MILLING CUTTERS

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• Q1: Define Milling Cutters.
  Ans: Milling cutters are rotating cutting tools used in milling machines to remove material from a workpiece and produce different shapes and surfaces.
• Q2: What is H.S.S?
  Ans: H.S.S stands for High Speed Steel.
  It is a tool material used to make cutting tools because it can cut metals at high speed without losing hardness.
• Q3: Name the types of Milling Cutters used in Milling Machines.
  Ans: The types of milling cutters are:

  ➔ Horizontal Arbor Milling Cutters
  • ➔ Plain Milling Cutters
  • ➔ Slotting Milling Cutters
  • ➔ Side and Face Milling Cutters
  • ➔ Slitting Saw Milling Cutters
  • ➔ Single Angle Milling Cutters
  • ➔ Double Angle Milling Cutters
  • ➔ Convex and Concave Milling Cutters
  • ➔ Involute Gear Milling Cutters
  ➔ Vertical Arbor Milling Cutters
  • ➔ End Milling Cutters
  • ➔ Shell End Milling Cutters
  • ➔ Ball End Milling Cutters
  • ➔ Dovetail Milling Cutters
  • ➔ T-slot Milling Cutters
  • ➔ Corner Rounding Cutters
• Q4: What are Horizontal Arbor Milling Cutters?
  Ans: Horizontal arbor milling cutters are cutters mounted on a horizontal spindle (arbor) of a milling machine. They are used for heavy cutting operations and for machining flat and shaped surfaces.
• Q5: Name the types of Horizontal Arbor Cutters.
  Ans: The types of horizontal arbor cutters are:

  • ➔ Plain Milling Cutters
  • ➔ Slotting Cutters
  • ➔ Side and Face Cutters
  • ➔ Slitting Saw Cutters
  • ➔ Angle Cutters
• Q6: What are Plain Milling Cutters?
  Ans: Plain milling cutters are cylindrical cutters with cutting teeth on their outer surface. They are used for machining flat surfaces parallel to the axis of rotation.
• Q7: Briefly discuss the working of Plain Milling Cutters.
  Ans: The working of plain milling cutters is as follows:
  The cutter rotates on a horizontal arbor.
  The workpiece is fed against the rotating cutter.
  The teeth on the cutter remove material layer by layer.
  A flat surface is produced on the workpiece.
• Q8: What are Slotting Milling Cutters?
  Ans: Slotting milling cutters are thin cutters used for cutting slots, grooves, and keyways in a workpiece.
• Q9: Briefly discuss the working of Slotting Milling Cutters.
  Ans: The working of slotting milling cutters is as follows:
  The cutter rotates at high speed.
  The workpiece is fed slowly towards the cutter.
  The cutter cuts a narrow slot or groove in the material.
  It is mainly used for keyway cutting.
• Q10: What are Side and Face Milling Cutters?
  Ans: Side and face milling cutters have teeth on both the sides and the periphery. They are used for cutting slots and grooves with high accuracy.
• Q11: Briefly discuss the working of Side and Face Milling Cutters.
  Ans: The working of side and face milling cutters is as follows:
  The cutter rotates on the arbor.
  The workpiece is fed against the cutter.
  Cutting is done by both side and peripheral teeth.
  It produces accurate slots and flat surfaces.
• Q12: What are Slitting Saw Milling Cutters?
  Ans: Slitting saw milling cutters are very thin circular cutters used for cutting narrow slots or for cutting off material.
• Q13: Briefly discuss the working of Slitting Saw Milling Cutters.
  Ans: The working of slitting saw milling cutters is as follows:
  The thin cutter rotates at high speed.
  The workpiece is fed slowly.
  The cutter cuts through the material like a saw.
  It is used for parting or cutting thin slots.
• Q14: What are Single Angle Milling Cutters?
  Ans: Single angle milling cutters have teeth inclined at a specific angle on one side. They are used for machining angular surfaces.
• Q15: Briefly discuss the working of Single Angle Milling Cutters.
  Ans: The working of single angle milling cutters is as follows:
  The cutter rotates on the spindle.
  The workpiece is fed towards the cutter.
  The angled teeth cut the material at a specific angle.
  It produces inclined surfaces.
• Q16: What are Double Angle Milling Cutters?
  Ans: Double angle milling cutters have teeth inclined on both sides forming a V-shape. They are used for cutting V-grooves and serrations.
• Q17: Briefly discuss the working of Double Angle Milling Cutters.
  Ans: The working of double angle milling cutters is as follows:
  The cutter rotates at high speed.
  The workpiece is fed against it.
  Both angled sides cut simultaneously.
  It produces V-shaped grooves.
• Q18: What are Convex and Concave Milling Cutters?
  Ans: Convex and concave milling cutters are specially shaped cutters used to produce curved surfaces. Convex cutters produce outward curves, while concave cutters produce inward curves.
• Q19: Briefly discuss the working of Convex and Concave Milling Cutters.
  Ans: The working of convex and concave milling cutters is as follows:
  The cutter rotates on the machine.
  The workpiece is fed against the cutter.
  The shape of the cutter forms the required curve.
  It produces curved profiles on the workpiece.
• Q20: What are Involute Gear Milling Cutters?
  Ans: Involute gear milling cutters are special cutters used for cutting gear teeth with an involute profile.
• Q21: Briefly discuss the working of Involute Gear Milling Cutters.
  Ans: The working of involute gear milling cutters is as follows:
  The cutter rotates on the milling machine.
  The gear blank is mounted and indexed properly.
  The cutter removes material to form gear teeth.
  Each tooth is cut one by one to obtain the required gear shape.
• Q22: What are Corner Rounding Milling Cutters?
  Ans: Corner rounding milling cutters are special cutters used to round off the edges or corners of a workpiece with a specific radius.
• Q23: Briefly discuss the working of Corner Rounding Milling Cutters.
  Ans: The working of corner rounding milling cutters is as follows:
  The cutter rotates on the spindle.
  The workpiece is fed towards the cutter.
  The rounded profile of the cutter removes material from edges.
  Smooth rounded corners are produced.
• Q24: What are Vertical Arbor Milling Cutters?
  Ans: Vertical arbor milling cutters are cutters mounted on a vertical spindle of a milling machine. They are mainly used for drilling, slotting, and contour machining.
• Q25: Name the types of Vertical Arbor Milling Cutters.
  Ans: The types of vertical arbor milling cutters are:

  • ➔ End Milling Cutters
  • ➔ Shell End Milling Cutters
  • ➔ Ball End Milling Cutters
  • ➔ Dovetail Milling Cutters
  • ➔ T-slot Milling Cutters
  • ➔ Corner Rounding Cutters
• Q26: What are End Milling Cutters?
  Ans: End milling cutters are cutting tools having teeth on both the end face and the periphery. They are used for slotting, profiling, and facing operations.
• Q27: Briefly discuss the working of End Milling Cutters.
  Ans: The working of end milling cutters is as follows:
  The cutter rotates vertically.
  The workpiece is fed in different directions.
  Cutting is done by both end and side teeth.
  It produces slots, grooves, and complex shapes.
• Q28: What are Shell End Milling Cutters?
  Ans: Shell end milling cutters are large cutters with a hollow center that are mounted on an arbor. They are used for heavy-duty milling operations.
• Q29: Briefly discuss the working of Shell End Milling Cutters.
  Ans: The working of shell end milling cutters is as follows:
  The cutter is mounted on an arbor.
  It rotates at high speed.
  The workpiece is fed against it.
  Large amounts of material are removed quickly.
• Q30: What are Ball End Milling Cutters?
  Ans: Ball end milling cutters have a hemispherical end. They are used for machining curved surfaces and 3D shapes.
• Q31: Briefly discuss the working of Ball End Milling Cutters.
  Ans: The working of ball end milling cutters is as follows:
  The cutter rotates vertically.
  The ball-shaped end cuts the material.
  The workpiece is fed slowly.
  Smooth curved surfaces are produced.
• Q32: What are Corner Rounding Milling Cutters?
  Ans: Corner rounding milling cutters are used to make rounded edges on the workpiece for better finish and safety.
• Q33: What are Dovetail Milling Cutters?
  Ans: Dovetail milling cutters are cutters with an angular shape used to cut dovetail grooves, which are used in joints and machine slides.
• Q34: Briefly discuss the working of Dovetail Milling Cutters.
  Ans: The working of dovetail milling cutters is as follows:
  The cutter rotates on the spindle.
  The workpiece is fed carefully.
  The angled sides cut the dovetail shape.
  Accurate dovetail grooves are produced.
• Q35: What are T-slot Milling Cutters?
  Ans: T-slot milling cutters are special cutters used to produce T-shaped slots in machine tables and components.
• Q36: Briefly discuss the working of T-slot Milling Cutters.
  Ans: The working of T-slot milling cutters is as follows:
  First, a straight slot is cut using an end mill.
  Then the T-slot cutter is used.
  The cutter enlarges the bottom part of the slot.
  A T-shaped slot is formed.
• Q37: Name some materials used for making Milling cutters.
  Ans: The materials used for making milling cutters are:

  • ➔ High Speed Steel (H.S.S)
  • ➔ Carbide
  • ➔ Carbon Steel
  • ➔ Alloy Steel
• Q38: What should be the diameter of the Milling Cutters?
  Ans: The diameter of the milling cutter should be selected according to the size of the workpiece, type of operation, and machine capacity.
• Q39: Write the Metric calculations of Cutting Speed.
  Ans: The formula for cutting speed is:
  
  V = π × D × N / 1000
  
  Where,
  V = Cutting speed (m/min)
  D = Diameter of cutter (mm)
  N = Speed (rev/min)
• Q40: What is Feed or Tooth?
  Ans: Feed per tooth is the distance the cutter advances for each tooth in one revolution. It is usually measured in mm/tooth.
• Q41: Calculate the revolutions required for a 75mm High Speed Steel Cutter while the cutting speed of the job material is 30m/mint.
  Ans: Given:
  D = 75 mm
  V = 30 m/min
  
  Formula:
  
  N = (1000 × V) / (π × D)
  
  N = (1000 × 30) / (3.14 × 75)
  N = 30000 / 235.5
  N ≈ 127 rev/min
  
  Therefore, required revolutions ≈ 127 rpm.
• Q42: Write the Metric calculations of Feed Rate.
  Ans: The formula for feed rate is:
  
  Feed Rate = f × Z × N
  
  Where,
  f = Feed per tooth (mm)
  Z = Number of teeth
  N = Speed (rev/min)
• Q43: Calculate the Feed Rate in mm/mint for a 75mm diameter, 06 Tooth Helical Carbide Cutter when machining a cast iron workpiece having cutting speed of 60m/mint and Feed or Tooth as 0.25mm.
  Ans: Given:
  D = 75 mm
  Z = 6
  V = 60 m/min
  f = 0.25 mm
  
  Step 1: Calculate N
  N = (1000 × V) / (π × D)
  N = (1000 × 60) / (3.14 × 75)
  N = 60000 / 235.5
  N ≈ 255 rev/min
  
  Step 2: Calculate Feed Rate
  Feed Rate = f × Z × N
  = 0.25 × 6 × 255
  = 382.5 mm/min
  
  Therefore, Feed Rate = 382.5 mm/min.
• Q44: Calculate the Feed Rate in mm/mint for a 80mm diameter, 06 Tooth Helical Carbide Cutter when machining a cast iron workpiece having cutting speed of 25m/mint and Feed or Tooth as 0.20mm.
  Ans: Given:
  D = 80 mm
  Z = 6
  V = 25 m/min
  f = 0.20 mm
  
  Step 1: Calculate N
  N = (1000 × 25) / (3.14 × 80)
  N = 25000 / 251.2
  N ≈ 99.5 ≈ 100 rev/min
  
  Step 2: Calculate Feed Rate
  Feed Rate = f × Z × N
  = 0.20 × 6 × 100
  = 120 mm/min
  
  Therefore, Feed Rate = 120 mm/min.