Industrial Milling Machine – Useful Tips While Selecting the Best

Milling machine is used in industries dealing in wood, metal, plastic etc. Solid hard materials can be formed into shapes of desire. With the advanced technology there is a great improvement in the working. Today they work much faster than what the speed was years ago.

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Milling Machine

It can execute many functions. It can drill, cut, rout etc. The machines are kept greased with a liquid which is dispensed on the location of cutting to clean away small pieces of metal.

milling machine

Types of Milling Machines

Main types available are:

  • Vertical Milling Machine is used for thrust drilling and its spindle is placed vertically.
  • Horizontal type is mainly used for cutting big and heavy material.
  • Column type is simple to use, with few parts. The mechanism for cutting is poised vertically and this can drill the materials.
  • The turret is very adaptable and can produce numerous products.
  • The C frame is commonly used in the workshops as it is very powerful.
  • The most accurate type of it is the CNC machine. As it works by means of computer and very intricate designs can be made on the work piece.

The size of the machines also differs, small machines that can be kept on a table and the big ones are as big as a room.

Tips for Buying the Milling Machine:

The type of Milling machine you buy depends largely on the kind of work you have to do. So first reflect on how simple or difficult and intricate the work is. The main conditions you must think about are:

  • Production needs – the capacity of it you wish to buy depends on your needs.
  • Frequency of use – if you are going to use the machine often then buy an industrial tools, and for less usage buy a commercial machine.
  • Axis – check how many axis the machine has.
  • Power – depending on the speed you require check the power of the electric motor, spindle, turbine and the engine power.
  • Speed – how fast the spindle head moves is the speed of the spindle, make a note of it.
  • Attachments – check how many attachments will come free with the machines, you might have to buy others.
  • Popularity – check online how popular that particular brand of machine is, read the feedback and comments of other people who are using the machine.

safety-tips

Safety measures to use while operating milling machines:

The operator must be trained well. The work piece must be clamped properly and  the operator must make sure the clamps and vises are activated properly or it can lead to serious accidents.

He must check regularly if and when the tools should be changed. The machines must have the guards to protect any small pieces from flying away. Safety glasses must be used while operating it.

Conclusion

Thus, it becomes easy to buy a particular brand of machine after learning important facts about it. Check the credentials of the company and also the machine you wish to buy. It’s a big investment, so be very sure about the type of machine you need, before you buy one..

Know the Important Safe Guards while Operating Milling Machine

A milling machine includes a cutter that functions at a high speed. Hence, it can harm the user if not operated properly. Moreover, the milled material may cause serious injuries, because the metal chip is very sharp. Further the metal pieces lying on the table can cut your skin; and the metal flakes flying around during the cutting process may damage your eyes. It is therefore necessary to be careful and alert while operating. Hence all related persons are advised to follow the safe guards listed below.

• You should make sure that your hand, shirt sleeve, glove, and long hair are kept at a safe distance from the milling machine, especially the spinning parts. Otherwise if anything gets entangled in the moving parts it will cause serious mishaps. Hence you should always be aware about the location of the stop button for immediately disconnecting the power supply, if an accident occurs while working.

• Usually a sharp metal rotates at high speeds on a milling device. Hence you should ensure that the work piece is fastened tightly. It is better to secure the material properly to avoid it from flying off the table and prevent any damage or accident.

• You should even secure all the tools in the relevant tool holders. This is essential because any loose tools can injure you or damage the machine. Further, if a tool breaks, you must instantly stop the tool and change the tool, and repeat that operation. Moreover the broken tool may also collide with the nearby tools in the line, and thus cause various other problems.

• Basically the metal which is being cut on a milling equipment has sharp edges. These dangerous metals should always be handled with care; otherwise it can cause considerable damage. Moreover, as some milling machines may not be enclosed, it is necessary to safe guard your eyes from the sharp metal chips and the coolant spray. Hence when you are working with raw metal; you must wear safety gloves and suitable eye protection.

• While operating it you should always close the doors and view the process from the window of the machine. This window will protect you from any loose parts, and sharp or large chips of metal. Moreover before starting the milling machine you should always clean the window whenever it gets dirty, and also replace it when it is damaged.

• Generally a water soluble fluid is used to cool the metal when it is being cut. However, a coolant may not be utilized for machining some metals. As a result the hot metal chips that are thrown off the work piece can burn your skin. Hence you must always use a shield while machining soft metals without a coolant. In case a safety cover is not available you should use a fire resistant material as a temporary guard.

Hence all users should know these important safe guards while operating milling tools.

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An Overview of CNC Milling Machine

The milling machine is a versatile tool that is utilized for machining solid materials. It can perform various simple as well as complicated operations, such as slot and keyway cutting, planing, drilling, contouring, diesinking, etc.

They are mainly classified in two basic configurations namely vertical and horizontal, based on its orientation. On vertical the spindle axle is vertical, where as on horizontal machines it is horizontal.

Later on with the development of technology, the computer numerical control or CNC milling machines were introduced in the market. These devices enable the users to input instructions related to different parts. Some CNC equipments also include remote control devices. Besides this they also help to increase the efficiency and reduce the manufacturing costs. Additionally this modern unit has the capacity to run at higher speeds and produce very accurate products on a large scale.

CNC Milling Machine

It is regarded as one of the highly significant tools. It is commonly used in various industrial segments for fabricating components. These help to effectively carry out repetitive and complex milling tasks that were earlier done manually since the past several years. As a result it assists to increase the profitability as well as productivity. Hence they are preferred over the traditional machines, and also considered as a very important machine in a large number of industries.

A variety of CNC units are now readily available in the market. And all the models can easily perform various cutting and drilling operations. The latest kinds of CNC are commonly known as multi axis machines as they either have 3, 4, or 5 axes. Consequently, which has more number of axes is relatively expensive, as compared to the machines with less number of axes. This is due to the fact that with higher number of axis can execute relatively complex operations. Thus, most of the large scale manufacturing units now prefer using 4 and 5 axis, since they help to enhance their output. Know more at – http://www.bhavyamachinetools.com/tool-room-machines/milling-machine.html

All CNC milling primarily include integrated control software. And the operations are controlled by that specific control software. Hence the operators should have the necessary skills in order to control these computerized machineries for performing highly accurate milling operations. Most of tools enable to deliver very precise products as compared to the conventional or manual equipments and also reduce wastage.

Further, these state of the art milling equipment are ergonomically designed. Hence the operators are not required to bend, bow and twist their body while setting and operating the device. Moreover, the cutting tool operates within an enclosed area. This serves as an effective preventative measure for avoiding injuries and accidents that may be caused by direct exposure to the milling operations. In short, all CNC assist in fabricating top grade and highly accurate components. Therefore, using a CNC milling will surely enable to provide higher returns on investment.

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Types of Milling Machines and Selection Guide for Workshop

A milling machine is a versatile tool that is widely used in the metal industry for performing several tasks such as milling, cutting, threading, carving, drilling, planing, contouring, die-sinking, etc. These milling tool have a cutter that can move at a variable speed in order to achieve the desired shape. This ability to run at an adjustable speed helps to deliver a highly precise work piece.

Nowadays, a wide range are available, and each type of milling device can perform a specific function. The most commonly used milling unit include the vertical, the horizontal, the column, bed type, turret, tracer controlled, planer-style , C-frame, etc.

Besides, the manufacturers also name the various kinds depending on the number of axis, the size of the tool, the way it is controlled, the orientation of the spindle, the source of power, the purpose of the machine, etc. Further, although there are many types available in the market; all are basically utilized for the same purpose, in spite of the fact that they have distinct names. The types and selection guide for workshop is as follows.

A Horizontal milling machine works parallel to the ground. Here the table on which the work piece is kept moves sideways, and the cutting tool moves up and down. The Turret device is also commonly referred as the Bridgeport-type.. It is a versatile machine that can be repositioned as required. This flexibility helps to produce a variety of products such as machine components, car parts, etc.

The Tracer Controlled can create machine parts as per the master model. It is commonly used in many industries, especially in the automobile sector; since it helps to easily make certain special machine components. In the Bed Type the worktable is situated on the bed, whereas normally the bed is always placed on the top. Here the knee part of the machine does not exist; hence it enables movement in a longitudinal direction.

The Planer-Style milling machine is almost similar to the bed type; except that it includes heads and cutters that perform a variety of milling functions. The Column milling equipment is highly popular, and consists of basic components, such as the work table, saddle, head, knee, and over arm. This simple machine has a cutting tool that is positioned vertically in order to drill metals. Since it is small and compact it is commonly used for producing car parts.

The C-Frame milling machine is very robust and runs on a hydraulic motor. It is powerful than a turret and is typically used in many industries. These days, the computer numerically controlled, CNC milling machines are very popular and used throughout the world. Hence selecting it will depend on your individual requirements, and also on your budget limits..

Reasons to Use Milling Machine for Shaping Metals

A milling machine is a tool that is basically used to shape or cut solid metals by removing the excess material in order to form a finished product. These are mostly utilized in the metalworking industry to perform a wide range of complex cutting operations; such as keyway and slot cutting, drilling, diesinking, threading, carving, milling, rebating, planing, routing, and much more.

Versatility is the primary reason to use milling machines for shaping metals. These are powerful tools with the capability of cutting a wide range of metals from aluminum to stainless steel. Nowadays, a variety of technologically advanced are manufactured to satisfy the growing needs of several industrial sectors.

Milling equipments are built with different specifications and each is named based on a particular function. All milling tools essentially serve the basic purpose of cutting and shaping metals. However, each is categorized into different groups based on the various standard specifications. These multi purpose machines can simultaneously carry out multiple tasks such as milling, cutting, drilling etc.

Milling tools are available in various sizes and can have a horizontal or a vertical orientation. In a horizontal the spindle faces horizontally, whereas a vertical has a spindle axis that faces vertically. It can be manually operated or mechanically automated. A computer numerical control or CNC milling tool is digitally operated, and helps to avoid accidents and save labor costs.

Every type has a different working speed to accurately cut the metals. It can be adjusted to move at a slow or fast speed as per the material being cut and according to specific requirements. Soft materials are usually shaped at higher speeds whereas hard materials are normally milled at a slow speed. Moreover, small quantities of a hard object can be cut at the same time.

A typical operation involves feeding the material over a device called a milling cutter. The ground slides, lead screws and teeth of the cutters; carve the work piece into precise and desired shapes. These popular machines can mill, thread, grind and do much more. A milling machine can even drill holes straight down like a drill press. The work piece can also be kept at the side of the tool in order to shape its edges.

There are numerous types of it, each with varying functions based on standard requirements. They are normally termed based on the orientation of the spindle; number of axis present; type of control; size of the tool; its purpose; as well as the source of power. The common types of manual milling include; turret milling equipment also known as vertical ram mills; box or column mills; c-frame mills; planer style mills, knee-mill or the knee-and-column mill; horizontal mill, bed type mill, tracer controlled mill etc.

The main advantage of manual milling machines is that they are not very expensive. Hence, It is a perfect solution for performing different tasks related to shaping various metals..