Copyright 2010 Society of Manufacturing Engineers. FUNDAMENTAL MANUFACTURING PROCESSES Milling & Machining Centers

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1 FUNDAMENTAL MANUFACTURING PROCESSES Milling & Machining Centers SCENE 1. FMP01A, CGS: FBI warning white text centered on black to transparent gradient FMP01B, motion background SCENE 2. continue motion background FMP02A, CGS: disclaimer white text centered on black to transparent gradient WARNING Federal law provides severe civil and criminal penalties for the unauthorized reproduction, distribution or exhibition of copyrighted media. Copyright 2010 Society of Manufacturing Engineers Always read the operating manual and safety information provided by the manufacturer before operating any manufacturing equipment. Make sure all machine guards are in place, and follow all safety procedures when working with or near manufacturing equipment. SCENE 3. FMP03A, SME logo open, with music SCENE 4. FMP04A, FMP open, with music ML04B, edited peter carey narration MUSIC UP AND UNDER THE FUNDAMENTAL MANUFACTURING PROCESSES VIDEO SERIES, EXAMINING THE TOOLS AND TECHNIQUES OF PRECISION MANUFACTURING. SCENE 5. continue FMP open ML05A, CGS: Milling & Machining Centers white text, centered on background FMP05B, blue background FMP05C, sound slug THIS PROGRAM EXPLORES THE BASICS OF MILLING AND MACHINING CENTERS. SCENE 6. ML06A, SME3454, 22:17:28:00-22:17:41:00 zoom out, milling of flat plastic surface

2 ML06B, SME2973, 13:06:29:00-13:06:47:00 zoom out, milling contoured surface ML06C, FMP001, 01:51:25:00-01:51:42:00 zoom out, milling of foam pattern ML06D, SME4025, 10:26:42:00-10:27:00:00 zoom out, milling with machining center MILLING IS A HIGHLY VERSATILE MACHINING PROCESS THAT USES ROTATING, MULTI-EDGE CUTTERS TO GENERATE FLAT..., OR CONTOURED SURFACES ON A VARIETY OF WORKPIECE MATERIALS. BECAUSE OF ITS EFFECTIVENESS, CUTTING TOOL CHOICES, AND COMPATIBILITY WITH AUTOMATION, MILLING WITH MACHINING CENTERS IS PERHAPS THE MOST IMPORTANT HIGH-VOLUME MANUFACTURING PROCESS FOR SHAPING MATERIALS. SCENE 7. ML07A, SME3808, 04:19:35:00-04:19:55:00 desktop milling machine ML07C, FTD88, 04:07:11:00-04:07:31:00 zoom in, milling operation of complex mold ML07D, CGS: Prototypes Patterns Molds Dies ML07E, SME4018, 02:14:02:00-02:14:16:00 zoom in, milling with workpiece movement ML07F, SME4026, 11:24:10:00-11:24:24:00 zoom out, tooling MILLING ALLOWS MORE VARIATIONS IN MACHINE DESIGN, WORKPIECE MOVEMENT, AND TOOLING THAN ANY OTHER MACHINING PROCESS. IT IS USED TO MANUFACTURE AN IMMENSE RANGE OF PARTS OF SIMPLE AND COMPLEX SHAPES, INCLUDING PROTOTYPES, PATTERNS, MOLDS, AND DIES. SCENE 8. ML08A, FMP018, 18:19:59:00-18:20:09:00 zoom out, table top milling machine ML08B, SME4026, 11:02:22:00-11:02:37:00 pan of shop floor mills ML08C, FTD48, 21:15:23:00-21:15:33:00 wide pan, large mill with aircraft wing ML08D, SME3339, 00:19:41:00-00:19:57:00 zoom out, milling operation MACHINES FOR MILLING RANGE IN SIZE FROM THOSE THAT SIT ON A TABLETOP, THROUGH A BROAD RANGE OF MILLS AND MACHINING CENTERS, TO GIANT MILLING MACHINES. DESPITE THEIR SIZE DIFFERENCES, THESE MACHINES ALL OPERATE ON THE SAME PRINCIPLES.

3 SCENE 9. ML09A, SME2503, 02:21:05:00-02:21:47:00 knee mill, cutting ML09B, FMP001, 01:23:42:00-01:24:02:00 wide, cnc machining center, cutting ML09C, FMP015, 15:38:25:00-15:38:42:00 zoom out, knee mill, cutting THESE PRINCIPLES ARE USED WHEN MILLING WITH THE COMMON KNEE MILL, AS WELL AS, THE VERSATILE COMPUTER NUMERICAL CONTROL, OR CNC, MACHINING CENTER. SCENE 10. ML10A, FTD89, 05:10:09:00-05:10:20:00 work clamped to table ML10B, FTD87, 02:13:00:00-02:13:18:00 zoom in, work in holding device ML10C, FTD49, 22:10:18:00-22:10:28:00 stationary work being milled ML10D, SME4018, 02:20:25:00-02:20:45:00 zoom out, cutter/work moving WORKPIECES ARE USUALLY CLAMPED TO THE MACHINE TABLE..., OR HELD IN A WORKHOLDING DEVICE. SOMETIMES THE WORK REMAINS STATIONARY..., AND SOMETIMES BOTH THE CUTTER AND WORKPIECE MOVE. SCENE 11. ML11A, SME2666, 04:07:22:00-04:07:33:00 zoom out, standard cutting tools ML11B, SME2669, 01:01:14:00-01:01:23:00 zoom out, special tools CUTTING TOOLS FOR MILLING ARE AVAILABLE IN STANDARD SHAPES, AS WELL AS TAPERED AND SPECIAL SHAPES. SCENE 12. ML12A, SME2667, 05:01:49:00-05:02:25:00 milling using cutter with multiple inserts ML12B, SME3339, 00:04:09:00-00:04:30:00 zoom out, end milling operation with a lot of chips DURING ROTATION, EACH TOOTH OF A MILLING CUTTER ALTERNATIVELY ENTERS AND LEAVES THE CUT, REMOVING A SMALL AMOUNT OF MATERIAL IN A SHORT, DISCONTINUOUS CHIP THAT IS TAPERED OR NON-UNIFORM IN THICKNESS. THIS METAL REMOVAL PROCESS IS A FORM OF INTERRUPTED CUTTING. THE REPEATED CYCLES OF ENTRY AND EXIT OF THE

4 CUTTER EDGES CREATES MECHANICAL SHOCK AND HEAT IN THE PART AND IN THE CUTTING EDGE. SCENE 13. ML13A, FTD89, 05:03:02:00-05:03:50:00 zoom out, milling operation ML13B, CGS: Motor Horsepower Maximum Spindle Speed Spindle Taper Size ML13C, CGS: Size of Toolholder/Tool Worktable Size Amount of Travel THE CAPABILITIES OF A MILLING MACHINE OR MACHINING CENTER ARE MEASURED BY MOTOR HORSEPOWER, MAXIMUM SPINDLE SPEED, AND SPINDLE TAPER SIZE, ALL OF WHICH DETERMINE THE SIZE OF TOOLHOLDER AND TOOL, WORKTABLE SIZE, AND THE AMOUNT OF TRAVEL. -- FADE TO BLACK -- SCENE 14. ML14A, CGS: Milling Machine Basics white text, centered on background SCENE 15. ML15A, FMP015, 15:05:37:00-15:05:54:00 zoom out, knee mill ML15B, FMP015, 15:35:17:00-15:35:39:00 zoom out, knee mill in operation THE FUNDAMENTAL PARTS AND PRINCIPLES OF MILLING MACHINES ARE BEST ILLUSTRATED BY THE LIGHTWEIGHT, VERTICAL-SPINDLE, RAM- TYPE KNEE MILL. ALTHOUGH IT IS RARELY USED FOR PRODUCTION MACHINING, IT IS USED IN TOOLMAKING, PROTOTYPE MACHINING, AND LOW-VOLUME MILLING. SCENE 16. ML16A, FMP015, 15:11:03:00-15:11:21:00 med, knee & column ML16B, CGS: Column ML16C, CGS: Knee ML16D, FMP015, 15:11:32:00-15:11:48:00 med, table & saddle ML16E, CGS: Table ITS DESIGN INCLUDES A COLUMN-AND-KNEE SUPPORT FOR THE MACHINE TABLE AND SADDLE. WORK CAN BE MOVED IN 3 AXES,

5 ML16F, CGS: Saddle ML16G, FMP015, 15:08:20:00-15:08:54:00 knee traveling vertically, saddle moving in and out, table moving side to side ML16H, CGS: Vertical Traverse Crank ML16I, CGS: Cross Traverse Handle ML16J, CGS: Table Traverse Handle RELATIVE TO THE CUTTER. THE VERTICAL TRAVERSE CRANK MOVES THE KNEE VERTICALLY ON THE COLUMN..., THE CROSS TRAVERSE HANDLE MOVES THE SADDLE IN-AND-OUT FROM THE COLUMN..., AND THE TABLE TRAVERSE HANDLE MOVES THE TABLE SIDE-TO-SIDE. SCENE 17. ML17A, FMP015, 15:14:40:00-15:15:00:00 zoom out, ram, head moving in ML17B, CGS: Ram ML17C, FMP015, 15:19:08:00-15:19:23:00 tilt, milling head ML17D, CGS: Head THE RAM, ON TOP OF THE COLUMN, SUPPORTS THE HEAD AND PROVIDES HORIZONTAL MOTION IN-AND-OUT FROM THE COLUMN -PARALLEL TO THE SADDLE MOVEMENT..., AT THE FRONT OF THE RAM IS THE MILLING HEAD, WITH MOTOR, TOOLHEAD, SPEED AND FEED CONTROLS, QUILL, AND SPINDLE. SCENE 18. ML18A, FMP015, 15:21:09:00-15:21:23:00 zoom out, quill/spindle, tool rotating ML18B, CGS: Quill ML18C, CGS: Spindle ML18D, SME2502, 01:20:32:00-01:20:52:00 tilted spindle milling THE NON-ROTATING QUILL HOLDS THE ROTATING SPINDLE, WHICH CAN BE MOVED ON ITS OWN AXIS. THE SPINDLE AXIS MAY ALSO BE TILTED TO MILL OR DRILL AT AN ANGLE TO THE TABLE. SCENE 19. ML19A, SME2504, 04:04:02:00-04:04:12:00 c.u. tool in chuck ML19B, FMP015, 15:27:19:00-15:27:29:00 c.u. tool placed in chuck, alternate shot ML19C, SME2504, 04:06:19:00-04:06:43:00 c.u. end mill secured in collet ML19D, SME2504, 04:10:05:00-04:10:30:00 small face mill mounted in spindle ML19AE, FMP015, 15:23:44:00-15:23:52:00 small face mill mounted in spindle, CUTTING TOOLS ARE HELD IN DRILL CHUCKS, COLLETS, OR OTHER TOOLHOLDERS, WHICH ARE HELD IN THE SPINDLE. OR TOOLS CAN BE MOUNTED DIRECTLY IN THE SPINDLE.

6 alternate shot SCENE 20. ML20A, FMP015, 15:40:00:00-15:40:38:00 operator setting of mill, zoom in, milling operation WITH MANUAL MILLS, THE OPERATOR SETS THE MACHINE PARAMETERS FOR EACH CUT, POSITIONS THE TOOL FOR THE START OF THE CUT, DIRECTS ALL OF THE MACHINE'S MOTIONS MANUALLY, AND CHANGES THE SETTINGS AND TOOLS AFTER EACH OPERATION. SCENE 21. ML21A, FMP015, 15:31:35:00-15:31:52:00 zoom out, part bolted directly to table with clamps ML21B, FMP015, 15:29:40:00-15:29:50:00 zoom out, part held by vise to table ML21C, FMP015, 15:28:30:00-15:28:42:00 zoom out, round part in chuck, bolted to table WORKHOLDING MUST LOCATE THE PART AND HOLD IT WITHOUT DISTORTION. THIS CAN BE ACCOMPLISHED BY BOLTING THE WORK TO THE TABLE USING CLAMPS..., VISES..., AND OTHER FIXTURES. ROUND PARTS MAY BE HELD IN A CHUCK. SCENE 22. ML22A, FMP015, 15:33:55:00-15:34:20:00 zoom out, c.u. knee mill with powered feed ML22B, FMP015, 15:34:46:00-15:35:02:00 zoom out, c.u. knee mill with powered feed, alternate take ML22C, FMP015, 15:37:12:00-15:37:38:00 zoom out, digital readout TO REDUCE OPERATOR EXERTION AND ACHIEVE A MORE UNIFORM CUT, KNEE MILLS ARE COMMONLY EQUIPPED WITH POWERED TABLE AND SADDLE FEED UNITS. THEY ALSO HAVE DIGITAL READOUT DISPLAYS THAT TELL THE MACHINIST THE PRECISE LOCATION OF THE TOOL RELATIVE TO THE WORK.

7 SCENE 23. ML23A, FMP018, 18:08:34:00-18:09:07:00 zoom in, cnc knee mill, cutting CNC KNEE MILLS ARE ALSO AVAILABLE, OFTEN GIVING THE OPERATOR THE OPTION OF AUTOMATIC OR MANUAL CONTROL. THIS FLEXIBILITY PLACES THEM BETWEEN THE CAPABILITIES OF TRADITIONAL MANUAL KNEE MILLS AND MODERN CNC MACHINING CENTERS. --- FADE TO BLACK --- SCENE 24. ML24A, CGS: CNC Machining Centers white text, centered on background SCENE 25. ML25A, SME4018, 02:09:10:00-02:09:36:00 zoom in, cnc control running machining operation PRODUCTION MACHINING CENTERS USE COMPUTER NUMERICAL CONTROL, IN WHICH INSTRUCTIONS FOR MACHINING ARE IN THE FORM OF A CODED PART PROGRAM. THE MACHINE'S COMPUTER TRANSLATES THIS PROGRAM INTO SIGNALS TO THE MACHINE'S AXIS MOTORS TO ACTIVATE THE MOTIONS NEEDED TO MACHINE A PART. SCENE 26. ML26A, SME4022, 07:16:35:00-07:16:52:00 zoom in, high speed machining ML26B, SME4091, 07:24:36:00-07:24:43:00 milling of transmission housing ML26C, SME4091, 07:26:20:00-07:27:02:00 drilling and tapping of transmission housing, edit at multiple points CNC MILLING HAS OBVIOUS ADVANTAGES OVER MANUAL MILLING FOR PRODUCTION WORK. FIRST, A SINGLE CNC MACHINE CAN PERFORM MULTIPLE CUTTING OPERATIONS WITHOUT REQUIRING A WORKPIECE TO BE

8 MOVED FROM ONE MACHINE TO ANOTHER, OR RECLAMPED. SCENE 27. ML27A, SME4018, 02:17:00:00-02:17:20:00 fast cnc cutting ML27B, FMP007, 07:19:46:00-07:20:34:00 zoom in, machining parts, all alike CNC MACHINES CAN CUT MUCH FASTER THAN MANUAL MILLS, AND THEY WORK WITH GREAT CONSISTENCY AND REPEATABILITY, WITH NO OPERATOR-INDUCED VARIATION. THE SAME MACHINE MOTIONS ARE REPEATED PART AFTER PART. SCENE 28. ML28A, SME4029, 16:24:05:00-16:24:17:00 software being used ML28B, SME4030, 17:35:30:0-17:35:57:00 zoom in, esprit software being used FINALLY, CNC PROGRAMS CAN BE DEVELOPED AND VERIFIED GRAPHICALLY TO ENSURE THAT TOOLPATHS ARE CORRECT BEFORE METALCUTTING BEGINS. IMPROVED GRAPHICAL USER INTERFACES AND SIMPLIFIED PROGRAMMING SOFTWARE ALLOWS OPERATORS TO VISUALIZE HOW A PART WILL BE MILLED -- EVEN BEFORE PARTS OR TOOLS ARE PLACED INTO THE MACHINE. SCENE 29. ML29A, SME4026, 11:48:29:00-11:48:55:00 zoom out, cnc machining center, milling part ML29B, SME4026, 11:57:01:00-11:57:12:00 zoom out, parts BECAUSE OF THEIR PRODUCTIVITY AND FLEXIBILITY, CNC MACHINING CENTERS ARE THE PRIMARY MACHINES FOR MILLING AND HOLEMAKING, PARTICULARLY FOR NON-ROUND, OR PRISMATIC, WORKPIECES. -- TOUCH BLACK --

9 SCENE 30. ML30A, FTD99, 09:30:27:00-09:30:48:00 zoom out, vertical machining center ML30B, SME3353, 10:10:42:00-10:10:57:00 zoom out, horizontal machining center THE TWO MAIN TYPES OF MACHINING CENTERS ARE THE VERTICAL SPINDLE MACHINING CENTER..., AND THE HORIZONTAL SPINDLE MACHINING CENTER. --- TOUCH BLACK --- SCENE 31. ML31A, CGS: Vertical Machining Center ML31B, FTD11, 10:04:29:00-10:05:10:00 zoom out, wide, vertical machining center ML31C, CGS: X Axis ML31D, CGS: x axis arrows ML31E, CGS: Y Axis ML31F, CGS: y axis arrows ML31G, CGS: Z Axis ML31H, CGS: z axis arrows VERTICAL MACHINING CENTERS, OR VMC'S, HAVE THE SPINDLE ORIENTED VERTICALLY, AND HAVE THREE LINEAR AXES OF MOTION: THE X AXIS, WHICH IS THE TABLE S MOTION SIDE TO SIDE..., THE Y AXIS, WHICH IS THE TABLE S MOTION IN AND OUT..., AND THE Z AXIS, WHICH IS THE HEAD MOVEMENT UP AND DOWN THE COLUMN. SCENE 32. ML32A, FMP006, 06:31:46:00-06:32:02:00 zoom in, milling on vertical mill VMC S MAY BE PREFERRED OVER HORIZONTAL MACHINING CENTERS WHEN WORK IS DONE PRIMARILY ON A SINGLE WORK FACE. SCENE 33. ML33A, FMP004, 04:43:57:00-04:44:27:00 parts indexed to new work surface ML33B, FMP003, 03:09:43:00-03:10:10:00 indexer on vmc ML33C, SME4030, 17:21:27:00-17:21:50:00 zoom in, high speed machining, part rotating while machined ML33D, CGS: B Axis ML33E, SME4018, 02:17:16:00-02:17:38:00 WHEN A ROTARY TABLE OR INDEXER IS ADDED TO THE VMC MACHINE TABLE, MORE THAN A SINGLE SIDE OF A WORKPIECE OR A MULTIPLE-PART SETUP CAN BE MACHINED

10 high speed machining, part rotating while machined WITHOUT OPERATOR INTERVENTION. ROTARY DEVICES EITHER INDEX THE PART TO PRESENT A NEW WORK SURFACE TO THE SPINDLE, OR THEY ROTATE IT, UNDER FULL CNC CONTROL, WHILE THE PART IS MACHINED. VMC'S WITH SUCH A DEVICE HAVE A FOURTH ROTARY AXIS OF MOTION, DESIGNATED THE B AXIS. --- TOUCH BLACK --- SCENE 34. ML34A, CGS: Horizontal Machining Center ML34B, SME2973, 13:10:47:00-13:11:12:00 zoom in, chips produced from milling operation ML34C, FMP012, 12:43:42:00-12:44:08:00 zoom out, hmc operating HORIZONTAL MACHINING CENTERS, OR HMC'S, HAVE HORIZONTAL SPINDLES; THUS THEY ARE PREFERRED FOR HEAVY, BOXY PARTS. CHIPS ARE CLEARED MORE EASILY WITH A HORIZONTAL MACHINE THAN ON A VERTICAL MACHINE, AND MORE AUTOMATED WORKHOLDING OPTIONS MAY BE POSSIBLE. SCENE 35. ML35A, FTD99, 09:35:53:00-09:36:36:00 zoom in, horizontal machining center ML35B, CGS: X Axis ML35C, CGS: x axis arrows ML35D, CGS: Z Axis ML35E, CGS: z axis arrows ML35F, CGS: Y Axis ML35G, CGS: y axis arrows HMC S COME IN A VARIETY OF DESIGNS FOR MACHINE MOTIONS. BUT IN ITS MOST COMMON ARRANGEMENT, AN HMC'S TABLE MOVEMENT SIDE-TO-SIDE IS DESIGNATED THE X AXIS..., ITS MOVEMENT IN-AND-OUT IS THE Z AXIS..., AND ITS HEAD MOVEMENT UP AND DOWN THE

11 COLUMN IS THE Y AXIS. SCENE 36. ML36A, FTD99, 09:40:40:00-09:40:52:00 horizontal fixture rotating AN HMC S TABLE TYPICALLY ROTATES TO ALLOW A CUTTING TOOL TO ACCESS FOUR SIDES OF THE WORKPIECE OR FIXTURE. --- FADE TO BLACK --- SCENE 37. ML37A, CGS: Toolchangers & Cutting Tools white text, centered on background SCENE 38. ML38A, FTD90, 06:27:16:00-06:27:36:00 toolchanger, changing tool, machining part ML38B, SME4026, 11:26:05:00-11:26:12:00 tool change ML38C, FTD101, 11:16:53:00-11:17:03:00 zoom in, toolchange BY MAKING A VARIETY OF TOOLS AVAILABLE FOR MACHINING, THE TOOLCHANGER DEFINES A MACHINING CENTER'S ABILITY TO PERFORM A VARIETY OF CUTTING OPERATIONS AUTOMATICALLY. THERE ARE MANY TOOLCHANGER DESIGNS. ALL MOVE TOOLS WITHIN SECONDS FROM STORAGE TO THE SPINDLE. SCENE 39. ML39A, SME4026, 11:58:14:00-11:58:25:00 tool storage, tools indexing ML39B, SME4026, 11:22:42:00-11:22:58:00 tilt, multiple tools in storage MOST MACHINING CENTERS HAVE 20 TO 40 TOOLS IN STORAGE. TOOL STORAGE MAGAZINES WITH OVER 200 TOOLS ARE ALSO POSSIBLE. A LARGE TOOL CAPACITY PROVIDES BOTH DIFFERENT TOOLS FOR MULTIPLE OPERATIONS, AS WELL AS REPLACEMENTS FOR WHEN TOOLS WEAR DOWN.

12 SCENE 40. ML40A, SME3339, 00:27:53:00-00:28:15:00 zoom out, end milling operation ML40B, FTD89, 05:07:34:00-05:07:56:00 metal being removed using face mill ML40C, FMP006, 06:36:18:00-06:36:34:00 face milling ML40D, FMP001, 01:42:41:00-01:42:55:00 end milling ML40E, FTD03, 03:19:58:00-03:20:12:00 zoom in, face milling ML40F, FTD13, 12:07:34:00-12:07:56:00 face milling operation IN GENERAL, A MILLING CUTTER IS A ROTARY TOOL WITH ONE OR MORE CUTTING EDGES, EACH OF WHICH REMOVES A SMALL AMOUNT OF MATERIAL AS IT CONTACTS THE WORKPIECE. THE VARIETY OF MILLING CUTTER TYPES IS IMMENSE. THEY COME IN VARIOUS SHAPES AND SIZES, MADE FROM SOLID TOOL MATERIALS OR COMPOSED OF REMOVABLE INSERTS. WE'LL EXAMINE ONLY SOME OF THE MOST IMPORTANT CUTTER TYPES, TOGETHER WITH THE BASIC MILLING OPERATIONS IN WHICH THEY ARE APPLIED. --- TOUCH BLACK --- SCENE 41. ML41A, CGS: Flat Surfaces & Square Shoulders ML41B, FTD07, 06:27:29:00-06:27:47:00 flat surface milling with shoulder GENERATING FLAT SURFACES WITH SQUARE SHOULDERS IS A BASIC OBJECTIVE OF MANY MILLING PROCESSES. SCENE 42. ML42A, CGS: Face Milling ML42B, FMP006, 06:30:09:00-06:30:49:00 face milling operation ML42C, FMP006, 06:06:28:00-06:06:40:00 small face mill, milling ML42D, FTD03, 03:17:00:00-03:17:13:00 zoom out, face mill, milling ML42E, FTD07, 06:13:24:00-06:13:56:00 face milling operation replacement FACE MILLING CUTTERS EFFECTIVELY GENERATE FLAT SURFACES, AT HIGH SPEEDS, WITH THE SPINDLE AXIS PERPENDICULAR TO THE WORK SURFACE. FACE MILLS CAN RANGE FROM A FEW CENTIMETERS TO A HALF-METER IN DIAMETER. SCENE 43. ML43A, SME2666, 04:16:50:00-04:16:59:00

13 c.u. rotating face mill stops on insert ML43B, SME2666, 04:17:11:00-04:17:33:00 face milling operation IN FACE MILLING, THE CUTTER BODY HAS MULTIPLE POCKETS THAT ACCEPT A VARIETY OF CUTTER INSERTS. METAL IS REMOVED BY THE PERIPHERAL EDGE OF THE INSERT, WHILE ITS BOTTOM EDGE CLEANS UP THE WORK SURFACE AND PRODUCES THE SURFACE FINISH. --- TOUCH BLACK --- SCENE 44. ML44A, CGS: Square Shoulder Milling ML44B, FTD19, 20:03:38:00-20:03:56:00 square shoulder face milling SQUARE SHOULDER FACE MILLS GENERATE A FINISH-MILLED SHOULDER THAT IS SQUARE TO THE FACE THEY MILL. --- TOUCH BLACK --- SCENE 45. ML45A, CGS: Edges, Shoulders, & Grooves ML45B, FTD07, 06:33:46:00-06:34:03:00 shoulder milling operation MILLING EDGES, SHOULDERS, AND GROOVES, MAY USE A COMBINATION OF END, PERIPHERAL, AND, OR FACE MILLING OPERATIONS. SCENE 46. ML46A, CGS: Edges ML46B, FTD23, 03:07:57:00-03:08:08:00 edging operation ML46C, CGS: Shoulders ML46D, FTD07, 06:46:02:00-06:46:12:00 shoulder operation ML46E, CGS: Grooves ML46F, FTD19, 20:11:25:00-20:11:36:00 zoom out, grooving operation ML46G, FMP006, 06:34:26:00-06:34:45:00 slotting cutter operation ML46H, FMP015, 15:40:25:00-15:40:38:00 edging operation CREATING EDGES, OR EDGING, MAY INVOLVE THE MILLING OF ONE OR TWO SURFACES..., SHOULDERS TYPICALLY HAVE TWO SURFACES..., AND GROOVES USUALLY HAVE THREE SURFACES. GROOVES MAY BE CLOSED AT ONE END, OR OPEN AT BOTH ENDS, AND THEY MAY BE CUT ON INTERNAL AND EXTERNAL FLAT SURFACES,

14 AS WELL AS ON ROUND SURFACES. SCENE 47. ML47A, CGS: Peripheral Milling ML47B, FTD19, 20:12:29:00-20:13:12:00 zoom in, peripheral milling operation PERIPHERAL MILLING CUTTERS HAVE CUTTING EDGES ON THEIR PERIPHERY WHICH ARE PARALLEL WITH THE AXIS OF ROTATION. PERIPHERAL MILLING IS USEFUL FOR CREATING LONG OPEN SLOTS AND FORMS. SCENE 48. ML48A, CGS: End Milling ML48B, SME3340, 01:01:27:00-01:01:38:00 end milling operation ML48C, FTD01, 01:27:13:00-01:27:39:00 end milling operation ML48D, FTD10, 09:03:20:00-09:04:00:00 zoom out, end milling operation on graphite END MILLING CUTTERS ARE ROUND-SHANK TOOLS WITH CUTTING EDGES ON THEIR PERIPHERY AND END. THE AXIS OF ROTATION IS PERPENDICULAR TO THE SURFACE PRODUCED BY THE END OF THE TOOL. CUTTER SIZE IS DEFINED BY ITS DIAMETER AND CUTTING DEPTH. SCENE 49. ML49A, SME4025, 10:03:19:00-10:03:34:00 end milling of deep pocket ML49B, FMP004, 04:49:47:00-04:50:06:00 zoom out, long end milling operation SINCE END MILLS CUT MORE WITH THE TEETH ON THEIR PERIPHERY THAN WITH THE TEETH AT THEIR END, THEY ARE SUSCEPTIBLE TO LATERAL FORCES. THIS MAKES THEM SUBJECT TO DEFLECTION, WHICH REDUCES THE ACCURACY OF THE MILLING OPERATION. SCENE 50. ML50A, FTD01, 01:30:51:00-01:31:24:00 shallow slot being milled ML50B, FTD23, 03:13:10:00-03:13:25:00 deep slot milling SHORT, SHALLOW SLOTS ARE OFTEN CREATED WITH END MILLS. DEEP, NARROW SLOTS MAY BE MILLED WITH AN END MILL, A THIN

15 SLITTING CUTTER, OR A GROOVING CUTTER. SCENE 51. ML51A, FMP006, 06:33:26:00-06:33:48:00 slotting cutter operation GROOVING OR SLOTTING CUTTERS ARE GENERALLY MORE EFFICIENT THAN END MILLS FOR CUTTING LONG AND DEEP SLOTS, BECAUSE OF THEIR LARGER DIAMETER AND GREATER NUMBER OF TEETH. SCENE 52. ML52A, CGS: Chamfering ML52B, FTD92, 08:18:23:00-08:18:49:00 zoom out, chamfering using mill ML52C, FMP008, 09:30:22:00-09:30:34:00 chamfering of workpiece holes ML52D, SME2534, 02:35:13:00-02:35:24:00 c.u chamfering end mill ML52E, SME2534, 02:35:27:00-02:35:38:00 c.u chamfering end mill ML52F, SME2503, 02:08:56:00-02:09:05:00 cutter angled to workpiece surface CHAMFERING ELIMINATES SHARP CORNERS FROM A WORKPIECE, AND IS A GOOD SAFETY MEASURE. CHAMFERS MAY BE PRODUCED WITH THE CHAMFERING END MILL, WHICH BREAKS THE SHARP EDGES OF THE WORKPIECE WITH A 45-DEGREE ANGLE CUT. CHAMFERS CAN ALSO BE GENERATED USING END MILLS, PERIPHERAL MILLING CUTTERS, LONG EDGE CUTTERS, OR FACE MILLS ANGLED 45 DEGREES TO THE WORK SURFACE. SCENE 53. ML53A, CGS: Pocket Milling ML53B, FMP006, 06:09:05:00-06:10:11:00 pocket milling operation ML53C, FTD23, 03:21:28:00-03:22:12:00 pocket milling operation alternate WITH POCKET MILLING, AN END MILL OR SMALL-DIAMETER FACE MILL DRILLS OR RAMPS DOWN TO A CERTAIN DEPTH AND THEN MILLS OUT AN INTERNAL SHAPE OR POCKET, OFTEN WITH A FLAT BOTTOM. SCENE 54. ML54A, CGS: Contour Milling ML54B, SME3339, 00:19:05:00-00:19:26:00 contour milling operation CONTOUR MILLING SCULPTS INTRICATE CURVED

16 FORMS IN THREE DIMENSIONS AND IS ESSENTIAL FOR DIE AND MOLD MAKING. CONTOUR MILLING IS COMMONLY PERFORMED USING AN BALLNOSE END MILL. --- TOUCH BLACK --- SCENE 55. ML55A, FTD23, 03:16:48:00-03:17:14:00 zoom in, milling using carbide inserts ML55B, SME4022, 07:11:24:00-07:11:37:00 high speed machining emphasizing tooling CUTTING TOOLS ARE CHOSEN NOT ONLY FOR THEIR GEOMETRIES; THEY ARE ALSO CHOSEN BY THEIR MATERIALS. MORE THAN EVER, TOUGHER CUTTER MATERIALS ARE AVAILABLE THAT EXTEND TOOL LIFE AND ALLOW FASTER CUTTING OF TOUGHER, HARDER WORKPIECE MATERIALS. SCENE 56. ML56A, FTD01, 01:17:52:00-01:18:04:00 zoom out, coated carbide inserts being used for milling ML56B, SME4022, 07:19:38:00-07:20:00:00 high speed machining emphasizing using cbn ML56C, SME2666, 04:24:13:00-04:24:23:00 zoom out, pcd insert ML56D, FTD07, 06:04:28:00-06:04:38:00 pcd insert on mill ML56E, SME2666, 04:24:49:00-04:25:03:00 pcd insert milling STANDARD CARBIDE, OR COATED CARBIDE TOOLS WORK WELL IN MOST CUTTING SITUATIONS. HOWEVER, CUBIC BORON NITRIDE, OR CBN TOOL INSERTS MAY BE NEEDED FOR CUTTING HARDENED MATERIALS. ADDITIONALLY, TOOLS WITH POLYCRYSTALLINE DIAMOND, OR PCD, SURFACES MAY BE NEEDED FOR CUTTING DIFFICULT TO MACHINE NON-FERROUS ALLOYS, SUCH AS NICKEL SUPERALLOYS. THE HIGHER COSTS OF THESE CUTTING TOOLS MUST BE WEIGHED AGAINST THEIR IMPROVEMENTS IN SPEED AND TOOL

17 LIFE. --- FADE TO BLACK --- SCENE 57. ML57A, CGS: Workholding & Workchanging white text, centered on background SCENE 58. ML58A, SME2502, 01:23:50:00-01:24:03:00 zoom out, workpiece clamped on knee mill table, being machined ML58B, FMP012, 12:42:15:00-12:42:32:00 zoom in, horizontal machining center WORKHOLDING DEVICES IN CNC MILLING INCLUDE THE STANDARD VICES, CLAMPS, AND T-SLOTS FOUND ON KNEE MILLS, AS WELL AS FIXTURES SPECIFICALLY DESIGNED FOR CNC MACHINING CENTERS. SCENE 59. ML59A, FTD90, 06:27:22:00-06:27:43:00 tombstone used on horizontal milling machine ML59B, SME2646, 01:01:39:00-01:01:51:00 tombstone with chucks ML59C, FTD90, 06:28:02:00-06:28:15:00 zoom in, machining of part on tombstone ML59D, FMP008, 09:42:38:00-09:43:00:00 part set up on tombstone FOR INSTANCE, TOMBSTONES MOUNTED ON THE MACHINING CENTER TABLE ARE USED TO HOLD MULTIPLE PARTS. THEY COME IN A WIDE VARIETY OF CONFIGURATIONS AND ARE COMMONLY USED ON HORIZONTAL MACHINING CENTERS. THE MACHINING PROGRAM IS WRITTEN TO MACHINE ALL PARTS ON THE TOMBSTONE BEFORE SHUTTLING IT OUT OF THE MACHINE. SCENE 60. ML60A, SME4024, 09:15:29:00-09:16:08:00 zoom out, multi-vise on machining center ML60B, SME2514, 01:09:35:00-01:09:48:00 multi-vice on indexer, rotary table SETUPS ON MACHINING CENTERS OFTEN UTILIZE MULTIPLE VISES IN A VARIETY OF ARRANGEMENTS TO MACHINE MORE PARTS PER CYCLE. MULTIPLE VISES MAY BE ARRANGED ON AN INDEXING DEVICE TO FURTHER EXPAND THE

18 PARTS-CARRYING CAPACITY OF THE MACHINE TABLE. --- TOUCH BLACK --- SCENE 61. ML61A, FTD88, 04:44:03:00-04:44:17:00 pallet of finished parts taken from mill ML61B, FTD88, 04:41:15:00-04:41:41:00 wide, finished pallet pulled from mill, pallets rotated to new workpieces ML61C, FTD88, 04:44:39:00-04:44:54:00 pallet of raw work stock placed in mill ML61D, FTD90, 06:31:39:00-06:31:51:00 part set up on tombstone ML61E, FTD90, 06:27:26:00-06:27:41:00 zoom in, milling operation on part WORKCHANGING REPRESENTS ANOTHER OPPORTUNITY TO GET MORE MACHINING DONE WITH LESS WASTED TIME. WORKCHANGING METHODS ALLOW UNPROCESSED WORKPIECES TO BE SET UP WHILE THE SPINDLE IS CUTTING OTHER WORKPIECES. SCENE 62. ML62A, SME4024, 09:14:52:00-09:15:15:00 multiple clamps set up on mill MOREOVER, A LONG MACHINE BED MAY PERMIT THE FIXTURING OF SEVERAL WORKPIECES, WHICH ARE MACHINED SEQUENTIALLY. SCENE 63. ML63A, FMP008, 09:31:31:00-09:31:52:00 swapping tombstones ML63B, FMP008, 09:34:48:00-09:35:16:00 part being milled ML63C, FMP008, 09:45:38:00-09:45:49:00 zoom in, new part on tombstone PALLET-CHANGERS EXCHANGE FIXTURES HOLDING MULTIPLE PARTS FROM THE SETUP AREA TO THE MACHINING AREA. HERE, ONE FIXTURE OF PARTS IS MACHINED WHILE PARTS ON THE PREVIOUS FIXTURE ARE REMOVED AND NEW WORKPIECES ARE INSTALLED. --- FADE TO BLACK --- SCENE 64. ML64A, CGS: Machining Center Accessories & Programming white text, centered on background

19 SCENE 65. ML65A, SME3339, 00:07:30:00-00:08:00:00 wide, worker milling on machining center ML65B, FTD08, 07:23:52:00-07:24:07:00 tool placed in presetting machine ML65C, CGS: Touch-Trigger Probe Tool Presetting Machine VARIOUS ACCESSORIES AND COMPUTER PROGRAMMING ASSIST MACHINING CENTER OPERATORS IN THEIR ACTIVITIES. OF THE MANY ACCESSORIES THAT MAY BE USED WITH MACHINING CENTERS, TWO ARE PARTICULARLY SIGNIFICANT: THE TOUCH-TRIGGER PROBE, AND THE TOOL-PRESETTING MACHINE. SCENE 66. ML66A, FMP012, 12:39:04:00-12:39:41:00 touch trigger probe used on workpiece in mill THE TOUCH-TRIGGER PROBE, TOGETHER WITH APPROPRIATE SOFTWARE, CAN MEASURE WORKPIECE DIMENSIONS BEFORE THEY ARE REMOVED FROM THE MACHINE TO DETERMINE IF CERTAIN FEATURES ARE DIMENSIONALLY CORRECT. SCENE 67. ML67A, FTD08, 07:25:13:00-07:25:39:00 tap placed in tool presetting machine ML67B, SME4026, 11:19:13:00-11:19:25:00 placing toolholder in tool storage THE TOOL-PRESETTING MACHINE ENABLES THE MACHINIST OR TOOLROOM TECHNICIAN TO ACCURATELY ASSEMBLE AND BALANCE TOOLS AND TOOLHOLDERS AT THE PROGRAMMED LENGTH AND DIAMETER, BEFORE THEY ARE PLACED IN THE MACHINING CENTER S TOOL STORAGE OR MAGAZINE. SCENE 68. ML68A, SME4022, 07:10:13:00-07:10:32:00 zoom out, cutting tools ML68B, FTD86, 01:54:57:00-01:55:12:00 chuck then tool secured in mill spindle THE CHOICE OF TOOLHOLDER ITSELF CAN BE

20 ML68C, SME4019, 03:19:55:00-03:20:06:00 zoom out, cutting tool clamped into tool holder ML68D, SME4030, 17:18:52:00-17:19:03:00 zoom out, dry machining ML68E, SME4027, 13:37:32:00-13:37:54:00 zoom in, heating up tool holder, end mill being dropped into holder ML68F, SME4027, 13:38:11:00-13:38:23:00 cooled end mill/tool holder removed from machine ML68G, SME4025, 10:09:51:00-10:10:05:00 zoom out, high speed machining CRITICAL. CHUCKS, COLLETS AND OTHER MECHANICAL-INTERFERENCE TOOLHOLDERS USE APPLIED CLAMPING PRESSURE TO SET TOOLS FOR COMMON MILLING SITUATIONS. IN RECENT YEARS, SHRINK-FIT TOOLHOLDERS HAVE BECOME MORE POPULAR, ESPECIALLY FOR HIGH SPEED MACHINING OPERATIONS. HERE, THE TOOLHOLDER DEVELOPS UNIFORM CLAMPING PRESSURE AS IT CONTRACTS AROUND THE TOOL SHANK, AFTER FIRST BEING HEATED AND EXPANDED. SHRINK-FIT SYSTEMS DO REQUIRE EXTRA EQUIPMENT, BUT THE COST MAY BE JUSTIFIED BY THE HIGHER CUTTING SPEEDS AND FEEDS THAT THEY ALLOW. --- TOUCH BLACK --- SCENE 69. ML69A, CGS: Programming & Simulation ML69B, SME3353, 10:02:39:00-10:02:54:00 zoom in, programming at mill ML69C, SME3353, 10:17:24:00-10:17:44:00 zoom 0ut, milling operation with display ML69D, SME4029, 16:23:24:00-16:24:04:00 trochoidal tool path running on part THE PROGRAMMING AND CONTROL SOFTWARE FOR CNC MACHINING CENTERS HAS BECOME INCREASINGLY SOPHISTICATED, AND EASIER TO USE. PROGRAMMING HAS ALSO MADE MILLING MORE ACCURATE, ALLOWING HIGHER PRODUCTIVITY AND BETTER PART SURFACE QUALITY. SOFTWARE CAN ALLOW A MACHINE TOOL TO LEARN HOW TO CORRECT FOR PROCESS VARIATIONS IN ITS ACTUAL TOOL PATH, IN COMPARISON WITH ITS DESIRED PROGRAMMED PATH. OTHER PROGRAMS SUPPRESS

21 MACHINING VIBRATIONS, IMPROVING PART SURFACE FINISH. SCENE 70. ML70A, SME4017, 01:46:17:00-01:47:02:00 zoom out, simulated machining operation SIMULATION PROGRAMS CAN ALSO BE USED TO OPTIMIZE A PROCESS BY PREDICTING WHAT THE CYCLE TIME OF A PROGRAMMED TOOL PATH WILL BE, BEFORE MILLING BEGINS. --- FADE TO BLACK --- SCENE 71. ML71A, CGS: Operating Parameters white text, centered on background SCENE 72. ML72A, FMP001, 01:12:43:00-01:13:16:00 zoom out, milling operation ML72B, CGS: Cutting Speed Feed Rate Axial Depth of Cut Radial Depth of Cut THE SELECTION OF OPERATING PARAMETERS IN MILLING INVOLVES MANY FACTORS. WITH THE MOST IMPORTANT INCLUDING: CUTTING SPEED, FEED RATE, AXIAL DEPTH OF CUT, AND RADIAL DEPTH OF CUT. SCENE 73. ML73A, CGS: Cutting Speed ML73B, FTD99, 09:36:42:00-09:37:03:00 horizontal face milling operation ML73C, FTD101, 11:17:18:00-11:18:14:00 face milling operation IN MILLING, CUTTING SPEED IS MEASURED IN TERMS OF SURFACE INCHES OR METERS PER MINUTE. THIS IS HOW FAST THE EDGE OF THE TOOTH AT THE PERIPHERY OF THE CUTTER ENTERS THE WORK. IT IS A FUNCTION OF CUTTER DIAMETER AND SPINDLE ROTATIONS PER MINUTE. TYPICAL VALUES FOR COMMON

22 MATERIALS MAY RANGE FROM APPROXIMATELY 40 TO 1,000 SURFACE FEET, OR 10 TO 300 METERS, PER MINUTE. SCENE 74. ML74A, CGS: Feed Rate ML74B, SME2667, 05:09:49:00-05:10:18:00 zoom in, milling operation ML74C, FTD87, 03:20:14:00-03:20:41:00 zoom out, milling operation THE FEED RATE IN MILLING IS EXPRESSED IN INCHES OR MILLIMETERS PER CUTTER EDGE OR TOOTH. IT IS BASED ON THE LINEAR DISTANCE A TOOL EDGE TRAVELS INTO THE WORKPIECE DURING ONE CUTTER REVOLUTION. IT COMBINES THE VARIABLES OF TABLE MOTION, CUTTER DIAMETER, AND NUMBER OF TEETH ON THE CUTTER. A COMMON FEED RATE IS TEN THOUSANDTHS OF AN INCH, OR A QUARTER OF A MILLIMETER, PER TOOTH. SCENE 75. ML75A, FTD99, 09:19:40:00-09:19:57:00 zoom out, milling operation IN MILLING, THE TABLE TRAVEL SPEED IS NOT EQUIVALENT TO FEED RATE; RATHER IT MUST BE SELECTED TO ACHIEVE THE DESIRED FEED RATE. SCENE 76. ML76A, SME2667, 05:12:44:00-05:12:59:00 zoom out, milling operation ML76B, CGS: Axial Radial ML76C, SME2666, 04:20:03:00-04:20:25:00 zoom in, small face milling operation ML76D, CGS: Axial Depth of Cut ML76E, CGS: Radial Depth of Cut ML76F, SME2667, 05:08:56:00-05:09:19:00 zoom in, pocket milling operation THERE ARE TWO TYPES OF DEPTH OF CUT: AXIAL, AND RADIAL. IN FACE MILLING, THE AXIAL DEPTH OF CUT IS THE DISTANCE THE TOOL IS SET BELOW THE UN-MACHINED SURFACE. ORDINARILY, AN

23 AXIAL DEPTH OF CUT IS SELECTED TO MINIMIZE THE NUMBER OF PASSES REQUIRED TO REMOVE A GIVEN AMOUNT OF MATERIAL. THE RADIAL DEPTH OF CUT IS THE WIDTH OR DISTANCE OF WORK SURFACE ENGAGED BY THE TOOL. SCENE 77. ML77A, FTD01, 01:15:42:00-01:16:21:00 zoom out, milling operation ML77B, CGS: Amount of Material Removed Average Chip Thickness Cutter Geometry Speed Workpiece Material EFFICIENT MILLING ALSO REQUIRES SPINDLE POWER CONSIDERATIONS, SO THAT THE MILLING CUTTER MAKES THE BEST USE OF AVAILABLE MACHINE HORSEPOWER. THE POWER REQUIRED FOR AN OPERATION VARIES WITH THE AMOUNT OF MATERIAL REMOVED, AVERAGE CHIP THICKNESS, CUTTER GEOMETRY, DESIRED SPEED, AND THE WORKPIECE MATERIAL. SCENE 78. ML78A, SME4021, 05:52:47:00-05:53:10:00 high speed machining operation using flood coolant ML78B, SME4031, 18:02:00:00-18:02:18:00 zoom out, high speed milling using flood coolant COMMON MACHINING OF TYPICAL WORKPIECE METALS USUALLY REQUIRES FLOODING THE PROCESS WITH WATER-BASED COOLANT TO COOL THE CUTTING INTERFACE AND TRANSPORT CHIPS AWAY FROM THE PROCESS. WATER-BASED COOLANT MUST HAVE THE RIGHT CHEMISTRY AND CLEANLINESS FOR EFFICIENT MACHINING. SCENE 79. ML79A, SME4087, 01:36:06:00-01:36:36:00 drilling, tapping, spot drilling on mill

24 using mql ML79B, SME4089, 03:12:47:00-03:13:06:00 zoom in, end milling using mql ML79C, SME4091, 07:13:20:00-07:13:30:00 chips produced from mql operation HOWEVER, SOME MATERIALS, SUCH AS ALUMINUM, CAN BE MACHINED WITH NEAR-DRY MACHINING, ALSO CALLED MINIMUM QUANTITY LUBRICATION, OR MQL. WITH MQL, ONLY A THIN MIST OF LUBRICANT, SUCH AS VEGETABLE OIL, IS APPLIED TO THE CUTTING SURFACE THROUGH SPECIALIZED TOOLING OR APPLICATORS. THUS, MQL SAVES COOLANT HANDLING AND DISPOSAL COSTS AND PRODUCES CLEANER CHIPS. SCENE 80. ML80A, SME4030, 17:13:32:00-17:13:56:00 zoom out, high speed machining operation ML80B, SME4026, 11:29:35:00-11:29:49:00 zoom in, high speed machining operation ML80C, SME4018, 02:08:03:00-02:08:23:00 zoom out, high speed machining steel VARIOUS WORK MATERIALS CAN ALSO BE MACHINED USING VERY HIGH SPINDLE SPEEDS. THIS IS COMMONLY REFERRED TO AS HIGH- SPEED MACHINING, OR HSM. HSM IS LOOSELY DEFINED AS MACHINING WITH ENHANCED SPINDLES THAT SUPPLY ROTATIONAL SPEEDS ABOVE 10,000 ROTATIONS PER MINUTE, OR RPM. THESE SPINDLE SPEEDS ARE COUPLED WITH RAPID AXIS MOVEMENTS, TRANSVERSE RATES, ACCELERATIONS, AND DECELERATIONS TO MAXIMIZE MATERIAL REMOVAL. SCENE 81. ML81A, SME4026, 11:32:39:00-11:33:00:00 fast high speed machining ML81B, SME4026, 11:42:00:00-11:42:20:00 zoom out, high speed machining operation GENERALLY, HIGH SPEED MACHINING IS PERFORMED USING A SHALLOW AXIAL DEPTH OF CUT THAT HELPS TO REDUCE CUTTING FORCES

25 AND FRICTIONAL HEAT WHILE INCREASING METAL REMOVAL RATES. THUS, HSM REDUCES DISTORTION IN THE WORKPIECE DURING CUTTING AND ALLOWS HIGHER THROUGHPUT THAN WITH CONVENTIONAL MACHINING, WHILE PRODUCING A GOOD SURFACE FINISH. --- FADE TO BLACK --- SCENE 82. FMP RVW, CGS: Review white text, centered on background MUSIC UP AND UNDER LET S REVIEW THE MATERIAL CONTAINED IN THIS PROGRAM. SCENE 83. ML06A, SME3454, 22:17:28:00-22:17:41:00 zoom out, milling of flat plastic surface ML06B, SME2973, 13:06:29:00-13:06:47:00 zoom out, milling contoured surface MILLING IS A HIGHLY VERSATILE MACHINING PROCESS THAT USES ROTATING, MULTI-EDGE CUTTERS TO GENERATE FLAT..., OR CONTOURED SURFACES ON A VARIETY OF WORKPIECE MATERIALS. SCENE 84. ML12A, SME2667, 05:01:49:00-05:02:25:00 milling using cutter with multiple inserts ML12B, SME3339, 00:04:09:00-00:04:30:00 zoom out, end milling operation with a lot of chips WORKPIECE MATERIAL IS REMOVED IN THE FORM OF A DISCONTINUOUS, TAPERED CHIP. THIS PROCESS IS A FORM OF INTERRUPTED CUTTING. SCENE 85. ML15B, FMP015, 15:35:17:00-15:35:39:00 zoom out, knee mill in operation ML16A, FMP015, 15:11:03:00-15:11:21:00 med, knee & column ML16B, CGS: Column ML16C, CGS: Knee ML16D, FMP015, 15:11:32:00-15:11:48:00 THE BASIC ELEMENTS OF MILLING MACHINES ARE ILLUSTRATED BY THE MANUAL KNEE MILL, WHOSE MAIN COMPONENTS INCLUDE:

26 med, table & saddle ML16E, CGS: Table ML16F, CGS: Saddle ML17A, FMP015, 15:14:40:00-15:15:00:00 zoom out, ram, head moving in ML17B, CGS: Ram ML17C, FMP015, 15:19:08:00-15:19:23:00 tilt, milling head ML17D, CGS: Head ML18A, FMP015, 15:21:09:00-15:21:23:00 zoom out, quill/spindle, tool rotating ML18C, CGS: Spindle ML22A, FMP015, 15:33:55:00-15:34:20:00 zoom out, c.u. knee mill with powered feed ML22B, FMP015, 15:34:46:00-15:35:02:00 zoom out, c.u. knee mill with powered feed, alternate take ML22C, FMP015, 15:37:12:00-15:37:38:00 zoom out, digital readout THE COLUMN..., KNEE..., TABLE..., SADDLE..., RAM..., HEAD..., SPINDLE..., AND VARIOUS CONTROLS, POWERED FEEDS, AND DIGITAL READOUTS. SCENE 86. ML25A, SME4018, 02:09:10:00-02:09:36:00 zoom in, cnc control running machining operation ML30A, FTD99, 09:30:27:00-09:30:48:00 zoom out, vertical machining center ML30B, SME3353, 10:10:42:00-10:10:57:00 zoom out, horizontal machining center PRODUCTION MACHINING CENTERS USE COMPUTER NUMERICAL CONTROL, OR CNC, IN WHICH INSTRUCTIONS FOR MACHINING ARE IN THE FORM OF A CODED PART PROGRAM. THE TWO PRIMARY CNC MACHINING CENTERS INCLUDE THE VERTICAL MACHINING CENTER..., AND THE HORIZONTAL MACHINING CENTER. SCENE 87. ML38B, SME4026, 11:26:05:00-11:26:12:00 tool change ML39A, SME4026, 11:58:14:00-11:58:25:00 tool storage, tools indexing TOOLCHANGING IS AUTOMATED ON MACHINING CENTERS, WHERE TOOL STORAGE CAPACITY MAY RANGE FROM 20 TO 200 OR MORE CUTTING TOOLS.

27 SCENE 88. ML40C, FMP006, 06:36:18:00-06:36:34:00 face milling ML40D, FMP001, 01:42:41:00-01:42:55:00 end milling ML42B, FMP006, 06:30:09:00-06:30:49:00 face milling operation ML46H, FMP015, 15:40:25:00-15:40:38:00 edging operation ML46D, FTD07, 06:46:02:00-06:46:12:00 shoulder operation ML46F, FTD19, 20:11:25:00-20:11:36:00 zoom out, grooving operation ML53B, FMP006, 06:09:05:00-06:10:11:00 pocket milling operation ML54B, SME3339, 00:19:05:00-00:19:26:00 contour milling operation ML55A, FTD23, 03:16:48:00-03:17:14:00 zoom in, milling using carbide inserts ML55B, SME4022, 07:11:24:00-07:11:37:00 high speed machining emphasizing tooling THERE ARE MANY CUTTERS AND TYPES OF MILLING OPERATIONS, WITH TWO OF THE MOST COMMON TOOLS BEING FACE MILLS, AND END MILLS. MILLING CUTTERS CAN CREATE FLAT SURFACES..., EDGES..., SHOULDERS..., GROOVES..., POCKETS..., CONTOURS..., AND OTHER FEATURES. BOTH TOOL SHAPE AND MATERIAL, AS WELL AS THE CHOICE OF TOOLHOLDER, ARE IMPORTANT PERFORMANCE FACTORS. SCENE 89. ML33B, FMP003, 03:09:43:00-03:10:10:00 indexer on vmc ML21B, FMP015, 15:29:40:00-15:29:50:00 zoom out, part held by vise to table ML21A, FMP015, 15:31:35:00-15:31:52:00 zoom out, part bolted directly to table with clamps ML59C, FTD90, 06:28:02:00-06:28:15:00 zoom in, machining of part on tombstone WORKHOLDING DEVICES SECURE THE WORK AND ORIENT IT IN DIFFERENT WAYS TO THE CUTTING TOOL. WORKHOLDING DEVICES INCLUDE THE VARIOUS VISES..., CLAMPS..., TOMBSTONES, AND OTHER FIXTURES. SCENE 90. ML61A, FTD88, 04:44:03:00-04:44:17:00 pallet of finished parts taken from mill ML61B, FTD88, 04:41:15:00-04:41:41:00 wide, finished pallet pulled from mill, WORKCHANGING METHODS ALLOW UNPROCESSED

28 pallets rotated to new workpieces ML61C, FTD88, 04:44:39:00-04:44:54:00 pallet of raw work stock placed in mill ML61D, FTD90, 06:31:39:00-06:31:51:00 part set up on tombstone ML61E, FTD90, 06:27:26:00-06:27:41:00 zoom in, milling operation on part WORKPIECES TO BE SET UP WHILE THE SPINDLE IS CUTTING OTHER WORKPIECES. SCENE 91. ML66A, FMP012, 12:39:04:00-12:39:41:00 touch trigger probe used on workpiece in mill ML67A, FTD08, 07:25:13:00-07:25:39:00 tap placed in tool presetting machine OF THE MANY ACCESSORIES THAT MAY BE USED WITH MACHINING CENTERS, TWO ARE PARTICULARLY SIGNIFICANT: THE TOUCH-TRIGGER PROBE..., AND THE TOOL-PRESETTING MACHINE. SCENE 92. ML72A, FMP001, 01:12:43:00-01:13:16:00 zoom out, milling operation ML73A, CGS: Cutting Speed ML73B, FTD99, 09:36:42:00-09:37:03:00 horizontal face milling operation ML74A, CGS: Feed Rate ML74B, SME2667, 05:09:49:00-05:10:18:00 zoom in, milling operation ML76C, SME2666, 04:20:03:00-04:20:25:00 zoom in, small face milling operation ML76D, CGS: Axial Depth of Cut ML76E, CGS: Radial Depth of Cut ML76F, SME6667, 05:08:56:00-05:09:19:00 zoom in, pocket milling operation CUTTING TOOLS, MACHINE POWER, WORKPIECE MATERIAL, AND OTHER FACTORS DETERMINE THE MAJOR OPERATING PARAMETERS IN MILLING, WHICH INCLUDE: THE CUTTING SPEED, WHICH IS THE SPEED AT WHICH THE TOOL EDGE ENTERS THE CUT..., THE FEED RATE, WHICH IS BASED ON THE DISTANCE THE TOOL EDGE TRAVELS INTO THE WORKPIECE IN ONE CUTTER REVOLUTION..., THE AXIAL DEPTH OF CUT, WHICH IS THE DISTANCE THE TOOL IS SET BELOW THE UN- MACHINED SURFACE..., AND THE RADIAL DEPTH OF CUT, WHICH IS THE DISTANCE OF WORK SURFACE ENGAGED BY THE TOOL.

29 --- FADE TO BLACK --- SCENE 93. continue music, up and under ML CRX, CGS, ROLL: credits white text, fade up mid-screen FMP EXM, extended motion background Produced By: Society of Manufacturing Engineers Executive Producer: Kristine Nasiatka Producer/Director/Cameraman: Jerome T. Cook Written By: Michael Tolinski, MText Technical Editing Frederick Mason Technical & Editorial Consulting: Gary Walters, Macomb Community College Equipment Access Provided By: Advanced Machine & Engineering Co. Atlas Tool, Inc. Bernard & Company Bowden Manufacturing Burr Oak Tool Inc. Chicago Mold Engineering Co., Inc. D-M-E Company FlashCut CNC Ingersoll Cutting Tools Machining Efficiencies, Inc. Master Unit Die Protomatic Washtenaw Community College

30 Production Assistance: Lance Rosol Graphics/Video Editing: Jerome T. Cook SCENE 94. continue motion background FMP DIS, CGS: disclaimer white text, centered on background Some machinery in this program had safety equipment removed to allow better recording of certain processes. Always read the safety information provided in the manufacturers' manual before machine operation. SCENE 95. FMP03A, SME logo open, with music