Metal Machining and Automation

(ME 3201)

PRESENTED BY

D R . S A N N D H YA R A N I B I S WA S
A S S I S TA N T P R O F E S S O R
D E PA R T M E N T O F M E C H A N I C A L E N G I N E E R I N G
NIT ROURKELA
Email: srb@nitrkl.ac.in
 Formula for Milling

 Cutting speed (Vc) = ( π ×D× N/1000) m/min

Where D= Diameter of the cutter

N=Spindle speed in rpm

 Feed rate (fr) = f × nt × N mm/min

Where f = feed (mm/tooth)

N = Rotational speed (rpm)

nt = number of teeth in the cutter

 Peripheral Milling

Front view
Side view
D
d

A
 Machining Time/Cutting Time

•Cutting time (Tc) = (L+A)/fr min

L= length of cut
A= approach distance = √d(D-d)
D = cutter diameter
d = depth of cut
fr = feed rate (mm/min)
Face Milling

Case: 1 When the cutter is centered

over the work piece

Top view

D
w

O A
 Face Milling

TOP view
D
w

O A

Case 2: When the cutter is offset to one side over the work piece
 Machining Time/Cutting Time

Cutting time (Tc) = (L+A+O)/fr min

Full face: A = O = D/2

Partial face: A= O =√ w (D-w)

L= length of cut
A= approach distance
O = cutter run out distance/over travel distance
fr = feed rate (mm/min)
 Material Removal Rate

Material removal rate (MRR) = w.d.fr

w= width of cut
d = depth of cut
fr= feed rate
 Methods of Indexing

1. Direct Indexing
2. Simple Indexing
3. Compound Indexing
4. Angular Indexing
5. Differential Indexing
 Problem

In a milling machine, a face milling operation is

performed on the top surface of a rectangular work
piece of 400 mm long and 80 mm wide. The milling
cutter follows a path that centered over the work
piece. The diameter of cutter is 90 mm and it has 8
teeth. Cutting speed is 90 m/min, feed is 0.25
mm/tooth, and depth of cut is 4 mm. Calculate the
machining time and material removal rate.
 Indexing

Indexing is the process of evenly dividing the

circumference of a circular work piece into equally
spaced divisions, such as in cutting gear teeth,
milling grooves in reamers and taps, squares,
hexagons, and octagons.
The index head of the indexing fixture is used for
this purpose.