The Role of Science in Manufacture

Future improvements in productivity are largely dependent on the application of science to manufacturing. This depends in turn on the availability of large numbers of scientifically trained engineers. The higher schools can serve the needs of industry in two ways: by performing basic research and by training well-qualified engineers in the manufacturing field.

There is a growing need for engineers who are familiar with the fundamental problems in metal processing and, manufacturing. In the near future many of the engineers will be recent university graduates. A few will come through courses of study in industry. Others, having a basic engineering knowledge will continue additional studies at colleges to prepare themselves for work in industry. Therefore, an engineer does not finish his education when he receives his diploma, particularly in the fields of interest to tool engineers who are to study new developments, constantly.

There are numerous ways in which industry and education can cooperate on problems of common interest. Scientists and research engineers are engaged in work that is intended to provide a scientific approach to many purely industrial problems. These scientists and engineers can make a real contribution to engineering education or academic research. They can, for example, teach advanced engineering courses and they can actively participate in basic and applied research. Similarly, large and complicated projects of new technologies could well be handled by institute researchers working on practical applications. This would often provide the most efficient approach to the solution of processing problems.

Unit 2 Milling Cutters with Helical Teeth

Milling cutters with helical teeth develop an axial force. Depending on the hand of the helix and the cutting direction, the axial force either tends to pull the arbour together with the cutter out of the spindle or, conversely, to drive it tighter into the spindle.

With a right-hand helix and a left-hand cutter or with a left-hand helix and a right-hand cutter the axial force is directed towards the spindle nose which is a correct procedure.

If, in operating end mills, chips flow should be directed upwards, preference is given to a right-hand cutter with a right-hand helix or a left-hand cutter with a left-hand helix.

The forces may cause deflection of the cutter arbour: they may pull the cutter off the arbour or the work out of the vice or fixture; they may cause chatter and even a breakdown of the machine as well as other machining troubles.

It is therefore necessary to properly determine all the forces acting in milling and, in conformity with their magnitude, to choose suitable cutters, arbours and clamping fixtures and a milling machine possessing sufficient rigidity and available power for the job in hand.

The harmful effect of milling forces is lessened if the following recommendations are complied with:

a) locate the cutter on the arbour as close to the support as possible;

b) use an additional support and braces when operating at high speeds or with a heavy cut;

c) when operating with longitudinal feed, lock the knee and saddle in position;

d) use a cutter with the proper hand of the flute helix;

e) clam parts reliably in vices, fixtures or on the machine table.