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Special Milling machines

Milling machines can be used to machine all types of surfaces with adequate accuracy. Column-and-knee, fixed-bed, planer-type, and continuous action machines are general-purpose tools employed for machining a great variety of parts.

Single-purpose machines, on the other hand, are used to perform single definite milling operations. This category includes gear-hobbing machines, thread milling machines, keyway milling machines, etc.

The development of large-lot and mass production has stimulated a more extensive use o milling machines. These machine are designed with due regard to maximum productivity and are frequently operated automatically. To distinguish them from single-purpose machines they are called special machines. These are machines employed in the clock and watch industry, machines for milling drill, tap and reamer flutes, machines used in the automobile, tractor and machine tool industry for milling certain workpieces in automatic transfer machines and production lines.

The progress in engineering often leads to changes in the form and dimensions of workpieces; for this reason it is not always expedient to employ special milling machines which, unlike general-purpose machines, cannot always be changed over for other jobs.

A recent development are the so-called unit-built milling machines which make it possible to combine their interchangeable unified components in various ways to suit the shape of the work and the location of the surface to be machined. To change over such a machine for a new job it is sufficient to replace or rearrange its separate units.

Unit 3 Turning a Profit by Reducing Set-ups

The use of live tooling and sub-spindles can help maximize productivity in turning operations by reducing set-up and handling time.

Manufactures want to be able to do as much as they can with one set-up. That means cutting the number of set-ups and the number of handing that you are doing on the shop floor.

It means a dramatics increase in the amount of time the tool is in the cut. Today, a tool is in contact with a workpiece only about 5% of the time the raw material is in the plant.

Reducing the number of set-ups and handing time also results in improved part quality, less operator involvement, lower inventories and greater machine utilization.

One significant development in turning machines is the introduction of the sub-spindle.

In turning machines without a sub-spindle, the part has to be chucked or put in a collet in order to turn it around to do second operations.

The sub-spindle enables you to pick off the part after you have finished the first end, and with the tooling still arranged on the turret you can do the second end before the part is finished its cycle.

The interest in sub-spindles has focused on either two axis o four axis machines with a sub-spindle.

The drawback to a two axis machine with a sub-spindle is that you only have one turret so you can only work on one operation at a time. Whereas if you go to a four axis machine with a sub-spindle, you can actually pick up the first operation and the second operation simultaneously.

A second important advancement in turning centers has been the development of live tooling.

Live tooling incorporates a drive system for the turret, which gives the turning centre the capability to do cross hole drilling, milling, an cutting a keyway or flat.

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