Milling Cutter

Face-Milling Cutter with Index able Inserts

Figure 24.5  A face-milling cutter with index able inserts.  Source:  Courtesy of Ingersoll Cutting Tool Company. 

Effect of Insert Shape on Feed Marks on a Face-Milled Surface

Figure 24.6  Schematic illustration of the effect of insert shape on feed marks on a face-milled surface:

 (a)  small corner radius, 

 (b) corner flat on insert, and 

 (c) wiper, consisting of small radius followed by a large radius which leaves   smoother feed marks.   

 (d)  Feed marks due to various insert shapes. 

            Face-Milling Cutter

        

                    Figure 24.7  Terminology for a face-milling cutter.

      Effect of Lead Angle on Undeformed Chip Thickness in Face Milling

Figure 24.8  The effect of the lead angle on the undeformed chip thickness in face milling.  Note that as the lead angle increases, the chip thickness decreases, but the length of contact (i.e., chip width) increases.  The edges of the insert must be sufficiently large to accommodate the contact length increase.

 

   Position of Cutter and Insert in Face Milling

 

Figure 24.9  (a)  Relative position of the cutter and insert as it first engages the workpiece in face milling.

(b)  Insert positions towards the end of cut.

     (c)  Examples of exit angles of insert, showing desirable (positive or negative angle) and undesirable (zero angle) positions.  In all figures, the cutter spindle is perpendicular to the page and rotates clockwise.

                 

                   Ball Nose End Mills

Figure 24.10  Ball nose end mills.  These cutters are able to produce elaborate contours and are often used in the machining of dies and molds.  (See also Fig. 24.2d.)  Source:  Courtesy of Dijet, Inc. 

 

                                Cutters

 

    Figure 24.11  Cutters for (a) straddle milling, (b) form milling, (c) slotting, and (d) slitting with a milling cutter. 

            

               T-Slot Cutting and Shell Mill

 

               Figure 24.12  (a)  T-slot cutting with a milling cutter.  (b)  A shell mill.