Basic Milling Procedures

Course Number: 826

This course covers the setup and use of the horizontal milling machine, and describes the functions of basic cutters and attachments. It uses "hands-on" projects so students actually gain experience on the milling machine. It includes a work-holding fixture project that can have practical value in the shop when finished.

Recommended Contact Hours - 8

Chapter 1: Using the Horizontal Milling Machine

Topics: Milling machine parts and functions; Vertical milling attachments; Speed and feed; Depth of cut; Lubricants; coolants

Learning Objectives:

• Identify the major parts of a universal horizontal milling machine and their functions.
• Define the use of a vertical milling attachment.
• Compute the milling spindle speed and the machine table feed rate.
• Install and align a workpiece in a V-block.
• Install and align a workpiece in a milling machine vise.

Chapter 2: Slab Milling Procedures

Topics: Slab milling cutters; Installing the arbor and cutter; Speed and feed selection; Depth of cut; Alignment; Trial cut; Rough milling; Finish milling cut

Learning Objectives:

• Select and install a slab milling cutter on a Style B arbor.
• Install a Style B arbor with cutter, spacers, key, and bearing sleeve into a horizontal milling machine.
• Complete a rough slab milling cut on a workpiece.
• Complete a finish slab milling cut on a workpiece.

Chapter 3: Milling Slots and Angles

Topics: Aligning cutter and workpiece; Milling a slot; Angle milling; Angular milling with a vertical milling attachment; Milling a dovetail

Learning Objectives:

• Mill a slot with the cutter in a horizontal and a vertical spindle position.
• Use a T-slot cutter in both a horizontal and vertical spindle position.
• Angle mill a bevel from both a horizontal and vertical spindle position.
• Use adapters for shank-type cutters.
• Cut a female dovetail in a workpiece using a dovetail cutter.

Chapter 4: Straddle, Side, and Face Milling

Topics: Selecting, mounting, and aligning the cutters; Machine setup; Making the first cut; Using trig functions for the final cut; Face milling

Learning Objectives:

• Select, set up, and align straddle milling cutters on a Style B arbor.
• Straddle mill a workpiece.
• Cut an angular step using a side milling cutter.
• Face the side of a workpiece with a shell end mill.
• Face a broad workpiece surface using a face mill.

Chapter 5: Milling Keyseats, Squares, and Flats

Topics: Keyseats for square and woodruff keys; Selecting and installing the cutter; Depth of cut; Speeds and feeds; Using automatic feed controls; Milling squares on round work; Milling tangs and flats

Learning Objectives:

• Select and install a standard Woodruff keyseat cutter.
• Mill a keyseat with rounded ends (for a square key) and a Woodruff keyseat (for a Woodruff key) in a workpiece.
• Make a plunge cut with a two-fluted end mill.
• Mill a square on the end of a shaft.
• Mill a tang and a flat on a cylindrical workpiece.