22563 Advanced Manufacturing Processes Unit 2 Notes PDF

            Absolutely! Milling is one of the most versatile machining processes, used to remove material from workpieces by feeding them into a rotating cutter featuring multiple cutting edges. The milling process can produce complex shapes with high precision.

Milling Machines:

Types:

1. Horizontal Milling Machine: The spindle is oriented horizontally, which means tools mounted on it are perpendicular to the table.
2. Vertical Milling Machine: The spindle is oriented vertically, so tools are aligned up and down.
3. Universal Milling Machine: Can function as both a vertical and horizontal machine.
4. Turret Milling Machine: Has a stationary spindle and the table is moved in both perpendicular and parallel directions to achieve cutting.
5. Bed-type Milling Machine: The table moves only perpendicular to the spindle's axis, while the spindle itself moves parallel to its own axis.
6. CNC Milling Machine: Controlled by computer programs; can operate in multiple axes for complex parts.

Components:

• Base & Column: The foundation of the machine.
• Knee: Supports the worktable and can be adjusted.
• Saddle: Sits atop the knee and supports the worktable.
• Worktable: Where the workpiece is mounted.
• Spindle: Holds and drives the cutting tools.
• Arbor: Holds the cutter in place.
• Overarm/Overhanging Arm: Supports the arbor.

Milling Processes:

1. Plain Milling: Produces a flat surface; also known as slab milling.
2. Face Milling: Produces a flat surface, but the cutter's axis is perpendicular to the workpiece; mainly uses a face milling cutter.
3. Angular Milling: Produces an angle surface; often uses single or double-angle milling cutters.
4. Form Milling: Uses formed cutters to create contours, outlines, and other shapes.
5. End Milling: Uses an end mill to produce pockets, slots, and profiles.
6. Profile Milling: Creates a surface profile; usually uses an end mill or a profile milling cutter.
7. Gang Milling: Uses multiple milling cutters mounted on the same arbor to produce complex parts in one pass.
8. Gear Milling: Produces gear teeth with specialized form cutters.
9. Helical Milling: Produces helical flutes or grooves.
10. Thread Milling: Produces threads using thread milling centers or similar machines.

Milling Cutters:

• Plain Milling Cutter: Used for slab milling.
• End Mill: Used for end milling.
• Ball Nose Cutter: Used for 3D contouring.
• Slab Mill: Used primarily for surface milling.
• Form Relieved Cutter: Used for profile milling.
• Involute Gear Cutter: Used for gear milling.

Feed and Speed:

• Feed: The rate at which the workpiece moves against the cutter.
• Speed: The rotational speed of the cutter.

Advantages:

1. Versatility: Can produce various shapes with different surfaces.
2. High Precision: Especially with CNC milling.
3. Complex Parts: Multi-axis CNC milling can produce intricate components.

Limitations:

1. Cost: Milling machines, especially advanced CNCs, can be expensive.
2. Maintenance: Regular maintenance is required for prolonged service.
3. Setup Time: It can take time to set up complex parts for milling.

            In essence, milling machines and processes play a crucial role in the manufacturing sector, offering the ability to produce a wide range of parts with precision and efficiency. Advances in technology, particularly CNC (computer numerical control), have further enhanced milling's capabilities, allowing for more complex and precise operations.