Cutter, face-mill

Face milling in this case, the axis of rotation of the cutter is normal to the machined surface and each tooth removes variable chip thickness ranging from the entry point. 

Baro PK, Joshi SS, Kapoor SG (2005) Modeling of cutting forces in a face-milling operation with self-propelled round insert milling cutter. Int J Mach Tools Manuf 45 831-839... 

Patel KM, Joshi SS (2005) Mechanics of machining of face-milling operation performed using a self-propelled round insert milling cutter. J Mater Process Technol 171 68-76... 

Zheng HQ, Li XP, Wong YS, Nee AYC (1999) Theoretical modelling and simulation of cutting forces in face milling with cutter runout. Int J Mach Tools Manuf 39 2003-2018... 

Designed for milling tee slots in machine tables, this cutter has teeth on its circumference and on both sides. To reduce chatter and provide maximum chip clearance, the teeth are alternately right-hand and left-hand helix, and each alternate side tooth is removed. To produce a tee slot, the groove is first cut using a side-and-face cutter, end mill or slot drill and finally the wide slot at the bottom is cut using a tee-slot cutter. Fig. 11.8(k). The shank is reduced to clear the initial groove. This cutter is available for standard tee slots to suit bolt sizes up to 24 mm. 

More usually referred to as a face mill , this cutter is used to face large smfaces. The cutter consists of a tough steel body with high-speed-steel or timgsten-carbide cutting edges in the form of inserts clamped in... 

Large face mills are mounted directly on the spindle nose. To ensure correct location and concentricity, a centring arbor with the appropriate international taper is held in the spindle by the drawbar. The diameter on the end of the centring arbor locates the cutter, which is driven by the spindle keys through a key slot in the back face of the cutter. The cutter is held in position by four screws direct into the spindle nose. Fig. 11.12. 

The principal methods of milling are classifled as peripheral, face, and end. These terms refer to the type of cutter used (see Fig. 2) and to the relationship of the spindle to the sxuface being milled. In some cases, the differences between the three methods are clearly defined, but more often a given milling operation is a combination of two methods. This is particularly true of end milling, which is almost invariably a combination of peripheral and face milling. 

MUling cutters vary widely in type and size and are broadly classified as peripheral mills, face mills, end mills, and special mills. Cutters can be of the solid, tipped, or inserted tooth types and have the same materials as single-point tools. Large cutters commonly have teeth of expensive material that are inserted and locked in place in a sofl steel or cast iron body. AU cutters should be ground and mounted to make sure etll teeth are cutting the same amount of material. Typical tool geometries are shown in Tables 6, 7, and 8. 

In face milling, positive inclination directs the chip outward, and negative indination directs the chip toward the center of the cutter. A positive inclination is therefore generally desired. 

Vertical milling axis of cutter rotation is perpendicular to surface of workpiece. Includes face milling, slotting, dovetail and woodruff milling. 

This cutter has teeth on the periphery or face and on both sides. It is used to produce steps, cutting on the face and side simultaneously. Fig. 11.8(b), or for producing slots. The use of these cutters in pairs with their sides cutting is known as straddle milling. Fig. 11.8(c). The teeth are straight on cutters up to 20 mm wide but are helical above tbis thickness. Side-and-face cutters are available in a variety of sizes up to 200mm diameter and 32 mm wide. 

More often referred to as a shell end mill . Fig. 11.8(h), this cutter has teeth cut on the circumference and on one end. The tooth end is recessed to receive a screwhead for holding the cutter on an arbor. A key slot on the back face provides the drive from two keys in the arbor. The... 

Designed for milling dovetail slides of machines, this cutter has teeth on its angle face and on the end face. To produce a dovetail slide, a step is machined to the correct depth and width the angle is then finally machined using the dovetail cutter. Fig. 11.8(1). It is available in a variety of sizes up to 38 nun diameter, with 45 and 60 angles. 

Cutters which are used close to the spindle, such as shell end mills, are mounted on a stub arbor. Fig. 11.10. This arbor is located, held, and driven in the spindle in the same way as a standard arbor. The cutter is located on a spigot or stub and is held in position by a large flanged screw. Two keys on the arbor provide the drive through key slots in the back face of the cutter. 

There are many different types of milling cutters available, and for convenience they can be classified according to the method of mounting those with a central hole for mounting on an arbor, those with a screwed shank for holding in a special chuck and the large facing cutters which mount directly on to the spindle nose. 

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