Milling 101: What are the considerations when it comes to milling operations, and how can operators reduce vibration in milling? Read on. Article by Sandvik Coromant.
Milling has been evolved into a method that machines a very broad range of operations. In addition to all the conventional applications, milling is a strong alternative for producing holes, threads, cavities and surfaces that used to be turned, drilled or tapped.
There are different types of milling operations. They are:
- Shoulder milling
- Face milling
- Profile milling
- Groove milling and parting off
- Chamfer milling
- Turn milling
- Gear machining
- Holes and cavities/ pocketing
The following are the initial considerations for milling operations:
The milled configuration
The features to be milled have to be carefully considered. These can be located deep, requiring extended tooling, or contain interruptions and inclusions.
Workpiece surfaces can be demanding, with cast skin or forging scale. In cases of bad rigidity, caused by thin sections or weak clamping, dedicated tooling and strategies have to be used. The workpiece material and its machinability must also be analyzed to establish optimal cutting data.
The choice of milling method will determine the type of machine needed. Face/shoulder or slot milling can be performed in 3-axis machines, while milling 3D profiles require alternatively 4- or 5-axis machines.
Turning centres today often have milling capability due to driven tools, and machining centres often have turning capability. CAM developments mean that 5-axis machines are increasingly common. They offer increased flexibility, but stability can be a limitation.
How to Reduce Vibration in Milling
Milling vibration can arise due to limitations in the cutting tool, the holding tool, the machine, the workpiece or the fixture. To reduce vibration, there are some strategies to consider.
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