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Benefits of Using Horizontal Milling Machines

by on Jul.30, 2010, under Mechanics

There is not much of a difference between horizontal and vertical milling machines. Both of these equipments are indispensable in cutting parts uniformly and quickly. These days’ horizontal machines are becoming more popular due to its overhead arm and its arbor driven cutters. These are also very easy to operate with few steps to remember. Some of the benefits of using horizontal milling machines are discussed below:

Design and set up: If you are looking to manufacture products which are cost-effective and of high quality, then a vertical milling machine should be of great help. They have scientific designs suitable for dealing with various hard materials. The time taken for this process is minimal and so as the number of steps required operating it. There is no need for a large set up to install these machines and also no need to employ numerous workers. You can have substantially savings on the labor cost, which is often the key setback in a manufacturing environment.

Automation and programming: The finished products of vertical machines are of finer quality, with better finishing. As a result, you get the final output, just as you would have planned. Majority of the modern horizontal milling machines are completely automated and requires minimal human intervention. Prior programming and automation result in minimal errors in production, with 25% less processing time.

Reduced processing time: These equipments perform diverse functions just like a general machine as well as other activities like tapping and boring. One milling machine performs these in one operation. Advanced milling also reduces the need for manual labor significantly, which significantly reduced the operational cost unlike earlier times. These machines no longer require multiple set ups and change in tools. Horizontal milling machines are advanced and do not require frequent movement of parts, location wise. These advancements have reduced delay in processing time drastically.

Arm supports and clutters: Horizontal machines have features of arm supports and clutters, which are driven by an arbor. These two features help to add value in production. You should pay attention to reduce incidence of accidents and ensure maximum safety. Maintenance of cutters is required at a proper interval of time to maintain its sharpness. Check the location of arm support while they awhile dealing with arbors for maximum results.

Horizontal milling machines should be purchased from a reputed and trusted vendor. Prior research is needed before choosing any model and make of equipment. Online stores are also great options to purchase them.

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13 Different Types of Milling Cutters For Your Milling Machine’s Cutting Tool

by on Jul.25, 2010, under Mechanics

There are 13 different kinds of milling cutters used in various milling machines. They each cut materials differently. They are: end mill, roughing end mill, slab mill, face mill, hollow mill, slot drill, ball nose cutter, side-and-face cutter, involute gear cutter, fly cutter, woodruff cutter, dovetail cutter, and hob.

Milling cutters are essential cutting tools needed in a milling machine. Different types of milling cutters are available in many sizes and shapes to efficiently perform any type of cutting work. Read on to know the different types of milling cutters.

End mill

This is a tool with cutting teeth on one end and on its sides. Made of a high speed steel (HSS), the end mill cutter is the most common tool used in a vertical milling machine.

Roughing end mill

A roughing end mill removes a huge chunk of material in a wavy cutting pattern. This cutting mill produces a rough surface finish and is also known as ripping cutters. The wavy teeth minimize the vibrations and chatter sounds that occur during the cutting process.

Slab mill

A cylindrical cutting tool that can be used individually or with other cutting tools for cutting horizontal surfaces, the slab mill is made from a HSS.

Face mill

Face mill cutters are capable of holding multiple tip inserts. This economical type of cutting tool has tips that are can be replaced when they become blunt. A face mill can perform various cutting actions due to the versatility of the inserts and tips that it can work with.

Hollow mill

A hollow milling cutter is a pipe shaped tool with thick walls. The cutting teeth, however, are on the inside surface area. This cutting tool is essentially used in finishing cylindrical protrusions.

Slot drill

A slot drill is a cutting tool that directly cuts straight into a material. It commonly has two or more fluted cutters and a singular tooth located at the center of the end face. Slot drills are generally used for making cuts in a keyway slot.

Ball nose cutter

The ball nose cutter is a hemispherical end cutter with a similar function to that of a slot drill. This is an ideal cutting tool for machines that shapes three dimensional contouring forms and shapes. Ball nose cutters are also commonly called ball mills.

Side-and-face cutter

The cutting of a side-and-face cutter is located on its circumference and side portion. They are available in different widths and diameters. The side teeth functions to cut only one side of the material.

Involute gear cutter

This twelve teeth cutting gear comes in eight cutter sizes. A circular cutting tool, it has cutting edges on its circumference.

Fly cutter

A fly cutter is an inexpensive tool that functions like a face mill. It is composed of one or two tool bits that rotate to remove shallow and facing cuts.

Woodruff cutter

Woodruff cutters are small tip cutters that are used in cutting keyways. It is an essential tool in key engineering.

Dovetail cutter

Dovetail cutters are cutting tools that produce a dovetail slot patterns.

Hob

Hobs are cutters used in a hobbing machine. These cutters are used to make gears abd provide the appropriate shape specification of each workpiece. It is also important to consider the least cost and the correct cutting specifications of a cutting work when choosing a milling cutter. Remember to always work safely with the every cutting tool.

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Guidelines For Selecting Plasma Cutting Machines

by on Jul.24, 2010, under Mechanics

In simplest terms, plasma cutting is the process of cutting any electrically conductive metal by using high velocity of ionized gas which is delivered from a nozzle. The high pressured ionized gas which becomes the plasma, conducts electricity from the plasma cutting torch to the work piece. The plasma while coming into contact with the work piece heats and melts the material. Thus the metal pieces are cut smoothly. As plasma cutting is perfect for cutting steel and non-ferrous material, it is widely used in industries as well as by amateurs.

When you are planning to buy a plasma cutting machine, certain guidelines should be essentially followed. One of the main factors to consider is the thickness of the metal that you are cutting. Generally the plasma cutters are rated on their cutting ability and amperage. If you are cutting metal with considerably less thickness, you must consider a lower amperage plasma cutter. Likewise, you must use higher amperage machines for thicker metals. Even though the smaller amperage cutter would be capable of cutting metals of any thickness, the quality would be lacking in thicker metal cuts. The optimal cutting speed of the machine should also be considered before purchasing the cutter. A machine with high amperage would cut the metal much faster than one with low amperage.

In most plasma cutters, the pilot arc conducts high frequency electricity through the air. This electricity would interfere with computers or other equipments. So it would be better to select lift arc method that eliminates the problems of high frequency starting circuits. The plasma cutting torches consists of a number of plasma cutting consumables that would require replacement. It is recommended that a machine with lesser consumable would be long lasting and cost effective.

While purchasing plasma cutters, it would be good to make test cuts with many machines and check the quality of each cut. Here, you must look for a cutter that would offer a tight focused arc. Another quality checking method is to lift the plasma torch from the plate during cutting and check how far you can move while maintaining an arc. Generally when the pilot arc is brought close to the work metal, a transfer occurs from pilot arc to cutting arc. A plasma cutter that provides a quick, positive transfer from pilot to cutting arc at large transfer height would the best choice for getting better support during cutting.

One of the main things to be noted is the working visibility of the machine. While you are tracing a pattern, it is essential to see what you are cutting. A plasma cutting torch which is smaller and less bulky would be the best to provide working visibility. Portability is yet another thing to be noted. It is always better to go for a light weight, portable cutting machine. The most important thing is ensuring the safety features of the machine. It is highly suggested that you must buy a machine with nozzle-in-place safety sensor. This sensor makes sure that the machine won’t start unless the nozzle is in place. It is also good to look for a machine that would provide a pre-flow sequence.

Gavin Bone is an author for Plasma Cutter. He has written articles Welder. For information visit our site mig welders.

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