Conventional milling machine

Types of conventional milling machines

A conventional milling machine refers to a large piece of equipment that cuts through wood, metal, and plastic for a variety of purposes. There are different types of machines according to how the parts are cut through or in which direction the material is moved. There is also a split according to what kind of materials the machine is made from or is designed to mill through.

• Axis: The standard milling machine consolidates cutting in two dimensions, but there are machines that cut in more directions. The 3-axis conventional milling machine is one of the most common types and features three central cutting directions and axis - left/right, forward/backward, and up/down. The machine's part can be moved along those three directions to cut through materials with assistance from the operator. Meanwhile, a 4-axis conventional milling machine includes 90-degree rotation along one additional axis, which allows for the part to be positioned more easily and cuts more efficiently. Finally, the 5-axis milling machine allows for even more precise cutting with the addition of two more rotational axes. It isn't just the parts of the machine that rotate that enable the cutting; sometimes, the cutting tool itself rotates as well.
• Method: Generally, there are two types of milling methods: face milling and peripheral milling, which are based on the direction of movement of the cutter and the workpiece. In peripheral milling, the cutter rotates in the opposite direction to the feed direction of the workpiece, thereby cutting the material in its periphery. On the other hand, in face milling, the cutter rotates towards the material being fed, which allows it to cut through the material more efficiently from the top.
• Milling machine types: There are also differences in the kind of machines that are being discussed above. A horizontal milling machine has the cutting tool placed perpendicular to the part feeding axis. Meanwhile, in a vertical milling machine, the axis of the cutting part is perpendicular to the horizontally fed material. A third type, the universal milling machine, can move in additional directions besides the standard left/right and forward/backward. In addition to those two directions, it can move vertically up and down as well as tilt in a 360-degree axis.

Specifications and maintenance of a conventional milling machine

Specifications

• Machine Size: The overall size of the machine is critical. As it determines how much floor space will be required to house the machine, the height and length of the machine should be considered to determine whether or not it can fit into a workshop or factory space.
• Cutting Tools: Conventional milling machines use various types of cutters, called end mills, which come in different sizes and lengths. The most common types are face mills, slab mills, and types of end mills.
• Cutting Speed: The cutting speed is the surface speed along the path that a milling cutter operates to remove material from a workpiece. This speed is typically measured in Feet per minute (FPM). It varies depending on the cutter's material, workpiece material, and diameter of the milling cutter.
• Power of Cutting Tools: The milling machine cutter usually has a power rating expressed in kilowatts (kW) or horsepower (HP). This rating indicates how much power the cutter generates when operating at its optimal speed and is determined by the cutter's motor and design.
• Table Size: The maximum size of the workpiece that can be held and processed is determined by the table's dimensions. The weight-bearing capacity of the table allows it to support heavy items.
• Feed Rate: This refers to how quickly the workpiece is moved toward the milling cutter. It is usually measured in inches per minute (IPM) or millimeters per minute (mm/min). The type, size, and power of the milling machine determine the maximum and minimum feed rates.

Maintenance

A manual milling machine requires regular maintenance and care to ensure ongoing operational efficiency and avoid breakdowns and downtime. Here are some useful maintenance tips for a conventional milling machine:

• Before starting, it is critical to examine all parts and components of the milling machine. Look for loose belts, damaged parts, and frayed or worn-out electrical wires.
• Tool holders, milling cutters, and other accessories should always be cleaned after use, as oil residue may accumulate on them. Lubricate the slides and oil channels of the machines with a high-quality lubricant to avoid rust and dirt accumulation.
• Throughwater and air pressure, the electrical parts of the machine should be dried to prevent short circuits and damage from water accumulation.
• Periodically check the oil levels of sorted parts and subassemblies to ensure appropriate lubrication levels and cleanliness during operation. Furthermore, aligning the machine parts to avoid unnecessary friction and wear between moving parts is necessary.

Scenarios of a conventional milling machine

The conventional milling machine has countless usage scenarios because it is used in many industries and sectors. Here are some of them:

• Machinery industry: The conventional milling machine is a staple machine tool in the machinery manufacturing and processing industry. It is used to cut and process various mechanical components and parts, such as brackets, plates, gears, and more. These components often require high precision and complex shapes, which can be achieved using a conventional milling machine. In conventional machining, a piece of work is held in a fixture and rotated against a cutting tool. The tool may move up and down or side to side, depending on the type of machine used. CNC mills are more modern devices that may use computer programming to control the direction and speed of the cutting.
• Tools and dies: Tool and die makers use conventional milling machines to create cutting tools and molds used for mass production. They also make jigs and fixtures used to hold workpieces on other machining equipment. Using an often computer-aided design program, these artisans make plans for what needs to be created. Next, they select steel or another metal for the material that will become the tool or die.
• Automotive industry: A car has many parts and components, some of which must be made to very precise specifications and tolerances to ensure it works properly. A conventional car still has quite a few moving parts that must be machined precisely to ensure they function correctly when cutting these parts. Car manufacturers use conventional milling machines. They are used a lot in the automotive industry. It is conventional milling, after all.
• Furniture industry: Furniture makers can use a conventional vertical or horizontal milling machine to make parts for tables, chairs, cabinets, etc. A CNC router is an advanced version of a conventional milling machine. It is often used to make furniture. Conventional routers are suitable for handling simpler jobs, which might be less costly. Not all furniture pieces are complicated and require super-high precision. Some things can be made just fine with a conventional router. Generally speaking, furniture makers use various furniture pieces like PVC board, solid wood, particleboard, engineering wood, etc. Those vary in quality and prices.
• Woodworking: Custom woodworking businesses often have to be very creative with their woodworking projects, as most of their work is done on extremely high-end pieces. These require high precision and accuracy and the use of exotic woods that need to be cut precisely to be utilized fully and properly. Maybe they must, for example, get a crown molding profile cut in mahogany using a milling machine. Or, they want to make an antique English style library with fully dedicated walls and ceilings that require custom woodwork that only ancient woodworking businesses know how to do. High-end custom woodworking companies instead use CNC routers and custom computers, as they have far more flexibility and require more extreme precision than could only be achieved with a conventional device. When making simpler pieces like cabinets and shelves, the more straightforward ones often use standard machines.

How to choose a conventional milling machine

While the availability of various types of milling machines can make purchasing a machine for resale easy, it is still necessary to consider some important factors. Buyers should first identify the needs and capacity of their target customers. They can do this by analyzing the types of materials their target customers mill and the level of expertise required to operate a milling machine.

Conventional milling machines require more technical knowledge than its CNC counterparts. If most of the buyers are first-time milling machine owners, it may be better to go for the CNC variant instead of a conventional one. Furthermore, determining the size and capacity of a typical customer's milling project can help buyers decide whether to purchase small-scale or industrial-scale milling machines.

Shipping would be a major concern for many business owners. It is important to consider the weight and dimension of the milling machine, along with any extra costs that may be incurred during shipping and customs clearance. Should storage fees or any other additional costs arise, those fees will normally be passed on to the final customer. Therefore, the final product pricing model will change. It may not be possible to retail the product at the same price as before.

Finally, knowing only the selling price is not enough. It is important to get in touch with different milling machine suppliers to find out their prices and MOQ requirements. Do a comprehensive risk analysis and ensure that all supply chain operations are streamlined before placing the final order.

Q&A

Q1: Is a conventional milling machine still used today?

A1: Yes, many industries still use conventional milling machines. They are used to teach beginners how to control milling machines manually. Some operators prefer them because of their lower initial cost.

Q2: Does a conventional milling machine have tools?

A2: Yes, like any other milling machine, the conventional machine has tools. They include end mills, face mills, slots, T-mills, ball end mills, thread cutting taps, reamers, fly cutters, and collets, among others.

Q3: What can one make using a conventional milling machine?

A3: One can make various parts in an engine. The parts include slots, flat surfaces, keyways, T-slots, grooves, thread slots, dovetail slots, and helically contoured parts.

Q4: Is there a unique way of operating a conventional milling machine?

A4: Yes, it is important first to understand the parts of a milling machine before learning how to operate it. The machine is bolted to the table. There is a horizontal cutter in the overs. The setup is used for an off-center milling operation. The workpiece must be secured properly before starting the milling process. The setup and milling operations must adhere to safe practices. Some of them include wearing safety glasses and staying away from moving parts.