Standard

 

MCA 201 – Advanced Milling I

Course Description

Provides instruction in advanced techniques of milling machine operations. Emphasis is placed on skill development through laboratory practice. Topics include: vertical milling, horizontal milling, compound angles, gear cutting, and safety.

 

Competency Areas

Hours

 

Vertical Milling

Class

5

Horizontal Milling

D. Lab

2

Compound Angles

P. Lab/O.B.I.

3

Gear Cutting

Credit

7

Safety

 

 

 

 

 

Prerequisite:

MCH 115, MCH 116

Corequisite:

 

 

Course Guide

 

Competency

After completing this section, the student will:

Hours

Class

D.Lab

P.Lab/

O.B.I.

VERTICAL MILLING                    

 

 

 

Definitions

Define up and down milling by locating holes and slots to .002 of an inch using the feed dials and edge finder.

 

 

 

Setup

Complete squaring of workpiece and cut opposite surfaces parallel.

 

 

 

 

Use dial indicator to set machine vise and/or workpiece on the vertical mill.

 

 

 

 

Select cutter size and the cutting speed for specific type metal.

 

 

 

Application

Cut keyways on a round shaft locating keyway center by using machine dials, shift diameter, and cutter diameter to calculate center line.

 

 

 

 

Cut dove tail and t-slots.

 

 

 

HORIZONTAL MILLING              

 

 

 

Initial setup

Determine speed and feed in inches per tooth and surface feet per minute for milling different materials listed in charts.

 

 

 

 

Use dial indicator to set up workpiece on machine table.

 

 

 

 

Define the types of milling cutters and how they are used.

 

 

 

 

Identify work holding systems and devices.

 

 

 

Specific setups

Set up the mill to cut shoulders and slots.

 

 

 

 

Set up the mill to cut flat surfaces.

 

 

 

 

Set up the mill to cut keyways on round shafts.

 

 

 

 

Set coolant rate and feed rate at the maximum cutting speed for the machine and material.

 

 

 

 

Square a workpiece cutting one side at a time using parallels and a machining vice.

 

 

 

 

Set up the horizontal mill to use side milling cutters.

 

 

 

COMPOUND ANGLES      

 

 

 

 

Set milling head to cut simple angles with end mill using a protractor.

 

 

 

 

Set workpiece for angular cutting using sine bar and gage blocks.

 

 

 

 

Set up mill using a shell mill to cut angles.

 

 

 

 

Set up mill to use peripheral teeth.

 

 

 

 

Set up mill using a dividing head to cut angles on round stock.

 

 

 

GEAR CUTTING                 

 

 

 

Introduction

Describe the types of gears and spur gear terms.

Use 14 formulas for finding information about spur gears.

 

 

 

Setup

Demonstrate the setup of a horizontal mill to cut spur gears to specifications.

 

 

 

 

Select a dividing head and footstock using the indexing formula to determine the turns of the sector arms to move the workpiece from one tooth to the next.

 

 

 

 

Explain the numbering system for a gear cutter.

 

 

 

 

Mount a gear blank on a mandrill for cutting.

 

 

 

 

Calculate the rpm for cutting the gear.

 

 

 

Application

Cut gears according to plans and specifications.

 

 

 

SAFETY

 

 

 

 

 

 

 

 

 

Suggested Resources

 

Books

 

ASM International. (1987). Tool materials for high-speed machining. Materials Park, OH: Author.

ASM International. (1988). Machining source book. Materials Park, OH: Author.

ASM International. (1989). Machining metals handbook (Vol. 16). Materials Park, OH: Author.

Baril, R. (1987). Modern machining technology. Albany, NY: Delmar.

Brown, W. C., et al. (1985). Modern general shop. South Holland, IL: Goodheart-Willcox.

Business Communications Staff. (1986). Advanced high technology machining systems. Norwalk, CT: Author.

Feirer, J. L. (1986). General metals. New York: McGraw-Hill.

Gingery, D. J. (1982). The milling machine. Springfield, MO: Author.

Kibbe, R. A. (1985). Milling machine operations. New York: John Wiley & Sons.

Kibbe, R. A., et al. (1991). Machine tool practices (4th ed.). Englewood Cliffs, NJ: Prentice Hall.

Matt, S. R. (1985). Machine tool operations: An introduction. Belmont, CA: Wadsworth.

McGeough, J. A. (1988). Advanced methods of machining. New York: Chapman & Hall.

Rizzo, L. (1984). Milling machine explained. Garden City, NJ: Bergwall.

Smith, G. T. (1989). Advanced machining. New York: Springer-Verlag.