This course is designed to provide theory and skill instruction supplemental to that introduced in Milling Operations I (MTT 124). Skill embellishment and expanded surface feature creation in the use of conventional metal working milling machines and attachments, along with associated accident prevention practices and procedures will be stressed. Concepts and mathematical calculations for machining of prismatic (cube-like) features and part geometry will be emphasized. Process planning, documentation and Geometric Dimensioning, and Tolerancing (GD&T) characteristics for milling work will be addressed. Cutters and insert (geometry and grade) selection, as well as cutting parameters, will be stressed.
Upon successful completion of this course, students should be able to:
Utilize detail drawings, layout, and inspection tools to produce parts via horizontal and vertical milling operations.
Plan sequential operations and develop a process, a tooling, and an operation sheet, for advanced piece-part manufacturing on milling machines.
Develop set-up and inspection procedures for milled parts.
Compare milling machine cutting tool material types, and their selection criteria.
Research machinability factors and ratings for various types and classifications of materials.
Refer to manufacturer's catalogs and apply theory of cutting tools to determine the application, and the identification of cutting tool adapters, cutters, and inserts.
Determine coolant selection, speed, and feed settings in regard to tool material and insert geometry requirements in order to obtain specific surface finish requirements on milled parts.
Interpret print requirements (including GD&T) and part geometry for machining and inspection of advanced milling parts.
Create internal features to include chamfers, bores, recesses, counterbores, countersinks, grooves and pockets using a milling machine.
Set-up and use various style cutters to create form (profile) geometry such as angle, convex, concave, radius, T-slot, and key-way features.
Mount and use milling machine accessories and attachments such as a right angle plate, rotary table, dividing head, boring head, angular vise, angle plate, V-blocks, sine bar/plate/vise.
Position fixtures and perform fly cutting, slitting, straddle, and gang milling operations.