A milling machine is purchased for many carpentry. But sometimes the scope of its application is significantly increased, and there is a need for reconstruction of the workplace. Do-it-yourself milling table for manual milling is an excellent opportunity to save money and create a high-quality work surface for yourself. Joinery is now in great demand, and in everyday life this tool is quite useful. And more convenient working conditions will make it simply irreplaceable.

Milling table

An experienced joiner can assemble a simple milling table with his own hands even without drawings, prepared sizes and diagrams. On the Internet there are many videos on this topic and phased explanations of the essence of the work. If you first decided to try yourself in this area, then do not despair, if you want, you can make a table for manual milling in just one day. In addition, you will be completely confident in the strength of your product, and you will also be able to choose the ideal sizes that are needed specifically for your premises. But, before making a circular milling table, you should understand what it is.

Milling table drawing

A home-made milling table cannot be distinguished from the store version if it is made in compliance with the basic rules and requirements. Milling machines move along the surface of the processed material, thereby leveling it. If this type of processing is made stationary, then the master will have to go to work much less time and effort.

Do-it-yourself milling table occupies a certain space in the room. Therefore, before making the installation, decide which table you want to see:

• aggregate;
• removable;
• stationary.

Aggregate Portable Stationary

Remember that most of the work can only be done in stationary mode. Also, consider how often you will use the machine, because for rare use the portable model is quite suitable, and for daily use - a stationary workstation.

What parts does the milling table consist of?

A homemade milling table can be done alone without resorting to outside help. To do this, it is necessary to make all the main parts of the structure for subsequent collection. Without one of the parts, a milling table can become practically useless, as it will not perform basic duties. Do-it-yourself milling cutter consists of the following parts:

• countertops;
• beds;
• floor emphasis;
• clamping ridges;
• mounting plate.

The tabletop under the manual milling cutter must be thick, strong and even. Kitchen worktops are great for this, or, if not available, regular plywood. It is only worth remembering that a universal milling table requires a thickness of at least 16 mm, so plywood sheets should be glued together with wood glue. Additional tools can give a smooth surface, for more convenient operation. In the center, you need to make a hole to install the router.

Drawings of the milling table can not do without a bed. It is responsible for the stability of the structure, absorbing all vibrations emanating from the tool. To do this, you can use old bedside tables, tables, but provided that they are very durable. Some focus on metal models, which is pretty practical.

Milling table from an old bedside table

The floor stop fixed on the countertop is responsible for the correct flow of material. It can be made stationary, for permanent materials, or sliding, if the master will work with elements of different sizes. This is a very important element in the work, since the quality of the milling cutter will depend on the evenness of all sides.

The clamping combs on the table for circular and milling are almost mandatory. They perfectly fix the material not only from the sides, but also from above. This comb can be mounted at any height using fasteners. Its dimensions are set based on the personal wishes of the master and what he will encounter in his work.

Experts advise immediately install sliding combs and stops, then the functionality of the working machine will increase significantly.

Assembly rules

DIY assembly of the milling table should be done in stages. First you need to decide on the countertop and make a hole in it for the tool. Further, material flow control systems are attached.

In this case, it is necessary to determine exactly where they are fastened to the smallest detail, since the quality of further work depends on this.

The milling machine itself must be firmly fixed under the countertop. It should not hang or hang, any movements can lead to injuries during operation or damage to equipment. It is better to fix it with self-tapping screws, for your own peace of mind.

The main thing in this way of working is to make the most convenient workplace for the master. And in this regard, the master himself works with all sizes, knowing what he really wants to get as a result.

Electronics at work

Making a circular and milling table with your own hands is quite simple, but do not forget that this tool works from electric current. Since the start and stop buttons will be in an uncomfortable place for the master, you need to take care of their use. You can exit and set the start and stop buttons of the mechanism in a convenient place, but this requires knowledge in electronics.

There is an alternative that is less safe for the router and the circular. The start button is clamped, and it is in a constantly on state, stopping only by the cable, when disconnected from the network.

A self-made new milling table should fully match the floor of the workplace. If the floors are uneven, you should make legs with a movable mechanism, otherwise the design will quickly become worthless. To ensure that the life of the table for the milling cutter significantly exceeds all expectations, its surface is varnished or other woodworking liquid. This not only increases the service life, but also additionally fastens the elements.

1 2 3

Protect yourself from damage that may occur during operation. Install a protective glass on the longitudinal stop, which will be an obstacle for flying chips, sawdust and other elements.

When making a milling table at home with your own hands, remember that working with it is rather dangerous and take better care of your safety.

The workshop of any person contains all the tools necessary for him. But at the same time, an urgent need for arranging a workplace may be necessary, and store prices may not suit. And in general, not all people have the opportunity to visit stores with similar goods.

Milling table drawing

The milling table has drawings and diagrams, so making it yourself will not be difficult. Moreover, you yourself will know which model you need, what sizes will be convenient for you. The purchase option may not always be the way out. Do not be afraid and drag out time, even a beginner will figure out how to make a table.

MILLING A PLANE WITH AN END MILL

  Milling a plane with a face mill is more often performed on a vertically milling machine. Consider an example of milling a plane of a bar (see Fig. 84) with a face mill on a vertically milling machine.
  Installation and fixing of the cutter. For processing, we choose an end mill made of high-speed steel P18 with large teeth. With a milling width of 60 mm  The end mill must have a diameter in the range of 80-100 mm. Choose a cutter with a diameter of 80 mm  with 10 teeth.
  Face milling cutter selected according to GOST 9304-59. If there are milling cutters in the pantry according to old GOSTs that differ in diameter and width from that considered in this example, you should choose a milling cutter with suitable dimensions, for example, diameter 75 mm  with the number of teeth equal to 10.
  To fix the end mill in the spindle of a vertical milling machine, you must:
  1) wipe the mandrel cone and the spindle conical socket dry;
  2) insert the milling mandrel with a tapered shank into the spindle socket and fasten it with a tightening screw using a wrench. Here it is also necessary to ensure that the cutting direction of the cutter coincides with the direction of rotation of the spindle. The direction of cutting of face mills is unambiguous, that is, it cannot be changed by turning the mill on the mandrel with another end, therefore, if necessary, it is necessary to change the direction of rotation of the spindle, that is, reverse it;
  3) put the end mill on the mandrel and tighten with a bolt (Fig. 98).

  When the cutter is fixed, it is necessary to check the runout of its end using an indicator; runout should not exceed 0.05 mm.
Setting the machine to milling mode. The procedure for determining the elements of the milling mode is similar to that described when processing a cylindrical mill. Milling width set to 60 mmcutting depth 3 mm, the feed to the tooth under conditions of a given surface cleanliness can be taken slightly larger than for a cylindrical cutter, taking into account the advantages of machining with a face mill, it is set here to 0.1 mm / tooth; cutting speed 27 m / minas for a cylindrical cutter.
  According to the beam diagram (see Fig. 54), we find that the number of revolutions of the machine spindle at υ \u003d 27 m / min  and the diameter of the cutter D = 80 mm  lies between n 6 \u003d 100 and n 7 \u003d 125 rpm. We accept the spindle speed equal to 100 rpm.
  Here and in further examples of processing on a vertical machine, it is accepted that work is carried out on a 6M12P vertical milling machine. If you are working on a machine of a different model, the spindle speed and table feed rate may not coincide with those indicated in the examples.
  With the cutter speed n \u003d 100 rpm, the number of teeth z \u003d 10 and the feed s tooth \u003d 0.10 mm / tooth  minute feed s is determined by the formula (4):

  We accept the longitudinal feed available on the machine, 100 mm / min.
  Set the gearbox speed limit to 100 rpm  and feed box limb to 100 mm / min  and determine by formula (1) the resulting cutting speed:

  Thus, we will conduct milling with a face mill 80X45x32 mm  (milling material - high-speed steel P18) with a depth of cut of 3 mmmilling width 60 mm, longitudinal feed 100 mm / min  or 0.10 mm / tooth  and cutting speeds of 25.1 m / min. We will mill with cooling.
  After setting up the machine proceed to milling.
  Methods of milling the plane of the bar. The procedure for milling a plane with a face mill on a vertically milling machine does not differ from milling with a cylindrical mill on a horizontally milling machine.
  When milling a plane with an end milling cutter, the same cases of rejection are possible as when milling a cylindrical milling cutter (defective size, unclean machined surface, surface cutting).

There are different types of hand milling machines, however, the most used and universal can be called manual submersible milling cutter, about the work of which, and is written below. A plastic tree, perfect in its aesthetics, and a universal hand milling cutter. This combination allows you to get products of almost any shape - from the simplest in the form of straight planes, to the most complex, more suitable for works of art than utilitarian things. Working with a manual wood milling machine provides an opportunity to fully enjoy creativity, creating original, exclusive products.

Types of work performed by the milling cutter

Milling grooves, grooves, quarters  and other recesses in the workpiece, which can be located both along and across the layers, be open (go to the edge) or closed. With some exceptions, these forms perform certain structural functions - most often they form detachable and integral connections.

Edge milling  - profiling. It is used for the production of molded profile products (cornices, plinths, platbands, glazing beads, etc.), as well as in interior decoration, furniture and various crafts. In addition to the functional elements, these elements carry a decorative load.

Milling complex surfaces and contours  when creating original furniture, exclusive interiors and manufacturing products for various purposes, claiming artistic sophistication. At the same time, templates are widely used that allow you to copy repeating complex forms with great accuracy, making them almost completely identical.

Milling special elementsbearing a purely functional load. These are grooves and openings for awnings and locks, spikes, etc. In mass production, these elements are performed by specialized milling cutters (filler, etc.). But in everyday life, universal hand milling machines quite successfully cope with them.

In order to give the product a certain shape, it is necessary to ensure accurate positioning of the cutter relative to the workpiece in three coordinates. The vertical position of the tool is ensured by the immersion mechanism, which moves the engine with the cutter along the vertical guides of the bed and locks it in the desired height position.

Horizontal positioning can be provided in various ways. With the help of a guide bearing mounted on the milling cutter, or a guide sleeve attached to the supporting surface of the milling cutter, as well as many special devices supplied with the milling cutters and purchased independently or made by oneself. There are a large number of manuals and recommendations that describe how to use the milling cutter using these devices, read one of them.

When using cutters with a guide bearing, the latter rolls along the edge of the workpiece or template located below or above the workpiece, thus providing a certain distance between the cutter and the part. Mills with a guide bearing and processing edges of parts are called edge. They are used only for machining the edges of workpieces. There are different shapes of edge milling cutters.

Profile Cutters  (a and b) give the edge various curly profiles bearing a decorative load.

Cone milling cutter  (c) Designed for bevelling an edge at an angle of 45 °.

Moulder Mill  (d) is used for rounding. It forms a quarter-circle profile and is of different sizes with a circle radius of 3-16 mm.

Disc mill  (e) cuts a horizontal groove in the workpiece of various depths and widths.

Seam Cutter  (e) is used for milling quarters performing a wide variety of functions.

Fillet cutter  (g) used to produce fillets at the edge. It is used to give decorative edges.

Mills without guide bearings, called slotted, are designed to process the workpiece anywhere. Their use requires the use of devices (read about branded and home-made devices for manual milling) that ensure the positioning of the cutter in a horizontal plane.

Rectangular Grooving Cutter  (a) is perhaps the most used. It is used for milling grooves, providing the connection of parts - both integral and detachable.

Fillet cutter  (b) creates semicircular grooves or grooves in the workpiece, often performing decorative functions.

V-shaped mill (c) forms a groove with walls located at an angle of 45 °. If you introduce the cutter to a greater depth, you will get a groove with vertical edges. Using a V-shaped cutter, letters and various ornaments are cut out.

Dovetail milling cutter  (d) it is usually used in furniture production for open and hidden stud joints.

Milling cutter mount in milling cutter

• The milling cutter is laid to one side.
• The spindle is fixed against rotation - depending on the design of the milling cutter, with a wrench or a lock button.
• It is released (if it is screwed onto the collet) or the clamping nut of the collet is screwed.
• The cutter shank is inserted into the clamping collet until it stops or at least 20 mm.
• Using a wrench (if the spindle is fixed with a wrench, then a second wrench is required), the clamping nut is tightened, the spindle is unlocked.

If there is no cutter in the collet, the clamping nut should not be tightened. This may damage the collet..

Setting the milling depth: 1 - revolving stop, 2 - immersion depth limiter, 3 - depth gauge lock screw, 4 - limiter slider, 5 - fine-tuning mechanism, 6 - immersion scale, 7 - spindle lock for setting the cutter.

The operation is performed in the following order:

• The milling cutter is installed by the supporting surface on the workpiece.
• The revolving emphasis, which sets the immersion depth, is set by its lowest emphasis opposite the end of the limiter.
• The stopper screw is released, as a result of which the latter acquires the ability to move freely in its guides.
• The unlocking mechanism of the immersion (lowering) of the router is carried out.
• The engine slowly drops down until the milling cutter touches the part.
• The engine lowering mechanism is again blocked.
• The depth gauge drops to touch the lowest stop.
• The limiter slider is set to “0” on the dive scale.
• The limiter rises to the position where its slider shows on the immersion scale the value of the milling depth that you want to set. This operation can be carried out by raising and lowering the limiter by hand (rough installation) or by using the fine-tuning mechanism (fine setting).
• The stopper locking screw is clamped, locking the slider in the installed position.
• The immersion mechanism is unlocked and the cutter rises with the motor.

Now, if you lower the motor with the cutter to its lowest position (until the end of the limiter contacts the shortest pin of the turret), the cutter will be inserted into the workpiece to the depth whose value is set on the scale.

If milling is carried out to a greater depth, it must be carried out in stages. This is done by turning the turret stop so that the depth gauge during the first passes first rests on the higher stops, and only in the final pass - on the lowest stop.

Choice of a mill rotation speed mode

In fact, the cleanliness of the processed surface is determined not by the speed of rotation of the cutter, but by the linear speed of movement of the cutting edge relative to the material. The larger the cutter diameter, the higher the linear speed. Therefore, when using large diameter cutters, the rotation speed is set less. For example, for a mill with a diameter of 10 mm, the speed should be from 20,000 rpm and higher, for a mill with a diameter of 40 mm - 10,000-12,000 rpm. Specific values \u200b\u200bare specified in the operating instructions. The rotation speed is also determined by the hardness of the processed material. The higher the hardness, the lower the speed of the cutter should be.

After prolonged operation at low speeds, the router should be turned on for several minutes at maximum idle speed to cool the engine.

Direction of rotation of the cutter

Milling

Before starting milling, the following must be done:

• The cutter is fixed in the collet.
• The engine speed suitable for the job has been established.
• The required milling depth is set using the immersion limiter (when working with submersible milling cutters) or a certain value of the milling cut-out with respect to the sole (when working with edge milling cutters) is fixed.
• A guide bearing or ring is installed (when working with edge milling cutters) or another device that provides the necessary tool path. In this case, the optimal cut thickness should be set - as a rule, not more than 3 mm.

The methods of working with a manual milling machine differ slightly depending on the mode of work. But in any case, the milling cutter is installed on the base - the workpiece or auxiliary surface. The milling guide element (bearing, ring, sole edge or other surface) is pressed against the guiding edge (part, rail or template), after which the engine is turned on and the milling cutter is started first (if immersion mode is used), then the milling machine moves smoothly along the path defined by the guiding element.

Basic safety measures when working with a milling cutter

• The milling cutter must be mounted and the milling cutter set up when the power cord is pulled out of the socket.
• Manual milling requires attention and concentration. When milling, it is necessary to stand firmly on your feet and hold the router firmly in your hands. You can’t work when tired, distracted or intoxicated. This may cause the milling cutter to be pulled out of the hands and serious injury.
• The workpiece must be firmly fixed, otherwise it can be torn off by the mill and toss it with great force and speed.
• When the cutter comes into contact with the material, you need to be especially careful to avoid the so-called back strike - the effect when the cutter hits the material and receives a retaliatory jet strike, which can lead to the tearing of the cutter out of the hands, its breakage or injury. To prevent a reverse blow, you need to firmly hold the router in your hands, firmly press it to the base and smoothly move the tool. The thickness of the cut layer should not be too large - no more than 3 mm.
• Clothing should not have dangling elements - such as can be wound on the cutter.
• Avoid inhalation of fine dust arising from milling. It is harmful to the lungs. Dust can be sucked off with a vacuum cleaner or you can use a respirator.

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The milling machine must know the type and number of the cone of the spindle socket of his machine and the mounting dimensions of the front end of the spindle.

The dimensions of the cone of the spindle socket and the mounting flange of the front end of the spindle of milling machines are standardized by GOST 836-47, and therefore end mills and milling mandrels made with a standard shank are suitable for these machines.

In fig. 59 shows the front end of the spindle of milling machines. The inner cone 2 into which the tool shank is inserted is made very steep. The rotation of the tool is transmitted by leashes 5 inserted into the grooves in the end face of the spindle and the screws screwed. The tool, which is mounted directly on the mounting flange 1, is centered by the cylindrical sharpening of the front end and is fastened with four screws inserted into the holes 4.

Fixing mounted milling cutters.Mounted milling cutters are mounted on mandrels, which are fixed in the machine spindle.

In fig. 60 shows mandrels having a tapered shank U, which corresponds to and is centered on the tapered socket of the front end of the spindle of domestic milling machines. The recesses 2 in the mandrel flange are put on leashes inserted in the grooves on the spindle end.

The mandrel shown in fig. 60, a, is intended for fixing milling cutters, working with great effort. It has a large length, allowing the use of an additional trunk earring. The mandrel shown in fig. 60, b, designed for easier work.

The mandrels shown in fig. 60, a and b, are called center. The center mandrel is fixed at one end in the socket of the spindle of the machine, and the trunk earrings are supported with the other.

The mandrel shown in fig. 60c, it is called the end one, since one end of it is fixed in the socket of the spindle of the machine, and a nozzle mill is installed on the other end, which works together with the mandrel as an end mill.

Securing cutters on center mandrels. In fig. 61 shows various cases of fixing milling cutters on center mandrels. The conical shank of the mandrel enters the conical bore 8 of the spindle, the other end enters the bearing 1 of the earring.

In fig. 61, a shows the fastening on the mandrel of a cylindrical cutter 5 with helical teeth. The cutter is worn on the middle (working) part of the mandrel and can be installed anywhere on the mandrel using the adjusting rings 3, 4, 6 and 7. These rings are put on the mandrel in the same way as the mill 5. The leftmost ring 7 abuts against the shoulder, available on the mandrel, and in the far right ring 3 rests nut 2, screwed onto the end of the mandrel.

In fig. 61, b shows the fastening on the mandrel of several mills close to one another (a set of milling cutters). From the drawing it can be seen that the width of the mounting rings is different here.

The normal set of alignment rings attached to the milling machine consists of rings with a width of 1 to 50 mm, namely: 1.0; 1.1; 1,2; 1.25; 1.3; 1.4; 1.5; 1.75; 2.0; 2.5; 3.0 3.25; 5.0; 6.0; 7.5; 8.0; * 10 20; thirty; 40 and 50 mm.

By means of adjusting rings, the cutters can be fixed at a certain distance from each other. In fig. 61, c shows the fastening of two cutters at a distance A from each other. This distance is established by selecting rings of the required width.

Sometimes, by adjusting the distance between the cutters on the mandrel, it is necessary to place thin gaskets made of aluminum or copper foil and even writing or tissue paper between the mounting rings, since using the rings available in the set, you cannot get the necessary distance between the cutters.

Innovative milling machine operator V. A. Goryainov constructed an adjustable adjusting ring (Fig. 62), which allows you to quickly provide the required distance between the cutters with an accuracy of 0.01 mm. The adjustment of the distance between the cutters 4 is carried out by turning using the key 5 of an adjustable mounting ring 6, having a limb with divisions of 0.01 mm Presetting of cutters is carried out using conventional mounting rings 3.

Milling cutters of small diameters, operating with small efforts, are kept from turning on the mandrel by friction forces arising between the ends of the cutter and the ends of the rings due to tightening with a nut. But in hard work, this friction is not enough, and the cutter is held on the mandrel with a key. A keyway is milled along the entire length of the middle (working) part of the mandrel, a key is attached to it, on which the cutter is put on. Rings in this case also put on the key.

The diameters of the holes in the milling cutters and rings, as well as the outer diameters of the working part of the milling mandrels, are made only of certain sizes. The following diameters of mandrels are accepted at domestic factories: 10, 13, 16, 22, 27, 32, 40 and 50 mm. The keyways and dowels are also manufactured in certain sizes, so that the milling cutters, mandrels, rings and dowels of the same number in the tool room are sure to fit together.

Milling mandrels should not have a runout, nicks and dents. There should be no nicks or burrs at the ends of the rings. The ends of the rings should be parallel and perpendicular to the axis of the ring.

When installing the cutters, it is necessary to place them as close as possible to the front end of the machine spindle in order to reduce the load on the mandrel. If for some reason this does not succeed, then you need to put an additional earring that unloads the milling mandrel. The procedure for installing and securing the cutter on the mandrel and securing the mandrel in the socket of the spindle of the machine is described in detail when considering the setup of the machine.

Fastening milling cutters on end mandrels. End mills and disk mills that do not require a large overhang are fixed at the end mandrels.

In fig. 63 shows an end mandrel. The conical end 1 is inserted into the conical socket of the machine spindle. The cutter is put on the cylindrical part of the mandrel and tightened with a screw 3. The key 2 prevents turning the cutter on the mandrel.

Fastening of mills with a conic and cylindrical shaft. Mills with a conical shank, the size of which coincides with the dimensions of the conical socket of the spindle, are inserted with the shank into the spindle and fixed in it with a tightening screw (ramrod). This is the easiest way to fix the cutter on both horizontal and vertical milling machines.

If the size of the cone of the shank of the cutter is smaller than the size of the cone of the spindle socket, then resort to adapter sleeves (Fig. 64). The outer cone of such a sleeve corresponds to the socket of the spindle of the machine, and the inner cone corresponds to the shank of the cutter. The adapter sleeve with the inserted cutter is installed in the spindle and tightened with a tightening screw (ramrod).

The milling cutter with a cylindrical shank is made using the cartridge shown in Fig. 65. The milling cutter is inserted into the cylindrical hole of the expanding collet of the cartridge 1 and secured by means of a nut 2 located on the front end of the cartridge and covering the expansion sleeve 3 with the shoulders. The chuck with the cutter on is mounted on the spindle of a horizontal or vertical milling machine and secured with a tightening screw. The cutter is removed after the nut 2 is released.

Fixation of mounted milling cutters of large diameter. Prefabricated face mills with a diameter of 80 mm and above are made by mounted.

Landing holes of such mills are made conical or cylindrical.

Milling cutters with a conical bore hole (Fig. 66, a) are mounted on the cone 1 of a special milling mandrel (Fig. 66, b) and are fixed on it with the insert 2 and screw 3. The insert 2 is included in the grooves 4 available in the cutter body. The mandrel with the milling cutter is mounted in the conical spindle socket using a tightening screw (ramrod) by screwing it into the threaded hole 5 of the mandrel. To prevent turning of the milling mandrel in the conical socket of the spindle, the mandrel has two grooves 5 included in the crackers 3 at the end of the front end of the machine spindle (see Fig. 59).

Milling cutters with a cylindrical bore hole (Fig. 67) are mounted on the cylindrical end 1 of the spindle (see Fig. 59) and fastened directly to its end with four screws that fit into the corresponding threaded holes of the spindle end.

The plane of the part, located at some angle to the horizontal plane, is called inclined plane. The inclined plane of the part, having small dimensions, is called bevelled. Milling of inclined planes and bevels with cylindrical mills can be carried out by setting the workpiece at the required angle to the axis of the milling cutter. This turn can be made in different ways.

Installation of the workpiece in a universal vise. When installing a universal vise at the required angle, it should be borne in mind that the inclined plane to be machined must be horizontal, i.e. parallel to the axis of the cutter.

Mounting the workpiece on a universal turntable. Rotary plates (Fig. 8.18) allow you to process planes with any angle of inclination ranging from 0 ° to 90 ° with the possibility of simultaneous rotation of the workpiece in a horizontal plane at an angle of up to 180 °. The workpiece is attached to the table of the universal plate with tacks or bolts, as when fixing the milling machine on the table. Universal vice and universal rotary plates are used in single or small batch production.

Fig. 8.18. Milling an inclined plane on a universal turntable

Installation of blanks in special devices. When processing workpieces with inclined planes or bevels under conditions of large-scale and mass production, it is advisable to install the workpieces at the required angle to the axis of the cutter in special devices. In such devices, two workpieces can be installed and milled simultaneously with an end or cylindrical mill.

Milling planes with face mills

Adjustment and adjustment of the machine to perform various tasks. When working on vertical and horizontal milling machines with face mills, the adjustment and adjustment are essentially the same as setting and adjusting a horizontal milling machine when working with cylindrical mills. Therefore, we dwell only on the distinctive features of commissioning and tuning when milling with face mills.

Installation and fastening of face mills on vertically milling machines . Depending on the type of mill used, it can be mounted on a vertically milling machine in several ways.

End mills with a calibrated through hole are centered on the cylindrical part of the mandrel 3 by the conical part, installed in the conical hole of the spindle and fixed in it with ramrod 1 and nut 2 (Fig. 8.19a). The base end of the mill rests on one of the ends of the transitional flange 4, the second end of which rests on the end of the mandrel 3. The spikes of the spindle 6 are in the grooves of the transitional flange, and the protrusions of the flange are in the grooves of the mill, transmitting torque from the mill spindle. The cutter is mounted on the mandrel with screw 5 using a special key.

Face mills with a centering recess (Ø 128.57A) are mounted directly on the spindle head and fixed on it with 4 screws 1 (Fig. 8.19b). Spikes of the spindle 2 are included in the grooves of the cutter body, transmitting torque from the spindle of the cutter.

End mills with a tapered shank with a nominal size of the largest cone diameter of Ø 59.85 mm and a taper of 7:24 are inserted into the conical bore of the spindle, secured with a ramrod 1 and nut 2 (Fig. 8.19c). The torque is transmitted by the spikes 3 included in the grooves of the mill body.

Face milling cutters having a through calibrated hole and grooves in the body, the width corresponding to the dimensions of the spindle studs, are mounted on a mandrel mounted in the machine spindle. The cutter is fixed to the mandrel with screw 7. The torque is transmitted by the spikes 3 included in the grooves of the cutter body (Fig. 8.19 g).

End mills having a shank with a Morse taper and a threaded hole are centered in the adapter sleeve 1 inserted into the spindle taper hole and fastened with a ramrod 2 and nut 3. Spindle spikes 4 enter the grooves of the adapter sleeve, transmitting torque from the milling spindle ( Fig. 8.19e).

Fig. 8.19. Installation of mills on the machine

Setting up vertical milling machines   appropriate cutting conditions are performed in the same way as the setting of horizontal milling machines.

Choice of type and size of cutter

The standard stipulates that the parameters are defined unambiguously for face mounted mills, that is, each diameter of the end mill corresponds to a certain value of the mill length L, hole diameter d and number of teeth z.

The diameter of the end mill is selected depending on the milling width t according to the formula:

D \u003d (0.6-0.8) * t

For roughing, face milling cutters with insert knives or with large teeth are selected. When finishing, you should take face mounted milling cutters with small teeth.

However, in all cases, it is necessary to give preference to face mills equipped with hard alloys, since the machine processing time in this case is significantly reduced due to an increase in cutting speed.

When milling steel and cast iron with carbide milling cutters to reduce the surface of a higher class of roughness, the feed to the tooth is reduced, and the cutting speed is correspondingly increased depending on the grade of the material being processed, the grade of hard alloy and other processing conditions.

Setting the end mill to the cutting depth   when working on a vertical milling machine is no different from the previously considered case of installing a cylindrical mill on the depth of cut.

When milling with an end mill on a horizontal milling machine (Fig. 8.20), the following procedure for setting the milling depth is used.

Fig. 8.20. End milling with a milling machine on a horizontal milling machine

Switch on the machine and the spindle rotation and, using the handles of the longitudinal, transverse and vertical feeds, carefully bring the workpiece to the mill until it touches lightly. Using the longitudinal feed handle, remove the workpiece from under the cutter, turn off the spindle rotation. Using the transverse feed handle, move the table in the transverse direction by the amount corresponding to the cutting depth. After setting the cutter to the required cutting depth, lock the table console and the slide of the transverse feed, set the cams for switching on the mechanical feed. Then, by smoothly turning the handle of the longitudinal feed of the table, bring the workpiece to the mill, without touching it, turn on the spindle, turn on the mechanical feed, mill the plane, turn off the machine and measure the processed workpiece.

Inclined planes and bevels can be milled with face mills on vertically milling machines, setting workpieces at the required angle, as when machining with cylindrical mills, using a universal vice (Fig. 8.21a), rotary tables or special tools (Fig. 8.21b). Milling of inclined planes 1 and bevels with end mills 2 can also be done by turning the spindle, and not the workpiece. This is possible on vertically milling machines, in which the milling head with the spindle rotates in a vertical plane (for example, as on machines 6Р12, 6Р13 (see Fig. 8.11), as well as on universal machines of the type 6Р82Ш, in which the vertical head has a turn in vertical and horizontal planes).

Fig. 8.21. Milling an inclined plane with face mills

Milling of inclined planes and bevels with face milling cutters can be performed with the help of a vertical head invoice.

The overhead vertical head is a special accessory for the horizontal milling machine.