Milling Techniques and Tools Quiz

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Questions and Answers

What is the purpose of straddle milling?

To sharpen the tooling used in milling

To produce a single surface on a workpiece

To create an irregular contour on a workpiece

To machine two or more parallel surfaces simultaneously (correct)

What distinguishes form milling cutters from other types?

Their teeth are ground to a specific irregular contour to produce desired shapes (correct)

They are used exclusively for sharpening other cutting tools

They require no maintenance or sharpening

They can only be used to cut straight surfaces

Which of the following is a common example of form milling cutters?

Lathe tools

Gear-tooth cutters (correct)

End mills

Twist drills

How should form milling cutters be sharpened?

Only by grinding the tooth face Signup and view all the answers

In straddle milling, what is used to hold the milling cutters?

An arbor Signup and view all the answers

What type of shape do form milling cutters typically produce?

Irregular contours Signup and view all the answers

What happens to the contour of a form milling cutter during the sharpening process if done incorrectly?

It can become distorted Signup and view all the answers

Which of the following applications is NOT commonly associated with form milling cutters?

Generating flat surfaces Signup and view all the answers

What direction must a right-hand cutter rotate when viewed from the front end of the machine spindle?

Counterclockwise Signup and view all the answers

How can other cutters be modified regarding their direction of rotation?

They can be reversed on the arbor. Signup and view all the answers

Which component of a basic milling machine serves as the main supporting frame?

The column Signup and view all the answers

What motion can occur through the knee of a milling machine?

Vertical motion Signup and view all the answers

What type of construction do most basic milling machines feature?

Column-and-knee construction Signup and view all the answers

What is the primary benefit of keeping the depth of cut small in finishing cuts?

It reduces vibrations and improves surface finish. Signup and view all the answers

What is the purpose of powered rapid traverse in a milling machine?

To move the worktable quickly for setup or after a cut Signup and view all the answers

How many mutually perpendicular directions can the worktable on a milling machine move?

Three Signup and view all the answers

What characteristic defines the milling process?

An interrupted cutting process. Signup and view all the answers

What type of feed rates are usually included for milling operations?

Manual and powered feed rates Signup and view all the answers

Which type of milling cutter is specifically designed for milling flat surfaces?

Plain milling cutter. Signup and view all the answers

How do helical teeth on a milling cutter impact the cutting process compared to straight teeth?

They engage the work gradually and reduce shock and chattering. Signup and view all the answers

What effect does cycling heating have on tools during the milling process?

It may lead to tool damage or wear. Signup and view all the answers

Which factor is critical for achieving a smooth surface when using a helical milling cutter?

Multiple simultaneous tooth engagement. Signup and view all the answers

What is a common consequence of using a cutter with straight teeth in the milling process?

Higher tendency for shock and chattering. Signup and view all the answers

Which statement best describes the impact loading experienced by tools during milling?

It arises from individual teeth entering and exiting the cut. Signup and view all the answers

What is the primary purpose of slitting saws in milling operations?

To mill deep narrow slots and perform cutting-off operations Signup and view all the answers

How do T-slot cutters differ from ordinary milling cutters?

T-slot cutters cut on five surfaces simultaneously. Signup and view all the answers

What must be done before using a T-slot cutter?

Mill the vertical groove with a slotting mill or an end mill. Signup and view all the answers

What characteristic of slitting saws helps to prevent binding during operations?

Their dished sides Signup and view all the answers

Why must T-slot cutters be fed with care?

They cut on multiple surfaces simultaneously. Signup and view all the answers

Which of the following describes slitting saws?

They usually have more teeth per unit of diameter than plain milling cutters. Signup and view all the answers

What type of cuts are T-slot cutters specifically designed to create?

Wide grooves of T-slots Signup and view all the answers

Which milling cutter requires the use of a slotting mill or an end mill before it can be used?

T-slot cutter Signup and view all the answers

What is a key advantage of planer-type milling machines when machining heavy workpieces?

They can remove large amounts of metal quickly with a single pass. Signup and view all the answers

Which factor is NOT considered when purchasing or using a milling machine?

Weight of the machine Signup and view all the answers

Planer-type milling machines share their basic design with which of the following?

Planers Signup and view all the answers

What is the typical horsepower available at the spindle of a milling machine?

70% of machine horsepower Signup and view all the answers

Which of the following is an accessory that can extend the usefulness of ordinary milling machines?

Attachment tools Signup and view all the answers

What type of workpiece feeding does a planer-type milling machine permit?

Slow feeding Signup and view all the answers

Which of the following components is essential for efficient milling operations?

Automatic tool changing Signup and view all the answers

What is NOT a criterion for assessing machine capability?

Machine speed Signup and view all the answers

Study Notes

Milling Surface Finish

Keeping the depth of cut small will limit the axial cutting force, reduce vibrations, and produce a superior finish
Milling is an interrupted cutting process, with individual teeth entering and leaving the cut
The process subjects the tool to impact loading, cyclic heating, and cyclic cutting forces

Milling Tools and Cutters

Plain milling cutters have straight or helical teeth on the periphery, and are used for milling flat surfaces
Helical teeth engage the work gradually, and usually more than one tooth cuts at a given time
This reduces shock and chattering tendencies, and promotes a smoother surface
Consequently, helical mills are usually preferred over plain mills
Two or more side-milling cutters are often spaced on an arbor to straddle the workpiece, called straddle milling
Form milling cutters have teeth ground to a special shape, usually an irregular contour, to produce a surface having a desired transverse contour
Slitting saws are thin, plain milling cutters, usually from 1/32 to 3/16 in. thick, which have their sides slightly “dished” to provide clearance and prevent binding
T-slot cutters are integral-shank cutters with teeth on the periphery and both sides, used for milling the wide groove of a T-slot

Machines for Milling

Basic milling machines are of column-and-knee construction, where the column is the main supporting frame
Most basic milling machines provide three controlled motion of the worktable in three directions: through the knee, through the saddle, and through the table
Planer-type milling machines utilize several milling heads to remove large amounts of metal, often needing only a single pass of the workpiece
When purchasing or using a milling machine, consider spindle orientation and rpm, machine capability, machine capacity, horsepower available at spindle, and automatic tool changing

Milling Accessories

The usefulness of ordinary milling machines can be greatly extended by employing various accessories or attachments

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Description

Test your knowledge on milling surface finishes and tools. This quiz covers essential concepts like the impact of depth of cut and the advantages of helical milling cutters over plain ones. Dive into the specifics of milling processes and improve your understanding of machining techniques.