[IE 21] 2.2 - Machining II: Milling - Grinding

milling

basic machining process by which a surface is generated by progressive chip removal

vertical milling machine

[Milling Machine] Tool moves sideways, built for heavy material removal

horizontal milling machine

[Milling Machine] Tool moves up/down, for precision and detail work

lathe

[Milling Machine vs Lathe] workpiece spins; for round parts

milling machine

[Milling Machine vs Lathe] cutter spins; flat or complex shapes

peripheral milling

[Milling Processes] axis of cutter rotation is parallel to the workpiece surface to be machined

slab milling

[Peripheral Milling] cutter width extends beyond the workpiece on both sides

slot milling

[Peripheral Milling] cutter width is less than the workpiece width

saw milling

[Peripheral Milling] cutter is very thin, used to cut the workpiece into two

side milling

[Peripheral Milling] cutter machines the side of the workpiece

straddle milling

[Peripheral Milling] cutting takes place on both sides of the workpiece simultaneously

form milling

[Peripheral Milling] cutters have the teeth ground to a special shape to produce a surface having a desired contour

face milling

[Milling Processes] cutter is mounted on a spindle with an axis of rotation perpendicular to the workpiece surface

conventional face milling

[Face Milling] face-milling cutter machines the entire surface, cutter diameter is greater than the workpiece width

partial face milling

[Face Milling] face-milling cutter machines only one side of the workpiece

plunge milling

[Face Milling] cutting is performed at the end of the tool instead of at the periphery

profile milling

[Face Milling] conventional end mill is used to cut the outside or inside periphery of a flat part

pocket milling

[Face Milling] material inside is removed to a fixed depth

surface contouring

[Face Milling] ball-end mill is fed back and forth across the workpiece along a curvilinear path; produce complex three-dimensional surface

up milling

[Milling Methods] traditional way to mill; cutter rotates against the direction of feed of the workpiece

down milling

[Milling Methods] cutter rotation is in the same direction as the feed rate

drilling

generates interior cylindrical surfaces in the form of holes with a tool with two cutting edges

drill press

[Drilling] machine used for drilling

center drill and countersink

[Types of Drills] used to start a hole and guide the twist drill

spade drills

[Types of Drills] widely used for making holes 1 in. or larger in diameter at low speeds or with high feeds

deep-hole drills or gundrills

[Types of Drills] used when deep holes are to be drilled

hole cutter or hole saw

[Types of Drills] used to make large holes in thin material

drill chuck

[Drilling] chuck is tightened by means of a chuck key, these fingers are forced inward against the drill

jigs

[Drilling] designed workholders used to hold workpieces during drilling

counterboring

[Operations After Drilling] cylindrical hole with a flat bottom at one end of a drilled hole so that a bolt head may have a bearing surface

countersinking

[Operations After Drilling] provides a beveled section at the end of a drilled hole to provide a proper seat for a flat-head screw or a rivet

spot facing

[Operations After Drilling] cleans up a rough surface in order to provide a smooth bearing surface at the end of a hole which is normal to the axis

boring

process of enlarging a hole that has already been drilled or cast

reaming

bring holes to a more exact size and better finish by slightly enlarging an existing hole

reamers

[Reaming] multi-edged cutting tools

broaching

machining process for a layer of material of desired width and depth usually in one stroke by a slender rod or bar type cutter having a series of cutting edges with gradually increasing protrusion

broach

[Broaching] cutting tool in which the feed of the cutting edges into the workpiece

abrasive machining

a material removal process that involves the interaction of abrasive grits with the workpiece

emery

[Natural Abrasives] a mixture of alumina (Al2O3) and magnetite (Fe3O4), is used on coated paper and cloth

corundum

[Natural Abrasives] natural aluminum oxide

quartz

[Natural Abrasives] used primarily in coated abrasives and in air blasting

diamond

[Natural Abrasives] crushed into grains or powder and used to make grinding wheels

aluminum oxide

[Artificial Abrasives] used in three quarters of all grinding operations, and is primarily used to grind ferrous metals

silicon carbide

[Artificial Abrasives] very hard but brittle; used for grinding softer, nonferrous metals and high density materials

synthetic diamond

[Artificial Abrasives] hardest of all materials; used to grind nonferrous materials

cubic boron nitride

[Artificial Abrasives] extremely hard and very good thermal resistance; used to grind hard ferrous materials

grinding

employs an abrasive product, usually a rotating wheel brought into controlled contact with a work surface

cylindrical grinding

[Types of Grinding] workpiece rotates about a fixed axis and the surfaces machined are concentric to that axis of rotation

internal grinding

[Types of Grinding] finishes the inside of a previously drilled, reamed, or bored hole

centerless grinding

[Types of Grinding] workpiece rotates between a grinding wheel and a regulating drive wheel

surface grinding

[Types of Grinding] produces flat, angular, or contoured surfaces by feeding work in a horizontal plane beneath a rotating grinding wheel

plain center-type cylindrical grinder

[Grinding Machines] work is mounted between headstock and tailstock centers

centerless grinding machine

[Grinding Machines] for centerless grinding

surface grinding machine

[Grinding Machines] used primarily to grind flat surfaces