What is milling?

Milling is the process of shaving the additional material from the flat or irregular surface of job or work item through the cutter. Cutter is advanced with the required forced and desired direction of milling to remove the unwanted material from the work piece.

What is a Milling Machine?

The Milling Machines are multipurpose machines to perform the cutting operations on metal, wood or any other hard surfaces. The milling machine has a cutter which is advanced on the job placed on the table in the required state to give the required cuts or shaves for getting the desired produce. It can work in vertical as well as horizontal directions to shave off small sections of unwanted extra surfaces to get the final product.

Uses of Milling Machines

A quality Milling machines is a versatile tool capable of multitasking work. It is used in cutting, boring, drilling, routing and shaping the surfaces. It is most commonly used in the workshops of institutes imparting technical education to the students.

Parts of Milling Machine and its functions

A brief description of parts along with the functional importance is mentioned below.

Base

A Base builds the foundation of a milling machine. All other parts of milling machine are mounted or affixed on it. It is made of cast iron since it needs the strength to carry the whole machine.

Column

A Column is mounted on the base of a milling machine in a vertical direction to support the table and knee. It is used to house all the driving parts responsible for the milling work. It is also made of cast iron.

Knee

The knee is the part responsible for supporting the saddle and table of the milling machine. Again, it is also made of cast iron. The knee moves vertically ie up and down sideways and changes the distance between tool and work piece. It is placed on the column. It is the knee that is adjusted by raising and lowering the lever for the job to be performed.

Saddle

It is affixed between the table and the knee. It plays the important role of interlinking balancer between table and knee. It moves diagonally to the column and slides on the sideways. Its main task is to set the horizontal motion for the work item. The saddle is also made of cast ion.

Table

The table is usually rectangular slot placed on the knee and this is part of a milling machine which is used to hold the work item. The table is also made of cast iron since the table holds the work item over it with clamping bolts. Table of milling machine provides the freedom up to the standard of three degrees.

Spindle

The spindle is another important part of the milling machine which is used to carry tool.  The spindle is that part of milling machine which drives the cutting tool in rotatory motion. There is a slot on the front side of the spindle where the cutting tool is affixed. The spindle may be manual or motor driven.

Arbor and Arbor Support

Arbor is a kind of extension for the spindle in the horizontal type of milling machine. It is fitted as per the requirement for the holding and moving the tool in the required direction. And arbor supports are used to support the arbor; it is joined with an arbor on end and overhanging arm on the other end. It helps in controlling the Arbor during cutting operations.

Ram

Ram is an overhanging arm positioned in the vertical direction. The ram can be a moved angular or transversal in and out direction on the column.

Working of Milling Machine

Working of milling machine can be better explained in below mentioned points.

1. Set the cutting tool on the Arbor attached to the spindle
2. Move the knee in a downward direction.
3. Place the work item over the table and clamp it with clamping bolts
4. Set all the controlling positions at zero before the milling operation.( position of the knee, saddle etc.)
5. Now, it is a time to set the spindle in motion by supply power through the motor, which will result in rotating the cutting tool.
6. Now feed the work item by moving the knee, saddle, and table.
7. Advance the cutting tool on a work item in the desired level to weed out the extra material from the surface to give the desired shape to the metal, wood, plastic and any other hard surface.

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What is Shaping Machine?

Shaping machine is a machine designed for giving desired shapes to the surfaces that may be horizontal, vertical and flat. A shaping tool is used to cut in curves, different angles, and many other shapes. A disc is responsible for the tool rotation which results in the forward and backward movement. The cutting tool is used to give the shape to the hard surface of metal or wood by removing the excess material.

Working Mechanism of Shaping Machine

The shaping machine operates in the reciprocating type of machine function. Here the work piece is fixed on the machine table and the cutting tool is placed on the work piece. Reciprocating movements over the work piece results in forward and backward strokes. Forward stroke is responsible for cutting action over the object and backward movement is responsible for restoring its position without any cutting action.

Description of Parts of Shaping Machine with its Functions

Working Mechanism of shaping machine is very simple but effective. The parts responsible for its working along with its functional importance are listed below.

Base: The base of shaping machine is kind of bed to hold the different parts of shaping machine, it is made up of cast iron since the strength of a base is very important. The base bears the vibration shock of forward and backward movement of stroke responsible for shaping action.

Body: Body of the machine consists of pats named Pillar, Frame, and Column. The body of the shaping machine is affixed on the base of the shaping machine. The column is also made up cast iron and it is box shaped part which is placed on the base. Column plays the covering role and supports the reciprocating movement in the operation of the machine.

Cross ways: These are the sideways affixed vertically and horizontally across the table to allow the movement of the table.

Stroke adjuster: Stroke adjuster absorbs the vibration shock of stock by controlling the length of the stroke.

Cross rail: The cross rail is affixed on the front part of the body which can be moved in an upward and downward direction. It enables to perform shaping operation at different positions.

Ram:  The Ram is responsible for the reciprocating action of the column sideways. Forward and backward movement of ram is called a stroke.

 Table: A table is kind of flat body affixed over the frame to hold the work piece on which shaping action needs to be performed,

Clapper box: It is used to carry the shaping tool holder. Clapper box is responsible for the smooth and hindrance free movement of backward stroke to prevent the damage in the form of wear and tear.

How the shaping task is performed over the object

A Shaping machine’s task is based on the stroke mechanism. Forward stroke performs the action and backward or return stroke brings back the tool to its original position for the next forward stroke. The working of a shaping machine is expressed in below points.

1. First and foremost task is to place the work piece on the table.
2. After that cutting tool is placed in the tool holder mounted on the Ram
3. It is time to supply power by starting the motor for performing a reciprocating action.
4. In the reciprocating action cutting tool performs the task on work piece and removes the extra material from the work piece to get the desired shape.
5. Here forward stroke performs the shaping action on the work piece by cutting the extra material and backward stroke or return stroke does not perform cutting action, it is kind of restoring stroke for the next actionable forward stroke.

Various Types of Shaping Machines

Shaping machines types are classified basis it motion type, Ram travel, table design, and the type of cutting stroke.

• Shaping machine classified under the type of Motion are Crank, Geared and Hydraulic.
• Shaping machine classified under the type of Ram Travel are Horizontal and Vertical
• Shaping machine classified according to the design of the table are Standard and Universal.
• Shaping machine classified according to the type of stroke are Push and Draw.

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Introduction

Surface grinder is a kind of machine for making the surface with smooth finish flat. It is one of the mostly used abrasive machining process. In it, a spinning wheel is covered in rough particle that cuts metallic or non-metallic substances and making the surface flat and smooth.

It is the most commonly used machine around the world. It is at last process, in which much of the impurities, oxides and other unwanted material is removed from the surface, hence making it much more smooth and flat.  It also makes the surface, perfect for the one’s purpose as for why or how he wants it to be.

Parts

Here are some of it’s parts and information regarding them.

It mainly consists of: –

• Abrasive wheel
• Chuck
• Rotary table

Chuck is a part which holds the product or material in stable place, as the work is being done upon it. There are two ways to hold the material in a place: –

Either by placing ferromagnetic pieces with a magnetic chuck and non-metallic and ferromagnetic material/pieces are held by a vacuum and mechanical means to place them in a particular place.

The most important consideration to be noted for a surface grinding machine is that what type of material has been used to make grinding wheel and also the material of the product that needs the work to be done upon.

Most probably, the product on which the work has to be done, has mild steel and cast iron and these two materials doesn’t clog the wheel also or disrupt its function. There are more materials are there such as brass, stainless steel, aluminium and some plastics. If grinding is done at high temperature, then the material can get weakened and also tends to become more corrode.

The grinding wheel doesn’t only is limited to cylindrical shape but gives various options of different shapes that is required by the product or the material, on which the works is needed to be done. These straight wheels are made ready by their operators for any shape work. There is one very important point to be noted that, the grinding wheel gives a reverse shape on the surface of product against which the wheel is made to grind.

A grinding machine can help in providing a particular shape or a smooth finish.

Varieties of Surface Grinders

Peripheral Or Horizontal-Spindle

In the case of this machine, the flat edge or the periphery of the wheel is make in contact with the product on which the work is need to be done, and it produces the flat surface. For high-precision work on angled or flat surface, peripheral grinding is recommended and used.

Wheel-face or vertical spindle grinders

In this, either the face of a cup, disc, cylinder or segmental wheel is used against the flat surface. The main work of the grinding wheel is for fast material removal and in some cases, it needs high precision too. The product is held on the table that is reciprocating, but it can be varied as per the task, with continuous rotation. This rotation makes loading / unloading one station, as while grinding work is being done on another.

Double Disc Grinders And Single Disc Grinders

This is very much the same to surface grinding. Although, it provides larger contact between the surface of workpiece and disc. Both horizontal and vertical spindle types are available. If there is a need of double side work on a single workpiece and on a same point of time, then double disc grinders are used. They are mainly for getting high and fine tolerance.

About Grinding Wheel Surface

Mostly diamonds, silicon carbide, CBN – cubic boron nitride or aluminium oxides are used for making the surface of the grading wheel. But out these four materials, aluminium oxide is the most commonly used and the most least used material is diamonds because of its cost as they are very much expensive. CBN and diamonds are used for grinding carbides and ceramics as these both needs some very hard grinding materials, aluminium oxide is not that much hard and strong.

Lubrication

For the maintenance of the grinding machine, lubricants are required for its smooth working. It helps in lubricating the interface and removing the chips or swarfs. Most commonly used lubricants such as water soluble oils, synthetic oils, petroleum-based oils and water-soluble chemical fluids are used. These lubrication fluids are mostly depending on workpiece materials and the table outlines.

EssKay lathe machines tools is one of the most reputed companies and brand for manufacturing the quality grinding machines, lathe machines, drilling machines and much more in India. For any queries, just contact us. Just browse through our website to know more about our quality product range and us. We believe in building strong relations with clients and providing them with top class service and quality.