Milling Flashcards
(20 cards)
What is milling?
Milling is a machining process using a rotating multi-edge cutting tool to remove material, enabling movement in various directions.
Name the three basic cutting actions in milling.
- Radial
- Peripheral
- Axial
What are the three main types of milling cutters?
- Face mills
- Peripheral mills
- End mills
What is the difference between face and end mills?
Face mills cut with their face and periphery, while end mills cut with their face and side edges.
What are the advantages of vertical milling machines?
Vertical spindles provide better access to deep or hard-to-reach areas.
What is climb milling?
The feed direction of the workpiece matches the cutter rotation, producing thicker chips initially and reducing friction.
What is conventional milling?
The feed direction of the workpiece opposes the cutter rotation, starting with thinner chips and increasing to maximum thickness.
What industries commonly use milling?
- Mold industry
- Aeronautical industry
How does the lead angle of a milling cutter affect performance?
Larger lead angles reduce chip thickness and cutting forces, allowing higher feed rates.
What are ball nose end mills used for?
- Contouring
- Profiling
- High-speed machining with smooth finishes
What is chip formation, and why is it critical in milling?
Chip formation refers to material removal by cutting edges, influencing tool wear, heat generation, and surface finish.
Define ‘average chip thickness.’
The mean thickness of the chips produced during milling, calculated using the Schlesinger formula.
What are the characteristics of peripheral milling?
Cutting is performed mainly by the cutter’s peripheral teeth to produce the final surface.
What are slotting cutters, and when are they used?
Thin peripheral mills used for cutting narrow slots or grooves.
Why are axial rake angles important in milling tools?
Positive axial rake angles produce smoother finishes and reduce cutting forces.
What is high-feed milling?
A method using shallow cuts and high feed rates to improve material removal efficiency.
Name two advantages of using face mills.
- High material removal rates
- Ability to machine large flat surfaces
What is the role of chip breakers in milling tools?
They control chip size and break chips into smaller, more manageable pieces.
What is the purpose of tool geometry optimization in milling?
To balance cutting forces, improve tool life, and achieve precise surface finishes.
What are the key parameters influencing milling performance?
- Cutting speed
- Feed rate
- Depth of cut
- Tool material
