Cutting by Milling - Course: Techniques for Machining of Material. Instruction Examples for Practical Vocational Training: Instruction example 6.4.: Segment

Cutting by Milling - Course: Techniques for Machining of Material. Instruction Examples for Practical Vocational Training

		(introduction...)
		Introduction
		Instruction example 6.1.: Backing material
		Instruction example 6.2.: Measuring point
		Instruction example 6.3.: Fixing bush
		Instruction example 6.4.: Segment

A collar-shaped workpiece has to be separated with a metal slitting saw blade into uniform segments (1 ring - 6 segments - 6 x 60°).

Material

C 35 (tempered steel, tensile strength 650 - 800 MPa)

Figure

Dimensions

Ø 160 x Ø 240 x 24 mm

Milling machine

Horizontal milling machine

Tools

Metal slitting saw blade (Ø 200 x 3 mm), cutter arbor (long), clamp iron, chucking screws, keys (spanner or ring spanner), marking gauge, flat file

Measuring and testing means

Vernier caliper, universal bevel protractor

Auxiliaries

Chuck flange, chip brush, hand broom, cleaning rag, T-slot cleaner

Required previous knowledge

To read a drawing, to measure and to test, to set-up and to operate horizontal milling machines

Sequence of operations	Remarks

1. Batch-quantity and visual control (number of collars)	Comparison with the specifications of the work accompanying data sheets

2. Functional test and lubrication of the milling machine	Lubrication and oil-level check according to the lubrication schedule

3. Fastening of the workpiece (collar) directly onto the machine table, adjustment according to the marking	The adjustment and localization are done with a marking gauge, the marking should be above a slot of the milling table! The clamping and positional stability are done by means of a clamp iron and lock screws.

4. Fixing the cutter arbor (long) and fastening the metal slitting saw blade	Do not forget the feather key at the right place, use chuck flanges!

5. Position the milling table into the working position	Place the metal slitting saw blade manually on the marking.

6. Fixing the cutting values	Use the nomogram or a table.

7. Setting-up the coolant and the milling protective systems

8. Cutting by milling after marking, cleaning, deburring, visual and quality control	Visual control, marking, surface finish, dimensional inspection, angle control

9. Continuation of the cutting by milling until all collars are separated into segments	Carry out permanent dimensional, angle and visual inspection.

Segment