Milling Process - Definition and Principle

Definition of Milling Process

  1. A milling machine is a machine tool that removes metal as the work is fed against a rotating multipoint cutter. 
  2. The milling cutter rotates at high speed and it removes metal at a very fast rate with the help of multiple cutting edges. 
  3. One or number of cutters can be mounted simultaneously on the arbour of the milling machine. This is the reason that a milling machine finds wide application in production work. 
  4. A milling machine is used for machining flat surfaces, contoured surfaces, surfaces of revolution, external and internal threads, and helical surfaces of various cross-sections.
Typical components produced by a milling are given in the figure. In many applications, due to its higher production rate and accuracy, milling machine has even replaced shapers and slotters.

What is the principle of milling process?

  1. In a milling machine, the metal is cut by means of a rotating cutter having multiple cutting edges. For cutting operation, the workpiece is fed against the rotary cutter. 
  2. As the workpiece moves against the cutting edges of the milling cutter, metal is removed in-form chips of trochoid shape. 
  3. Machined surface is formed in one or more passes of the work. The work to be machined is held in a vice, a rotary table, a three jaw chuck, an index head, between centres, in a special fixture or bolted to the machine table. 
  4. The rotatory speed of the cutting tool and the feed rate of the workpiece depending upon the type of material being machined. 
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Crater Wear | Definition with Diagram

What is crater wear?

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https://en.wikipedia.org/wiki/Tool_wear
  • More common in ductile materials which produce the continuous chip.
  • Crater wear occurs on the rake face.
  • At very high-speed crater wear predominates.
 
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  • For crater, wear temperature is main culprit and tool defuse into the chip material & tool temperature is maximum at some distance from the tooltip. 
  • Crater depth exhibits linear increase with time.
  • It increases with MRR.
  • Crater wear has little or no influence on cutting forces, workpiece tolerance or surface finish.

Flank Wear | Reason, Effects and Stages

What are the reasons of Flank Wear?


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  1. Abrasion by hard particles and inclusions in the workpiece.
  2. Shearing off the micro welds between tool and work material.
  3. Abrasion by fragments of built-up edge ploughing against the clearance face of the tool.
  4. At low-speed flank wear predominates.
  5. If MRR increased flank wears increased.

What are the effects of Flank Wear?

  1. Flank wear directly affect the component dimensions produced.
  2. Flank wear is usually the most common determinant of tool life. 

Stages of Flank Wear

Primary wear: The region where the sharp cutting edge is quickly broken down and a finite wear land are established.
Secondary wear: The region where the wear progresses at a uniform rate.
Tertiarywear: The region where wear progresses at a gradually increasing rate. In the tertiary region, the wear of the cutting tool has become sensitive to increased tool temperature due to high wear land.
Regrinding is recommended before they enter this region.

Tool Failure | Definition and Types

Tool failure

Tool wear is a gradual phenomenon of failure of the tool due to its operating conditions.There is an equation which provides the relationship between several aspects of the tool.
Moreover in general
  • If surface hardness tool > surface hardness of workpiece then no substantial increase in tool wear with speed increase.
  • If surface hardness tool < surface hardness of workpiece then there is the substantial increase in tool wear with speed increase.
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https://en.wikipedia.org/wiki/Tool_wear

Tool failure is two types

1. Slow death: The gradual or progressive wearing away of rake face (crater wear) or flank (flank wear) of the cutting tool or both.

2. Sudden death: Failures leading to the premature end of the tool predict. Tool failure mechanisms include plastic deformation, brittle fracture, fatigue fracture or edge chipping. However, it is difficult to predict which of these processes will dominate and when tool failure will occur.

Types of Tool Wear

(a) Flank Wear
(b) Crater Wear
(c) Chipping off of the cutting edge

Automation - Basic Introduction - Mechanical Engineering

About Automation - Introduction

automation, mechanical, automation (industry), production, mechanical engineering (professional field), mechanical design, engineer, work, education, engineering, manufacturing, career, industrial, industry, robots, engineering (industry), technology, robotics (industry), minecraft, process, electronics, control, a Automation control. an Automation framework. Automation a tool. automation-a-robotics. an Automation define. Automation a process.

The creation and application of technology to monitor and control the production and delivery of products and services.

Basic Notions

  1. Control–to regulate, direct or command.
  2. System –a collection, set of elements (subsystems)
  3. Control system –an interconnection of components forming a system configuration that will provide the desired system response.
A control system is an arrangement of physical components connected or related in such a manner as to command, regulate, direct or govern itself or another system.

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Input– the stimulus, a command applied to a control system
  1. Physical variable
  2. Abstract ones: reference, set point or desired values for the output of the control system.

Output– the actual response resulting from a control system.
  1. Control systems can have more that one input or output.
  2. The input & the output present the desired response and the actual response.

Three basic types of control systems:

  1. Man-made (e.g. an electric switch)
  2. Natural including biological-control systems
  3. Components are man-made and natural

Control system applications:

  1. Robotics
  2. Space-vehicle systems
  3. Aircraft autopilots & controls
  4. Ship & marine control systems, intercontinental missile guidance systems.

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Samsung Galaxy J5 Prime (Gold Colour, 32 GB Internal Memory)  (3 GB RAM)

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