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6. Typical Milling Operations

6.1. Plain Milling

Plain milling is the milling of a flat surface with the axis of the cutter parallel to the machining surface. It
can be carried out either on a horizontal machine or a vertical machine as shown in figure 16.

6.2. End Milling

End Milling is the milling of a flat surface with the axis of the cutter perpendicular to the machining
surface as shown in figure 17.

Figure 17. End Milling

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Summary of Contents for Cobra Mill

Page 1: ...Cobra Mill Instruction Manual Chester UK Ltd Clwyd Close Hawarden Industrial Pk Hawarden Nr Chester Flintshire CH5 3PZ Tel 01244 531631 Email sales chesteruk net www chesteruk net ...

Page 2: ...Contents 1 Introduction 2 2 Health Safety 3 5 3 Machine Specification 6 7 4 Operation 8 9 5 Controls 10 6 Part Diagrams Lists 11 13 7 Circuit Diagram 14 15 8 Guide To Milling 16 Chester UK Cobra Mill 1 ...

Page 3: ... company Export Education Model Engineering UK Sales all with dedicated sales personnel who are trained to answer your questions When buying from Chester you can be assured of a complete back up service with mechanical and electrical engineers that are available to give advice if required Stock is a large part of any business and Chester have always invested substantially in building a large quant...

Page 4: ...se face and or a dust mask if the cutting operation is dusty 3 Don t overreach Keep a proper footing and balance at all times 4 Never stand on a tool Serious injury could occur if the tool is tipped or if the cutting tool is accidentally contacted 5 Never leave the tool running unattended Turn power off Leave tool until it comes to a complete stop 6 Drugs alcohol and medication Do not operate the ...

Page 5: ...tered areas and benches invite accidents 2 Don t use in a dangerous environment Don t use power tools in damp or wet locations or expose to rain Keep the work area well lit 3 Keep children etc at a safe distance All children etc should be kept at a safe distance from the work area 4 Don t Install use this machine in an explosive dangerous environment Maintenance 1 Disconnect Machine from the power...

Page 6: ...ch Do not remove this switch from the machine for any reason and check it s function frequently 2 Interlock switch on cutting area As soon as the pulley cover is open the machine will come to a stop with the function of this switch Do not remove this switch from the machine for any reason and check it s function frequently Chester UK Cobra Mill 5 ...

Page 7: ...roke 30mm Throat 140mm Table Working Surface 145x240mm Longitudinal Travel 180mm Cross Travel 90mm Max Distance Spindle To Table 220mm No Of Spindle Speeds Variable Range Of Speeds 100 2000rpm Spindle Taper MT2 Motor 150W Supply 240V Weight nw gw 25 38kg Dimensions LxWxH 480x380x680mm Chester UK Cobra Mill 6 ...

Page 8: ...Control Knob 3 Fuse Box 4 Power Light Green 5 Yellow Light only 110V 6 High Low Change Knob 7 8 Fine Feeding Handwheel 9 10 Work Table 11 Cross Feed Handwheel 12 Longitudinal Feed Handwheel 13 Handle 14 Lifting Handwheel 15 DC Motor Chester UK Cobra Mill 7 ...

Page 9: ...kwise b in order to secure the tapered shank 6 Pull out the fixing pin 7 Install the protective cover a Removal Of The Tapered Shank 1 Disconnect from the main power supply before you replace the cutter 2 Remove the protective cover a 3 Use a 14 open end wrench c to loosen the spindle draw bar counter clockwise i in order to remove the tapered shank 4 Knock the taper shank i gently with a plastic ...

Page 10: ... The following adjustments are possible 1 Base Y Axis Cross Slide 2 X Axis Cross Slide Work Table 3 Mill Head Seat Vertical Column 4 Mill Head Spindle The Way To Adjust 1 Loosen the locked nuts 2 Adjust the foremost pressure of the mitre wedge by locked nut If necessary loosen all the adjusting screws to the same 3 Tighten and loosen the adjusting screws also keeping the pressure of each adjusting...

Page 11: ...ed setting Caution Never attempt to change from a HIGH to a LOW speed whilst the machine is running Starting Under Normal Conditions 1 Take all the necessary precautions previously stated and ensure the workpiece is fixed firmly 2 Select an appropriate speed level 3 Select the FORWARD off REVERSE to a FORWARD or REVERSE position 4 Proceed to start the machine as described above 5 Whilst not in use...

Page 12: ...Part Diagrams Lists Chester UK Cobra Mill 11 ...

Page 13: ...1 53 Joint shaft 1 17 Screw M6 x 5 1 54 Screw M5 x 18 1 18 Compression spring 1 55 Joint screw 1 19 Steel ball 5 1 56 Worm base 1 20 Gear box 1 57 Helical gear 1 21 Spindle sleeve 1 58 Spacer 1 22 Screw M6 x 14 2 59 Pin A3 x 18 1 23 Bearing 61905 2E 2 60 Key 2 x 18 1 24 Spindle box 1 61 Worm shaft 1 25 Check ring for hole 38 2 62 Dial 1 26 Spring seat ring 1 63 Damp spring 1 27 Compression spring ...

Page 14: ...t block 1 133 Inside Six hom Wrench S 3 6 1 95 Lifting screw 1 134 Double end Wrench 5 5 8 10 1 96 Screw support 1 135 Round nut Wrench D 38 42 1 97 Hand wheel 3 136 Oil can 1 98 Handle bolt 3 137 Fuse 1 99 Handle sleeve 3 138 Taper shank 1 100 Key 3 x 10 3 139 Chuck key 1 101 Cover board 1 140 T nut 4 102A Fuselage 1 141 Cross screw 1 103 Screw 4 142 Cross wedge 1 105 Worktable 1 143 Connect plat...

Page 15: ...Circuit Diagram 220 240V 50 60Hz Chester UK Cobra Mill 14 ...

Page 16: ...100 120V 50 60Hz Chester UK Cobra Mill 15 ...

Page 17: ...Many complicated operations such as indexing gang milling and straddle milling etc can be carried out on a milling machine This training module is intended to give you a good appreciation on the type of milling machines and the various types of milling processes Emphasis is placed on its industrial applications operations and the selection of appropriate cutting tools On completion of this module ...

Page 18: ...Machine Their functions are a Column The column houses the spindle the bearings the gear box the clutches the shafts the pumps and the shifting mechanisms for transmitting power from the electric motor to the spindle at a selected speed b Knee The knee mounted in front of the column is for supporting the table and to provide an up or down motion along the Z axis c Saddle The saddle consists of two...

Page 19: ...2 2 Vertical Milling Machine ...

Page 20: ...ng Figure 7 End Mill b Rough Cut End Mills For rapid metal removal Figure 8 Rough Cut End Mill c Slot Drills For producing pockets without drilling a hole before hand Figure 9 Slot Drill d Face Milling Cutters For heavy cutting Figure 10 Face Milling Cutter Note Most vertical milling cutters are of end mill types and are specified by the material the diameter the length the helical angle the types...

Page 21: ...f plastic moulds tool dies and jigs fixtures Figure 12 shows a typical plastic mould produced by milling Figure 11 Components Made by Milling Figure 12 Plastic Mould 5 Milling Processes Milling is a metal removal process by means of using a rotating cutter having one or more cutting teeth as illustrated in figure 13 Cutting action is carried out by feeding the workpiece against the rotating cutter...

Page 22: ...of travel of the workpiece in mm min But most tool suppliers recommend it as the movement per tooth of the cutter f Thus F f u N where F table feed in mm min f movement per tooth of cutter in mm see table 1 u number of teeth of cutter N R P M of the cutter where C S and feed rate for some common material Tool Material High Speed Steel Carbide Material Cutting Speed Feed f Cutting Speed Feed f Mild...

Page 23: ...up cut milling the cutter rotates in a direction opposite to the table feed as illustrated in figure 14 It is conventionally used in most milling operations because the backlash between the leadscrew and the nut of the machine table can be eliminated Figure 14 Up Cut Milling b Down Cut Milling In down cut milling the cutter rotates in the same direction as the table feed as illustrated in figure 1...

Page 24: ...the cutter parallel to the machining surface It can be carried out either on a horizontal machine or a vertical machine as shown in figure 16 6 2 End Milling End Milling is the milling of a flat surface with the axis of the cutter perpendicular to the machining surface as shown in figure 17 Figure 17 End Milling ...

Page 25: ... between two side and face milling cutters on the spindle arbor as shown in figure 19 for the milling of two surfaces parallel to each other at a given distance Figure 19 Straddle Milling 7 Milling Set Up Correct use of holding device and a good set up are of crucial importance in achieving a safe accurate and efficient operation of the machine Large workpiece can be mounted directly onto the mach...

Page 26: ...pported by parallel bars to provide the supporting datum Round bar must be placed between the workpiece and the movable jaw to ensure that the workpiece is in perfect contact with the fix jaw The vice handle should be tightened by hand to avoid over clamping of the workpiece as well as the vice Hide face hammer should be used to assure that the workpiece is in perfect contact with the supporting b...

Page 27: ...face shield figure 24 to prevent accident that may be caused by chips cutting fluid and tool breakage Machine operators must also take care of their body such as fingers which keep out of any moving parts especially the rotating cutter of the machine to prevent any unnecessary accident hurt The milling machine must be stopped immediately when any accidence occurred so the operator must stand near ...

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