an overarm: Spindle mounted to a movable
housing on the column to permit positioning the milling cutter forward or
rearward in a horizontal plane.
Machine principal components:
1. Column: supports the spindle. The tool has no linear movements,
just the rotational cutting movement.
2. Knee: supports the work table. It has all the linear movements: X, Y
& Z.
Machine types:
1. VERTICAL MACHINE
2. HORIZONTAL MACHINE
3. UNIVERSAL MACHINE
MACHINE TYPES
Z
X
Y
Conventional milling machines
Column and knee type (turret type)
by Endika Gandarias
VIDEO
17. 17
Conventional milling machines
MACHINE TYPES
Cutter is directly mounted in the spindle.
Typical for face and end milling operations.
Arbor supports the cutter and an overarm
the arbor.
Typical for side or peripheral milling
operations.
1 2
Column and knee type (turret type)
VERTICAL MILLING MACHINE HORIZONTAL MILLING MACHINE
by Endika Gandarias
18. 18
It is a vertical and horizontal milling machine at the same time.
Types:
MACHINE TYPES
Conventional milling machines
3
Vertical & horizontal
spindle
Hure spindle:
It has a swiveling spindle that allows to swivel the
spindle at different angles. Vertical milling
attachment
Column and knee type (turret type)
UNIVERSAL MILLING MACHINE
by Endika Gandarias
VIDEOVIDEO
19. 19
The tool has the perpendicular movement.
The worktable has the X & Y movements.
Greater rigidity. Used for voluminous and
heavy parts.
A special machine type:
» It has a roughing spindle and a
finishing spindle.
Conventional milling machines
Bed type
Z
MACHINE TYPES
ROTARY TABLE TYPE
by Endika Gandarias
Z
20. 20
A stylus follows the profile of a template and guides the
cutter movement synchronizing with the table movement,
to produce a similar profile as on the template.
The movement of the stylus is controlled through
electronic or hydraulic systems.
It is used for engraving small and height profiles,
producing cams, dies,…
Machining time: important.
Idle time: small.
Set-up time: important.
Series: Unitary or medium.
Precision: IT7/8, Ra ~ 1.6 µm.
MACHINE TYPES
Conventional milling machines
Copy or Traced Controlled milling machine
by Endika Gandarias
22. 22
Automatic movements execution.
Manual tool change.
Manual part change.
Usually, it is not needed any special workholding
device.
Machining time: less than in an universal milling.
Idle time: very short
Set-up time: slightly important (programming)
Series: 10 to 1000 parts, or more.
Precision: IT7/8, Ra ~ 0.8 ÷1.6 µm.
MACHINE TYPES
CNC machines
CNC Milling machine
by Endika Gandarias
23. 23
The part has the longitudinal axis movement.
Spindle carriers are mounted on cross-rails (bridge structure).
Large size milling machines.
Suitable for flat surfaces of heavy components.
May use several spindle heads (vertical or horizontal).
Bed type
MACHINE TYPES
1
CNC machines
BRIDGE TYPE OR PLANER MILLING MACHINE
by Endika Gandarias
Y
X
Z
VIDEO
24. 24
Similar to the bridge type machine, but
the workpiece has no movement at all.
Typically used for large size parts.
The part has no movement at all.
Bed type
MACHINE TYPES
2 3
CNC machines
GANTRY MILLING MACHINE TRAVELLING COLUMN MILLING MACHINE
by Endika Gandarias
Y
Z
X
X
Z
Y
VIDEO VIDEO
25. 25
It is a CNC milling machine equipped by an
automatic tool changer.
Automatic tool changer using tool magazine or
carousel.
Automatic part changer using pallets (optional).
Machining time: similar to CNC Milling machines.
Idle time: smaller than in CNC Milling machines.
Set-up time: slightly important (programming &
setting-up)
Series: 10 to 1000 parts, or more
Precision: IT7/8, Ra ~ 0.8 ÷1.6 µm.
MACHINE TYPES
CNC machines
Machining Centre
tool magazine tool carousel
tool magazine CNC
by Endika Gandarias
26. 26
Automatic tool changer
Automatic part changer
(pallets)
(optional)
MACHINE TYPES
CNC machines
Machining Centre
by Endika Gandarias
VIDEO
VIDEO
27. 27
MACHINE TYPES
CNC machines
Machining Centre
Machine has CNC controlled
X,Y & Z linear movements.
Machine has CNC controlled X,Y & Z linear movements
+ 1 rotational movement.
a) Horizontal rotary table
b) Vertical rotary table
c) Rotary spindle
To obtain surfaces with a cylindrical pattern (e.g. gears,
polygonal geometries,…).
3 AXIS
4 AXIS
Integrated vertical rotary table
(C axis)
Horizontal rotary table (A axis)
by Endika Gandarias
VIDEO VIDEO
28. 28
MACHINE TYPES
CNC machines
Machining Centre
Machine has CNC controlled X,Y & Z linear movements
+ 2 rotational movements.
Types:
Trunnion table
Vertical machine Horizontal machine
Combination type
Swiveling head
Heavier parts can be machined.
Shorter tools are needed.
A larger working volume.
More powerful spindle Heavier removal
rates.
Bigger rotational movement capability.
1
2
3
5 AXIS
by Endika Gandarias
Higher versatility (part can be clamped
on the rotary table or out of it).
VIDEO
VIDEO
29. 29
• Several technologies are integrated into one machine:
turning, milling, drilling,…
• It has evolved from turning machines.
• The heart of the machine is the tool spindle (B
spindle), which even can be tilted. It provides milling,
drilling and tapping capability along with turning,
facing, grooving and threading.
• This spindle is serviced by an automatic tool changer
that resides outside the cutting zone.
• It may have a double spindle and one/two tool turrets.
• Application: very complex parts.
VIDEO
MACHINE TYPES
CNC machines
Machining Centre MULTITASKING MACHINE – HORIZONTAL (I)
by Endika Gandarias
31. 31
• Parts normally larger in diameter than for a horizontal
multi-task machine.
• Does not require support via a steady rest, tailstock or
sub-spindle.
• It has evolved from 5 axis machining centers:
a) High rpm capability of the C axis (turning table).
b) Adopting the spindle for stationary operations.
MACHINE TYPES
CNC machines
Machining Centre MULTITASKING MACHINE – VERTICAL
by Endika Gandarias
Trunnion table
Combination type
VIDEO
33. 33
WORKHOLDINGDEVICES
Vise
Clamps
Modular fixturing system
Indexer / Rotary table
Magnetic chuck
Vacuum chuck
Freeze chuck
Dedicated fixture
Features of a workholding device:
Proper part immobilization.
Accesibility to the machining area.
Ability to absorb machining efforts.
Minimum part deformation.
Short part clamping & unclamping time.
by Endika Gandarias
WORKHOLDING DEVICES
VIDEO
34. 34
Vise
The most common type of workholding
device for small parts.
Part is hold by pressure driven:
Mechanically
Pneumatically
Hydraulically
Types based on the degree of freedom:
Plain vise
Plain vise with swivel base
Universal vise with swivel base
Plain vise Plain vise with swivel base Universal vise
by Endika Gandarias
WORKHOLDING DEVICES
HYDRAULIC VISEPNEUMATIC VISE
MECHANICAL VISE VIDEO
35. 35
Clamps
Used for big size or irregular parts.
Part is hold using clamps, t-slot bolts, screws, washers, nuts, parallels, step blocks,…
It is important to keep in mind the efforts/deformations produced on the part.
by Endika Gandarias
WORKHOLDING DEVICES
Step block
Toe mold clamp
Angle plate
Cam clamp
Washer
C clamp V blockSwing clamp
T-nut
T-slot bolt
VIDEO
36. 36
Modular fixturing system
Based on a drilled and/or grooved baseplate.
It offers flexibility or versatility.
It allows to build different workholding systems from a set of standard
components (clamps, positioners,…).
by Endika Gandarias
WORKHOLDING DEVICES
VIDEOVIDEO
37. 37
Commonly used for machining angularly equidistant surfaces.
The chuck allows to hold and rotate the part working at different
angles.
Similar clamping possibilities to the turning process:
Jaw chuck
Between chuck and center
Between centers
Indexing head / Rotary table
by Endika Gandarias
WORKHOLDING DEVICES
MOTOR DRIVEN
MANUALLY OPERATED
VIDEO
VIDEO
VIDEO
38. 38
Magnetic Chuck
WORKHOLDING DEVICES
Ideal for ferromagnetic parts.
Powerful workholding system.
Usually electronically activated.
Part centering may be time consuming.
by Endika Gandarias
VIDEO
39. 39
Vacuum Chuck
WORKHOLDING DEVICES
Ideal for thin and flat metal sheets, non-porous surfaces.
Hold down forces are not extremely high.
Uniform holding pressure on the entire workpiece surface.
Coolant can be used without affecting the chuck’s performance.
by Endika Gandarias
VIDEO
40. 40
Freeze Chuck
WORKHOLDING DEVICES
To clamp small workpieces.
No tension builds up within the workpiece.
Clamping time +/- 90 seconds.
Holding precision ± 3μm
by Endika Gandarias
VIDEO
41. 41
Dedicated fixture
WORKHOLDING DEVICES
It is a custom-designed fixture.
Capital investment must be absorbed by the job.
It is used for medium to big-batch production runs.
by Endika Gandarias
Dedicated fixture Modular fixture
VS.
43. 43
TOOLHOLDING DEVICES
TOOLHOLDINGDEVICES TOOLHOLDER
Weldon / Whistle Notch
ER Collet chuck
Power chuck
Hydraulic chuck
Shrink fit (Thermal)
Save lock
Polygonal clamping
SPINDLE TYPE
ISO / SK / BT
HSK
Capto
BIG PLUS
KM
EXTENSION ADAPTOR
by Endika Gandarias
44. 44
Whistle NotchWeldon
ER Collet chuck
TOOLHOLDING DEVICES
Weldon / Whistle Notch
Power chuck Shrink fit (thermal)Hydraulic chuck
Toolholder
by Endika Gandarias
VIDEOVIDEO
VIDEOVIDEO
VIDEO
45. 45
Safe Lock
Pull out protection
Polygonal clamping
TOOLHOLDING DEVICES
Toolholder
by Endika Gandarias
VIDEO
Clamping steps
VIDEO
46. 46
HSKISO / SK / BT Capto
KM
Spindle type
TOOLHOLDING DEVICES
VIDEO
BIG PLUS
ISO / SK / BTBIG PLUS
by Endika Gandarias
54. 54
SIDE AND FACE MILLING
MACHINING OPERATIONS
Slot Milling
2
TOOLING
VIDEO
Horizontal milling
machine
Vertical milling
machine
Commonly used on
components that cannot
be rotated.
by Endika Gandarias
55. 55
MACHINING OPERATIONS
Helical Slot Milling
It requires a previous slot milling operation of width
bigger than the T-shape tool shank.
The use of air flow is highly recommended in order
to evacuate the chip continuously.
T-shape Slot Milling
by Endika Gandarias
It requires a coordination between the rotational
speed (N) and the feed per revolution (fn).
VIDEOVIDEO
57. 57
MACHINING OPERATIONS
Dovetail Milling Form Milling
Two or more milling cutters mounted on the same
arbor.
Displacing the cutters half a pitch in relation to
each other assists in avoiding vibration.
High productivity, high removal rate.
Medium/big series.
The use of a fly-wheel reduces torsional vibrations.
Gang Milling
by Endika Gandarias
VIDEO VIDEO
60. 60
MACHINING OPERATIONS
Gear Milling
Hobbing (productivity ↑)Disc cutting
TYPE OF GEARS
TOOLING
External & Internal gears Splines Bevel gears and pinions
by Endika Gandarias
VIDEOVIDEO VIDEOVIDEO
61. 61
A curved surface is milled while rotating
the workpiece around its centre point.
MACHINING OPERATIONS
Periphery turn milling – 3/4 axesFace turn milling – 4/5 axes
Main method for external machining. Used mainly for internal features.
Same principle as for circular milling /
ramping, but with component rotating.
2 METHODS:
Turn Milling
by Endika Gandarias
VIDEO
62. 62
VIDEO
MACHINING OPERATIONS
Boring
Excellent dimensional
tolerances and surface
roughnesses.
ROUGHING FINISHING
VIDEO
by Endika Gandarias
a a a >a
BORE FACE GROOVING
It is a productive alternative way to produce
circular grooves.
Increased productivity.
Diameters from 47mm to 1275mm.
It can be done in vertical or horizontal machines.
64. 64
MACHINING OPERATIONS
Thread Milling
by Endika Gandarias
TAPPING1
Synchronization of the feed movement and rotational movement is a must.
If the machine spindle is not prepared for direct threading, a special
toolholder needs to be used.
VIDEOVIDEO
65. 65
THREAD MILLING2
Internal threading
External threading
MACHINING OPERATIONS
by Endika Gandarias
A B
A B VIDEO
CNC thread generator: http://vargen.vargus.com/VargusGenWeb/Pages/ThreadSelection.aspx
66. 66
a) Manual reamers: long entry (A)
and length (L)
b) Milling reamers: short entry (A)
and length (L)
c) Reamer with no shank or
separated shank.
VIDEO
MACHINING OPERATIONS
The reamer never should be
spinned counterclockwise.
Reaming
Straight flute
Axial coolant supply
For blind holes
Spiral flute
Lateral coolant supply
For through holes
by Endika Gandarias
RIGHT WRONG
Objective: To achive a good surface roughness and good
dimensional tolerances (H7) in a pre-drilled hole.
High penetration rates and small depths of cut.
The tool is called “reamer”.
VIDEO
70. 70
BIOMEDICAL APPLICATIONS
VIDEOVIDEO
by Endika Gandarias
MONOBLOCK PROSTHESIS –
Titanium
BONE PLATE –
Titanium
MOULD FOR PILLS –
Steel
DENTAL BRIDGE PROSTHESIS –
Titanium
IMPLANTABLE MEDICAL PORT
OR DRUG DELIVERY SYSTEM
– Titanium
77. 77
OPERATION OVERVIEW
1. Face milling
2. Boring
3. Back facing
4. Drilling
5. Thread milling
GEARBOX HOUSING
Cast iron
WIND POWER APPLICATIONS
by Endika Gandarias
OPERATION OVERVIEW
1. Face Milling
2. Shoulder Milling
3. Helical or Circular Interpolation
4. Finish Boring
5. Back Facing
6. Drilling
7. Threading
8. Chamfering
HUB
Cast iron
78. 78
OPERATION OVERVIEW
1. Face and shoulder milling
2. Contouring
3. Fine boring
4. Drilling
5. Face milling
MAIN FRAME
Cast iron
WIND POWER APPLICATIONS
by Endika Gandarias
80. 80
GLOSSARY
by Endika Gandarias
ENGLISH SPANISH BASQUE
Angle plate Placa angular Plaka angeluar
Arbor Mandril Mandril
Bed type Bancada fija Bankada finkoa
Between centers Entre puntos Puntuen artean
Between chuck and center Plato de garras y punto Atzapardun playera eta puntuaren artean
Bevel gears Engranes cónicos Engranai konikoak
Blade Álabe Alabe
Blood Sangre Odol
Bone Hueso Hazur
Boring Mandrinado Mandrinaketa
Bridge type Tipo puente Zubi erakoa
Cam Leva Espeka
Cast iron Fundición Fundizio
Chamfering Achaflanado Alakaketa
Clamp Brida Brida
Collet chuck Portaherramientas de pinzas Pintza etxea
Coolant Refrigerante Hozkarria
Copy or tracer mill Copiadora Kopiagailua
Counterclockwise Giro antihorario Erloju orratzen aurkako biraketa
Cutting depth Profundidad de pasada axial Sakontze sakonera
Cutting speed Velocidad de corte Ebaketa abiadura
Cylinder head Culata Kulata
Dedicated fixture Utillaje específico Tresneria espezifikoa
Dovetail Cola de milano Mirubuztan
Drilling Taladrado Zulaketa
Drug Droga Droga
Ear muff / Ear plug Orejera de casco Entzumen kaskoak
Face milling Planeado Planeaketa / Lauketa
81. 81
GLOSSARY
by Endika Gandarias
ENGLISH SPANISH BASQUE
Feed per revolution Avance por vuelta Aitzinamendua birako
Feed rate Avance por minuto Aitzinamendua minutuko
Finishing Acabado Akabera
Flute Estría Ildaska
Fly-wheel Soporte Euskarri
Freeze chuck Amarre por congelación Hozte bidezko lotzea
Gang milling Fresado en grupo / Arbol de fresas Multzokako fresaketa
Gantry type Tipo pórtico Portiko erakoa
Gearbox housing Carcasa de caja de engranes Engranai kutxako karkasa
Gloves Guantes Eskularruak
Goggles Gafas de seguridad Segurtasun betaurrekoak
Hobbing Tallado Tailaketa
Hub Cubo Kubo
Hydraulic chuck Portaherramientas hidraúlico Erraminta etxe hidraulikoa
Idle time Tiempos no productivos Denbora ez produktiboa
Indexer / Rotary table Plato divisor Plater zatitzailea
Insert Plaquita intercambiable Plakatxo trukagarria
Jaw chuck Plato de garras Atzapardun platera
Knee Ménsula Mentsula
Machining centre Centro de mecanizado Mekanizazio zentrua
Machining time Tiempo de mecanizado Mekanizazio denbora
Main frame Bastidor principal Bastidore nagusia
Milling Fresado Fresaketa
Modular fixturing system Utillaje modular Tresneria modularra
Multitasking machine Máquina multitarea Ataza anitzeko makina
Numerical control Control numérico Zenbakizko kontrola
Overarm Carnero Ahari
Overhang Voladizo Hegalkina
82. 82
GLOSSARY
by Endika Gandarias
ENGLISH SPANISH BASQUE
Pallet Palet Paleta
Parallel Calzo paralelo Altxagarria
Pill Pildora Pilula
Pitch Paso Neurri
Planer Planeadora Gainazal leunak mekanizatzeko makina
Plate Placa Plaka
Power chuck Portapinzas de alto apriete Estutze haundiko pintza etxea
Reamer Escariador Otxabua
Reaming Escariado Otxabuketa
Rib Costilla Saihets
Rotary table Plato rotatorio Plater birakaria
Roughing Desbaste Arbastaketa
Safe lock Portaherramientas de amarre de seguridad Lotze ziurrezko erraminta etxea
Safety guidelines Normas de seguridad Segurtasun arauak
Set-up time Tiempo de puesta a punto Prestaketa denbora
Shoulder milling Escuadrado Eskuairaketa
Shrink fit Portaherramientas térmico Erraminta etxe termikoa
Slot milling Ranurado Artekaketa
Spindle Cabezal Burua
Spindle speed Velocidad de giro Biraketa abiadura
Stainless steel Acero inoxidable Altzairu erdoilgaitza
Stamping die Molde de estampación Estanpazio moldea
Steering knucle Portamanguetas Mangeta etxea
Step block Calzo escalonado Altxagarri mailakatua
Swing clamp Brida oscilante Brida kulunkari
Swivel base Base giratoria Oinarri birakorra
Swiveling head Cabezal giratorio Buru birakaria
Tail Cola Buztan
83. 83
GLOSSARY
by Endika Gandarias
ENGLISH SPANISH BASQUE
Tap Macho de roscar Hariztatzeko ardatza
Tapping Roscado con macho Ardatzarekin egindako hariztaketa
Thread milling Roscado con fresas Fresekin egindako hariztaketa
Tool magazine / carousel Cambiador de herramienta Erraminta aldagailua
Tool shank Mango de la herramienta Erramintaren kirtena
Toolholder Portaherramientas Erraminta etxea
Toolhonding device Sistema de amarrar herramientas Erramintak lotzeko sistemak
Travelling column Columna movil Zutabe mugikorra
T-shpe slot Ranura en T T erako arteka
Turbo charger Turbocompresor Turbokonpresore
Turn milling Torneado fresado Torneaketa fresaketa
Vaccum chuck Amarre por vacío Huts bidezko lotzea
Vise Mordaza Baraila
Washer Arandela Zirrindola
Wing Ala Hego
Workholding device Sistema de amarrar piezas Piezak lotzeko sistemak