Metal Removal Technology: Processes and Methods of Milling
Added on 2023-06-04
39 Pages11910 Words257 Views
Data Science and Big DataMechanical EngineeringMaterials Science and EngineeringPhysicsEnvironmental Science
|
|
|
Running head: METAL REMOVAL TECHNOLOGY
Metal Removal Technology
Name of the student:
Name of the university:
Author Note
Metal Removal Technology
Name of the student:
Name of the university:
Author Note
1METAL REMOVAL TECHNOLOGY
Executive summary
The process of metal removal is an innovative economic option regarding primary manufacturing.
Despite the costs of tooling and least setup the huge machining times are requires as it is cost
effective for high amounts. Due to high tolerances and outcomes of the surfaces, as offered by
machining it is used to add and refine precision features for present part. In this research different
processes of metal removal through milling are discussed. Apart from this different process of
milling methods are analyzed. These results are done through processes of experimentation with
suitable time schedule that are analyze on the study.
Executive summary
The process of metal removal is an innovative economic option regarding primary manufacturing.
Despite the costs of tooling and least setup the huge machining times are requires as it is cost
effective for high amounts. Due to high tolerances and outcomes of the surfaces, as offered by
machining it is used to add and refine precision features for present part. In this research different
processes of metal removal through milling are discussed. Apart from this different process of
milling methods are analyzed. These results are done through processes of experimentation with
suitable time schedule that are analyze on the study.
2METAL REMOVAL TECHNOLOGY
Table of Contents
1. Introduction:......................................................................................................................................4
2. The motivation behind the research:..................................................................................................5
3. Conducting of literature review:........................................................................................................6
3.1. The process of milling:...............................................................................................................6
3.2. Basic of milling machines:.........................................................................................................7
3.3. Reducing milling trips and time with milling cutting edges:.....................................................8
3.4. Advanced milling with developed cutting edges and structure:.................................................8
3.5. Types of Milling Machines.........................................................................................................8
3.6. Problem statement:...................................................................................................................10
3.7. Milling operations:....................................................................................................................10
3.8. Taping operations:....................................................................................................................12
3.9. Manual vertical milling machine:.............................................................................................13
3.10. Tooling in milling:..................................................................................................................14
3.11. Meeting strict regulations and promoting environmental stewardships:................................16
3.12. Reducing overall selenium to various low single-digit ppb levels with one step process:.....17
3.13. Material processing:................................................................................................................18
4. Methods of milling for the research:...............................................................................................21
5. Experimentation:..............................................................................................................................22
5.1. Work piece materials used:.......................................................................................................23
Table of Contents
1. Introduction:......................................................................................................................................4
2. The motivation behind the research:..................................................................................................5
3. Conducting of literature review:........................................................................................................6
3.1. The process of milling:...............................................................................................................6
3.2. Basic of milling machines:.........................................................................................................7
3.3. Reducing milling trips and time with milling cutting edges:.....................................................8
3.4. Advanced milling with developed cutting edges and structure:.................................................8
3.5. Types of Milling Machines.........................................................................................................8
3.6. Problem statement:...................................................................................................................10
3.7. Milling operations:....................................................................................................................10
3.8. Taping operations:....................................................................................................................12
3.9. Manual vertical milling machine:.............................................................................................13
3.10. Tooling in milling:..................................................................................................................14
3.11. Meeting strict regulations and promoting environmental stewardships:................................16
3.12. Reducing overall selenium to various low single-digit ppb levels with one step process:.....17
3.13. Material processing:................................................................................................................18
4. Methods of milling for the research:...............................................................................................21
5. Experimentation:..............................................................................................................................22
5.1. Work piece materials used:.......................................................................................................23
3METAL REMOVAL TECHNOLOGY
5.2. Design of experiment (DOE):...................................................................................................24
5.3. Equipment used:.......................................................................................................................24
5.4. Data analysis:............................................................................................................................24
6. The current progresses:....................................................................................................................25
7. Timeline of the current project:.......................................................................................................27
8. Conclusion:......................................................................................................................................29
9. References:......................................................................................................................................31
5.2. Design of experiment (DOE):...................................................................................................24
5.3. Equipment used:.......................................................................................................................24
5.4. Data analysis:............................................................................................................................24
6. The current progresses:....................................................................................................................25
7. Timeline of the current project:.......................................................................................................27
8. Conclusion:......................................................................................................................................29
9. References:......................................................................................................................................31
4METAL REMOVAL TECHNOLOGY
1. Introduction:
The metal removal process or machining is the most financial option as far as primary
manufacturing is concerned. This has been paid for and cutting away and discarding the achievement
of ultimate part. Moreover, despite the tooling costs and least setup, the long machining times has
been needed and thus it is cost prohibitive for huge quantities. Thus metal removal is used for
restricted amount as in fabrication of various prototypes and custom tools. This is for manufacturing
procedures. It is also used commonly as a secondary methods. Here minimal material is eradicated
and overall cycle time is short (Zaretalab et al. 2018). Moreover, because of huge tolerances and
surfaces outcomes, offered by machining, it is utilized for adding and refining various precision
features for current part and smoothing a surface for efficient finish.
Metal removal also involves various procedures, where every elements are removed from the
part or work-piece. Most common metal removal processes are denoted as the traditional machining.
These have been mechanically cutting smaller chips of metals through sharp tools. Besides, non-
traditional machining procedures are used as thermal or chemical means to remove materials. The
traditional processes are placed into three type of categories. This is abrasive machining, multi-point
cutting and single point cutting (Li et al. 2015). Besides, under a given process of various activities
that are done. This has been using particular cutting motions and tools. This machining part has been
needing various operations done with proper planning sequence for developing intended elements.
Milling is the metal removal method through using rotary cutters for removing materials
from work-pieces. This is done through advancing the cutter to work-piece at specific directions.
This is held at a specific angle that is relative to the axis of their tool. In this research various metal
removal processes through milling are demonstrated. Further, various processes of milling methods
1. Introduction:
The metal removal process or machining is the most financial option as far as primary
manufacturing is concerned. This has been paid for and cutting away and discarding the achievement
of ultimate part. Moreover, despite the tooling costs and least setup, the long machining times has
been needed and thus it is cost prohibitive for huge quantities. Thus metal removal is used for
restricted amount as in fabrication of various prototypes and custom tools. This is for manufacturing
procedures. It is also used commonly as a secondary methods. Here minimal material is eradicated
and overall cycle time is short (Zaretalab et al. 2018). Moreover, because of huge tolerances and
surfaces outcomes, offered by machining, it is utilized for adding and refining various precision
features for current part and smoothing a surface for efficient finish.
Metal removal also involves various procedures, where every elements are removed from the
part or work-piece. Most common metal removal processes are denoted as the traditional machining.
These have been mechanically cutting smaller chips of metals through sharp tools. Besides, non-
traditional machining procedures are used as thermal or chemical means to remove materials. The
traditional processes are placed into three type of categories. This is abrasive machining, multi-point
cutting and single point cutting (Li et al. 2015). Besides, under a given process of various activities
that are done. This has been using particular cutting motions and tools. This machining part has been
needing various operations done with proper planning sequence for developing intended elements.
Milling is the metal removal method through using rotary cutters for removing materials
from work-pieces. This is done through advancing the cutter to work-piece at specific directions.
This is held at a specific angle that is relative to the axis of their tool. In this research various metal
removal processes through milling are demonstrated. Further, various processes of milling methods
5METAL REMOVAL TECHNOLOGY
are analyzed. Further, the results are analyzed and processes of experimentation with proper time
schedule is discussed.
2. The motivation behind the research:
The study aims to review printed materials. This is helpful to gain knowledge and understand
primary milling procedures and theories. Besides, this is useful to become aware of latest
technologies and functions and features of machine centers. This primary vertical know mill
machine is examined, parameters of successful metal removal are recognized. Here applying the
technology to milling is explained. Various machine center functions and features are also
highlighted. Besides different cutting tools, work-changing and work-holding devices are been also
detailed (Khorasani and Yazdi 2017).
At present, various processes are applied where materials are removed with the help of
various processes. This helps in obtaining the final part. The milling machines denotes to the tools
that are designed for solid materials, woods and metals. Very often there milling machines are
automated. These are positioned in different horizontal and vertical orientation for carving out
materials in the basis of pre-existing designs (Wan et al. 2017). Here, the designs are commonly
CAD directed. There are various milling machines that are also CNC operated through
conventionally and manually automated milling devices that are also popular. They are also able to
perform, dynamic movement for work piece and tools. They can also undertake different types of
multi-axis machining. Due to different variation of application, operation and orientation, the milling
machines consists of various functions and numerous principles of operations. As far as tooling is
concerned, the milling machine are outfitted with various heads of tools. This is done to accomplish
various needs of machining. Here, few tools include ball end mills, fluted mills, rounding mills and
cutters. Furthermore, few milling machines have consisted of ends of rotating tools changing the
are analyzed. Further, the results are analyzed and processes of experimentation with proper time
schedule is discussed.
2. The motivation behind the research:
The study aims to review printed materials. This is helpful to gain knowledge and understand
primary milling procedures and theories. Besides, this is useful to become aware of latest
technologies and functions and features of machine centers. This primary vertical know mill
machine is examined, parameters of successful metal removal are recognized. Here applying the
technology to milling is explained. Various machine center functions and features are also
highlighted. Besides different cutting tools, work-changing and work-holding devices are been also
detailed (Khorasani and Yazdi 2017).
At present, various processes are applied where materials are removed with the help of
various processes. This helps in obtaining the final part. The milling machines denotes to the tools
that are designed for solid materials, woods and metals. Very often there milling machines are
automated. These are positioned in different horizontal and vertical orientation for carving out
materials in the basis of pre-existing designs (Wan et al. 2017). Here, the designs are commonly
CAD directed. There are various milling machines that are also CNC operated through
conventionally and manually automated milling devices that are also popular. They are also able to
perform, dynamic movement for work piece and tools. They can also undertake different types of
multi-axis machining. Due to different variation of application, operation and orientation, the milling
machines consists of various functions and numerous principles of operations. As far as tooling is
concerned, the milling machine are outfitted with various heads of tools. This is done to accomplish
various needs of machining. Here, few tools include ball end mills, fluted mills, rounding mills and
cutters. Furthermore, few milling machines have consisted of ends of rotating tools changing the
6METAL REMOVAL TECHNOLOGY
dependences in the required activities. Here, the communications with computer programming with
machine are done as there is any change in the tooling.
Various tools used in milling machines are on the basis of intended and material shapes. Due
to the fact that materials such as steel and woods consists of various physical characteristics, the tool
bits are required to be machine those metals properly. As the machine of milling utilizes any tool bits
that are not strong enough for machine steel, the tooling and machines itself also undergoes
damages. This is also strong for soft materials damaging the work-pieces (Stephenson and Agapiou
2016). Here, the primary tooling bit over milling machines are known as cutters. It refers to a shaped
bar consisting saw teeth. This rotates very fast for cutting down and shaping materials. This is
attached to arbors and is known as madel. This includes a shape bar varying in ending, length and
size and used to hold the cutters strongly. A saw ending of millings are oriented, sized and shaped in
various ways. These teeth are located in various orientations in straight up and down manner.
Besides, it is angled in helical orientations and the straight teeth are preferable in operations over
denser materials as the helical teeth creates smooth cuts over soft materials (Sun et al. 2016).
Further, there are various cutters at these categories. This includes t-clot cutters, angle cutters and
dense end cutters. These are subjected to various standard sizes having CAT sizes as the
commonly0utilizwed standardizations categories. As mechanical modelling is a vital feature of this
process of engineering, the review is concentrated of various diffusion, isotherm and kinetic models.
3. Conducting of literature review:
3.1. The process of milling:
It is versatile part of machining processes. This removal of metal is dine through relative
motions of multi-axis, multi-edge cutter, motions of rotating movements of work-pieces. It is a form
of interrupting cutting. Here various repeated cycles of exit and entry motions of those cutting tools
dependences in the required activities. Here, the communications with computer programming with
machine are done as there is any change in the tooling.
Various tools used in milling machines are on the basis of intended and material shapes. Due
to the fact that materials such as steel and woods consists of various physical characteristics, the tool
bits are required to be machine those metals properly. As the machine of milling utilizes any tool bits
that are not strong enough for machine steel, the tooling and machines itself also undergoes
damages. This is also strong for soft materials damaging the work-pieces (Stephenson and Agapiou
2016). Here, the primary tooling bit over milling machines are known as cutters. It refers to a shaped
bar consisting saw teeth. This rotates very fast for cutting down and shaping materials. This is
attached to arbors and is known as madel. This includes a shape bar varying in ending, length and
size and used to hold the cutters strongly. A saw ending of millings are oriented, sized and shaped in
various ways. These teeth are located in various orientations in straight up and down manner.
Besides, it is angled in helical orientations and the straight teeth are preferable in operations over
denser materials as the helical teeth creates smooth cuts over soft materials (Sun et al. 2016).
Further, there are various cutters at these categories. This includes t-clot cutters, angle cutters and
dense end cutters. These are subjected to various standard sizes having CAT sizes as the
commonly0utilizwed standardizations categories. As mechanical modelling is a vital feature of this
process of engineering, the review is concentrated of various diffusion, isotherm and kinetic models.
3. Conducting of literature review:
3.1. The process of milling:
It is versatile part of machining processes. This removal of metal is dine through relative
motions of multi-axis, multi-edge cutter, motions of rotating movements of work-pieces. It is a form
of interrupting cutting. Here various repeated cycles of exit and entry motions of those cutting tools
7METAL REMOVAL TECHNOLOGY
has been accomplishing the actual removal of metals with discontinuous generation of chip. Xiao et
al. (2016) mentioned that The milling comprises of variations of machine work-pieces, tooling and
machine types that any other type of machining method. These milling machines coming from
models of tabletops ate the standard vehicle knee mills. They have been operating in similar
principles and parameters of operations. The most vital part of those operating parameters includes
various aspects. The cutting speed is included here which is the speed at which tools has engaged
with the task. Further, it includes feed rates. This includes where the distance tool edge has been
travelling in cuter revolution. Moreover, there is axial depth of cutting. It represents the tools to set
below of machined surfaced. Here, radial depth of cut where the quantity of work surface has been
engaged by that tool. Moreover, the abilities of milling machines are calculated by spindle taper size,
maximum spindle speeds and motor horsepower.
3.2. Basic of milling machines:
The primary milling machine includes vertical spindle, ram-type “knee” mill. However, it is
adapted well for producing milling. This is ideal of making tools and machining prototypes.
Moreover, the knee mills are mainly used for various manual operations. However, Zhou et al.
(2018) argues that these abilities can also expanded. The knee has been travelling vertically, up and
down the columns and supporting table and saddles. Here the saddle has been moving out and in
from column, where table has been moving side by side of that columns. Apart from this, the ram, at
top of that column has been supporting milling head that contains feed controls, speed, tool heads
and motors, spindle and quills. This non-rotating quill has been holding rotating spindles. Here, ram
can be removed from both in and out from that columns and is tilted for drilling and angular milling.
The cutting of tools are secured in collecting and drilling chucks that are held in that spindle. Here,
works are commonly protected to tables through using clamps and bolts through using fixtures and
vises that ate bolted to tables. This work table has containing longitudinal “T” slots for facilitating
has been accomplishing the actual removal of metals with discontinuous generation of chip. Xiao et
al. (2016) mentioned that The milling comprises of variations of machine work-pieces, tooling and
machine types that any other type of machining method. These milling machines coming from
models of tabletops ate the standard vehicle knee mills. They have been operating in similar
principles and parameters of operations. The most vital part of those operating parameters includes
various aspects. The cutting speed is included here which is the speed at which tools has engaged
with the task. Further, it includes feed rates. This includes where the distance tool edge has been
travelling in cuter revolution. Moreover, there is axial depth of cutting. It represents the tools to set
below of machined surfaced. Here, radial depth of cut where the quantity of work surface has been
engaged by that tool. Moreover, the abilities of milling machines are calculated by spindle taper size,
maximum spindle speeds and motor horsepower.
3.2. Basic of milling machines:
The primary milling machine includes vertical spindle, ram-type “knee” mill. However, it is
adapted well for producing milling. This is ideal of making tools and machining prototypes.
Moreover, the knee mills are mainly used for various manual operations. However, Zhou et al.
(2018) argues that these abilities can also expanded. The knee has been travelling vertically, up and
down the columns and supporting table and saddles. Here the saddle has been moving out and in
from column, where table has been moving side by side of that columns. Apart from this, the ram, at
top of that column has been supporting milling head that contains feed controls, speed, tool heads
and motors, spindle and quills. This non-rotating quill has been holding rotating spindles. Here, ram
can be removed from both in and out from that columns and is tilted for drilling and angular milling.
The cutting of tools are secured in collecting and drilling chucks that are held in that spindle. Here,
works are commonly protected to tables through using clamps and bolts through using fixtures and
vises that ate bolted to tables. This work table has containing longitudinal “T” slots for facilitating
End of preview
Want to access all the pages? Upload your documents or become a member.
Related Documents
The Effect of Feed Rate and Cutting Speed on Surface Roughness in Millinglg...
|7
|1040
|330
Assignment on Research Methodology PDFlg...
|9
|1450
|20
Industry Analysis Report for Machine Shopslg...
|18
|7162
|38
Report on Miling Processlg...
|5
|781
|97
Metal Removal Technology (Turning Process) - Deskliblg...
|41
|12368
|365
Optimization Techniques in Machining Processlg...
|10
|1855
|32