Vertically milled with CNC. CNC vertical milling machine. Vertical wood milling machine

The 6t12 machine is a unit for performing vertical milling work, which has been produced on the territory of the Gorky plant since the mid-80s of the last century. The design of the 6t12 machine is very similar to the products of the P line, but the main difference is greater unification.

Main technical indicators and advantages

Despite the fact that the presented model has been produced in Russia for more than 30 years, this does not prevent the machine from still creating good competition with more modern models. There are several reasons for this.

For example, the minimum deviation in the location of the treated surface and its shape is explained by the fact that the load-bearing elements have higher rigidity. Also, to increase rigidity, scraped guides with a compatible profile are used.

The spindle supports used by the vertical milling machine are equipped with paired angular contact and double-row roller bearings, which are characterized by increased load capacity. This facilitates power cutting with high quality processing. If standard lubrication is used, and the structural elements themselves have the correct tension, the bearing life will be longer than the amount of time before performing overhaul. To determine the class of bearings, you must read the technical data sheet.

In a screw pair, backlash is eliminated using a specially designed movable nut, which is included in the axial play control mechanism. Bimetallic materials are used in the production of all running nuts. Parts subject to more accelerated wear in areas of friction are produced using steel that is surface hardened with high-frequency heat. Exactly the same heat treatment method is used to strengthen gears. As a result, the equipment operates for a long period of time without the need for maintenance. And when the time comes to complete it, the cost of spare parts will be minimal.

The composition of a centralized effective lubrication system includes two groups. The first includes lubricant for the mechanisms in the console, and the second includes an oil supply system for the mechanisms located in the frame. Each of them, accordingly, provides separate power from its own plunger-type pump.

If the 6t12 1 machine is used every day in two shifts, the overhaul cycle will be at least 11 years. But achieving such indicators is only possible if the user complies operational requirements and primarily mills steel.

Increased drive power reserves, a wide range of speeds and feeds, minimal system compliance - all this contributes to high-performance processing of metal workpieces, which include plates made of STM or high-strength materials.

Achieving additional time savings is made possible thanks to the electromechanical method of fixing the tool. The table itself moves in automatic cycles. The revolutions are switched without sequential passage of steps.

Components

Considering the main characteristics, the basic design advantages of this equipment model are the presence of the following components:

• a device for slowing down the feed speed (the machine uses a proportional circuit);
• a mechanism to protect against metal shavings falling on the operator and others;
• an electromagnetic clutch that effectively brakes the spindle assembly in the horizontal plane;
• clutch to protect the main feed electric motor from overload;
• a device that allows you to adjust the gap in the screw pair (when feeding in the longitudinal direction).

It is also worth noting that the fixation of working tools on this machine is carried out according to a mechanized principle. Thus, the manufacturer was able to achieve a significant reduction in the time required to process a metal workpiece.

Location of components

The image presented above shows the layout of all the components of the 6t12 machine. In total, the presented vertical machine used consists of the following components and assemblies.

1. Coolant pump starting system.
2. Control system for the direction in which the spindle rotates - right or left.
3. Electric motor to drive the table.
4. A dial whose surface has a scale indicating the feed amount.
5. Mushroom for switching feed.
6. Handle for moving the table manually and vertically.
7. The handle that presses the slide to the console.
8. A handle designed to control the longitudinal movement of the table.
9. Electric motor for spindle drive.
10. Duplicate handle, including longitudinal movement of the table.
11. Flywheel for moving the table manually and in the transverse direction.
12. Cams for turning off the longitudinal table feed system in automatic mode.
13. Coolant supply valve.
14. Start button panel mounted on the front of the skid.
15. Duplicate handle for turning on vertical or transverse transmission.
16. Switch for the workspace lighting system.
17. Switch for the entire machine.
18. Handle for selecting spindle speed.
19. A dial whose scale indicates the number of revolutions.
20. Gearbox indicator.
21. Start button panel on the spindle box.
22. Cams that automatically turn off the vertical table feed.
23. Cams that automatically turn off the cross feed of the table.
24. Handle, including vertical and transverse feed of the table.

Location of controls

The layout of all control bodies is shown in the image above. It is worth noting that the design of the equipment in question is characterized by a convenient arrangement of buttons and other controls. This facilitates a quick transition to performing the required operations. Even a specialist with minimal practical experience, thanks to the comfortable placement of control elements, will be able to intuitively understand the main list of functions.

How does the rotating head of the machine work?

The image above shows the current drawing of the rotary head, which is used in the 6T12 machine. It is centered in the annular recess located in the neck of the frame, secured with 4 bolts that fit into 1 different groove of the frame flange.

The spindle consists of a double-bearing shaft, which is integrated into the sliding sleeve. Adjusting the axial play comes down to the need to grind rings 4 and 3. Elimination of increased play in the front bearing becomes possible by tightening the nut and grinding ring 5. The owner is required to follow the correct maintenance procedure. To get rid of the radial play, the value of which is one hundredth of a millimeter, a grinding of approximately 0.12 millimeters is required.

The spindle rotates through a pair of cylindrical and conical wheels that are installed in the head. The gears and bearings installed in the turning head are lubricated by a pump in the frame. Bearings responsible for the correct operation of the sleeve movement mechanism and spindle rotation - using the injection method.

Kinematic diagram

The main task of the kinematic diagram is for the owner to understand how the main elements of the equipment interact and contact each other. The callouts include the number of gear teeth. The main movement is made possible by a flanged electric motor via an elastic coupling. The number of revolutions can be changed due to the movement of three gear blocks along special splined shafts.

The feeders are driven by a flanged electric motor mounted in the console. Thanks to two three-crown blocks and a movable gear, access to 18 different feeds is provided, which are transmitted to the console via a ball overload clutch.

Obtaining accelerated movements becomes possible when high-speed clutches are turned on, which rotates thanks to intermediate gears from an electric feed motor. The main element of the entire structure of the machine is the bed, on which other mechanisms and components are fixed. It is rigidly attached to the base using a set of pins.

Electrical diagram

Scan of the drawing electrical diagram served in the picture above. The equipment is optimized for operation in a three-phase network with a voltage of 380 volts alternating current frequency 50 Hz. The control circuit operates at 110 volts AC. In control circuits, the current is constant; they operate at a voltage of 65 volts. To service local lighting, a voltage of 24 volts is supplied.

Exploitation

To increase operating efficiency, each machine is equipped with a set of auxiliary circuits - bearings, slings, lubrication, kinematics, and so on. The rest of the manual includes electrical equipment. Here is indicated circuit diagram connecting electrical appliances, and also provides a set of specifications for the selection of spare parts.

Based on statistical data obtained during the long-term production of the machine, the manufacturer has compiled a list of wearing parts. For them, a separate drawing of each element is provided. Thanks to unification, it becomes possible to use spare parts from other series of 6T machines, including 6T13.

Safety precautions

When performing work, it is necessary to adhere to general safety requirements. Each specialist must check the following working parts:

• grounding;
• correspondence of the voltage in the network with that used by the machine;
• checking the brake, signal and push-button devices for serviceability;
• checking the correct functioning of the locking device;
• checking the serviceability of the lubrication and cooling system;
• checking the condition of each hard stop that limits the movement of the calipers.

If any of the above elements are in poor technical condition, starting the electric motor is unacceptable. An initial diagnosis with further troubleshooting is required.

The key feature that any vertical milling machine has is the vertical orientation of the spindle. Moreover, in some modern models it can, if necessary, move along the axis or change the angle of inclination. Such features significantly expand the functionality of the equipment.

Another important difference from horizontal milling machines is the design of the arbor. In this case, it is a flange with Morse tapers on both sides (an end mill is installed in the mandrel on one of them). Most vertical milling machines also allow you to work with disk cutters. In this situation, a mandrel similar to that used in horizontally oriented models, but much shorter, is usually used.

Otherwise, the vertical milling machine has all the main functional elements and components

• equipment of this class:
• base plate;
• bed;
• console;
• spindle;
• sled;
• trunk;
• feed box;
• power plant.

It is important to note that some models of vertical milling machines have a cantileverless design, which is best suited for processing large and/or heavy workpieces. In this case, the slide and work table move along the guides on the bed. As a rule, the price of such devices is higher than that of console-type analogues.

Functionality

Modern vertical milling machines allow various types of milling blanks made of non-ferrous metals, alloys, steel or cast iron. Most models of such equipment are suitable for using various types of cutting tools, which makes it possible to carry out not only milling, but also cutting surfaces, drilling, countersinking and boring holes.

The milling process allows you to produce parts of various shapes and sizes. The most common version of a metal milling machine is the version where the spindle is located vertically. Such equipment began to be called vertical milling machines.

Cantilever vertical milling machines are made on the basis of horizontal milling machines with slight modifications to the gearbox and frame.

The stage of development of machine tools before the advent of CNC

All machines can be divided into two groups:

1. A group in which setting operating modes, feeding and other actions are carried out by a person.
2. A group of metal processing machines, the operation of which is fully or partially automated using a numerically controlled unit.

Vertical spindle milling machines without CNC have been used for several decades. The following models have become the most popular: 6Т12, 6М12П, 6Р12, 6Р12Б. These representatives of the group of milling machines were very common in the former USSR. Only after the superiority of CNC from an economic point of view and other characteristics was proven by calculations and in practice, these metal machines began to be replaced with new ones. However, 6P12 can be found in almost all large machine-building plants.

If we briefly describe the characteristics of this equipment, we can highlight the following features:

1. They process almost all metals and alloys, including cast iron. According to this indicator, the limitation is the resistance of the cutting tool used to abrasion and destruction when processed under the specified operating modes of a certain type of material.
2. similar design: the presence of a milling head, table, slide, spindle, bed.
3. reliability and unpretentiousness are qualities that determined the popularity of the above machines. At the time of production, these machines were exported to many countries around the world.
4. With the help of them you can carry out milling, drilling, boring. In addition, we note the appearance of a mechanism for rotating the head at an angle of 45° relative to the table. This feature made it possible to create elements that are located relative to the base plane at a certain angle.

Kinematic diagram of the 6N12 cantilever milling machine

A distinctive feature of the equipment is the ability to use certain indicators of processing characteristics: feed rate, tool rotation speed, etc. In addition, all models differ in table size. This indicator determines the ability to process workpieces of certain sizes and weights.

In the decoding, the first number means a group of milling machines, the next letter means the modernization of the main model, the second number means a subgroup of vertical milling machines, and the last number is the size of the table. Other characteristics can be found in the specification.

Console and non-console models

The main difference between all vertical metal milling machines is the presence or absence of a console. Almost all modern CNC versions are of the console type. However, previously consoleless machines were quite popular for the following reasons:

1. The absence of a console meant that the base for the table was the floor of a factory or a concrete slab.
2. The use of a floor or a concrete slab as a base for the slide led to a significant increase in the rigidity of the structure and to its reduction in cost.
3. Increasing the rigidity of the structure made it possible to process large and heavy parts.

Cantilever type milling machine

However, due to the fact that the table base cannot be taken into account in the created machining programs, the machining accuracy was significantly less than that of models with consoles. That is why numerical control is extremely rarely installed on machines of this type.

Vertical milling machines in the information technology era

The operating principle of the metal milling machines under consideration determined the low mobility of the spindle head (this was carried out only for adjustment purposes). Milling of flat surfaces is carried out by changing the position of the table with a rigidly fixed workpiece relative to the original coordinate. It is this feature that causes low processing accuracy.

All processes, from setting cutting modes to controlling the position of the table, are controlled by the milling operator. The human factor determines the high percentage of defects by modern standards, as well as deterioration in productivity.

Touching upon the performance indicator, we note that when designing machines several decades ago, the possibility of using cutting tools made of superhard material was not taken into account, and many models do not have a coolant supply system (cooling lubricant). Therefore, when using such machines, it is also impossible to increase productivity.

Vertical milling machines 6T12, 6M12P, 6R12, 6R12B were manufactured at factories in the USSR. For many years now, these factories have ceased to exist, and other representatives of the machine tool industry do not produce the models in question due to economic unprofitability.

Modern vertical milling machines

Despite the undeniable advantage of introducing CNC, mechanically controlled vertical milling machines are still produced, for example, JET JVM-836 TS. Modern equipment is used in their design and production, which made it possible to achieve high precision in the positioning of all structural elements, its rigidity, and this had a positive effect on the possible accuracy achieved during milling. In addition, almost all structural elements began to operate from electric drives. An exception is the table and spindle feed drives, which are of the mechanical type (however, they are duplicated with an electric drive to be able to set a constant feed rate).

CNC versions deserve special attention, for example, the Haas TM-2 machine. The use of modern technologies has made it possible to make almost the entire process automated (after entering the program and securing the workpiece, operator intervention is not required before it is removed). The description of such milling complexes includes the following characteristics:

1. Working at high spindle rotation speeds, using high feed rates, spindle movement in two planes, high positioning speeds together with process automation make it possible to obtain high-precision parts in minimal time.
2. Complex coolant supply system and chip removal from the cutting zone.
3. Maximum protection for others.
4. Possibility of milling along complex trajectories.

If we consider the issue of advantages and disadvantages, the characteristics of modern metal milling machines with a vertical spindle, it is worth indicating certain models, since they have many differences and the descriptions have different content. Their only common disadvantages, which are inherent in almost all versions, can be considered high cost and short guaranteed service life, and if problems occur, it is extremely difficult to find a specialist (and the cost of repairs can also be high).

In conclusion, we note that the metal milling machine shown at this point, despite its complex design, belongs to the vertical milling group, since the spindle is located in the vertical plane. The cost of this model is about $50,000, it is capable of creating finished parts with one relocation, that is, the workpiece must be repositioned once so that the surface that was the base during the previous milling step can be processed.

You may also be interested in the following articles:

Vertical drilling machines: classification and characteristics
Metal milling machines Horizontal milling machines for metal

Today, it is very typical to use parts of complex configurations in various branches of mechanical engineering - forming surfaces of dies, molds, gears, copiers and many others. The main methods for manufacturing such complex-profile products are the following: casting, stamping and cutting. But only mechanical processing by milling makes it possible to achieve surface parameters close to the specified ones, which significantly reduces the finishing time.

Often, a vertical milling machine acts as the optimal and even the only possible equipment for processing flat products of complex configuration. This is especially true in modern conditions of the transition of most machine-building enterprises to small-scale production.

The technological process, in which a vertical milling machine is the main unit for the production of parts with complex profiles, is also the most economically justified in this aspect. This allows you to avoid unnecessary costs of energy resources and production capacity. In our time, there is generally a steady tendency towards the universalization of any industrial production.

A typical technological process for processing surfaces of complex configuration consists of the following operations: blanking, milling and finishing. The latter, as a rule, is performed manually, which makes it extremely labor intensive. Therefore, the high class of surface cleanliness that a vertical milling machine can achieve significantly simplifies the finishing operation and improves the quality of the product. Thus, this unit minimizes material costs, which is extremely important in a market economy.

A vertical milling machine is designed to perform various, mainly metalworking operations with face, cylindrical, shaped, angular and other multi-cutting tools (mills). Such machines process a variety of planes, grooves of any cross-section, gears, die models, frames, corners and other parts made of non-ferrous metals and their alloys, various grades of steel and cast iron.

A vertical milling machine is characterized by the presence of a vertically located spindle, which in many models is capable of moving along its own axis and rotating in a horizontal plane, which significantly expands the technological capabilities of the unit. The spindle head is located in the upper part of the frame, which also contains the gearbox. The main working movement of the machine is the rotation of the spindle.

The main structural components of a vertical milling machine include the following: gearbox, bed, slide, console, spindle and dividing heads. The latter is an extremely important element, since it is it that turns the workpiece to the angle required for processing. In addition, the dividing head ensures continuous rotation of the workpiece when milling helical grooves.

Nowadays, CNC vertical milling machines are increasingly used in industry. A distinctive feature of such modern equipment is that all types of feeds in them are controlled by signals that are recorded on magnetic tape. Originating in the windings of special coils, these signals are then transmitted through traction motors to the machine feed screws. This control ensures pinpoint accuracy of processing.

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Application of vertical metal milling machine

The vertical milling machine, along with the drilling machine, are the two most used machines in the industry.

Or rather, in production: where processing of metal or wood is needed, the machine will always help out.

In general, the scope of application of this machine is akin to the area in which casting, stamping, and cutting are performed.

Thanks to milling, the desired edges and shapes are obtained, which speed up the overall finishing of each part.

In addition, the use of the machine is economically justified. Of course, the machine itself in a workshop can easily cost 1-2 million rubles, but at the same time, dozens of parts can be made on it per day (and if the unit is equipped with CNC, even more), which together bring a noticeable income.

Metal milling is considered a separate work only conditionally, because the machine does not bring the part to its consumer appearance. First comes the procurement operation, then the milling operation, and finally the finishing operation.

The most expensive is finishing, since for the most part the person’s experience and his skillful hands decide here, and as a result, more time is spent.

But using the machine in the first two operations allows you to generally shorten the production cycle or give more time for finishing the metal, which will give the part High Quality.

If you use a vertical milling machine equipped with CNC, the accuracy and quality of the workpiece will easily surpass the result of the work of the most seasoned master: ultra-precision down to fractions of a millimeter, coupled with work of any complexity, allows you to create parts from one piece of workpiece according to the required specification.

Device of a vertical milling machine

Metal milling, unlike drilling, requires strength specifically in the lateral segment of movement.

Therefore, the drives are powerful, and the tool (mill) is made of hard alloys.

A milling machine with or without CNC consists of the following components and mechanisms:

• bed - the supporting structure of the entire machine;
• spindle - mounted on top of the frame, rotates in a vertical projection;
• spindle axis - rotates at the desired angle to the workpiece surface;
• a table for holding the workpiece, along which it can move along a slide;
• slides - needed to move the part along the console;
• console - a supporting beam, fixed to the frame at one end, supports and moves the table with the part along the slide;
• feed box - changes the feed speed and its direction.

It is worth mentioning separately that the console is not a mandatory part of the machine. For this reason, today there are two types of metal milling machines - non-cantilever and cantilever. The machine can also be additionally equipped with CNC.

A cantilever metal machine is equipped with a spindle, which in other machines can be shifted along the axis lengthwise and rotated along a horizontal plane.

Another important difference between the vertical sample and the horizontal one is the Morse taper on the flange (ISO-40 according to the international nomenclature), which includes the cutter.

To install a disk cutter, a mandrel is placed (mandrels are sometimes interchangeable - from a horizontal machine they are placed on a vertical one and vice versa). By the way, most of the machines used today are console ones.

Non-cantilever metal machines process vertical, horizontal surfaces, at an angle, creating grooves.

Non-cantilever metal cutting machines are not equipped with a console, and the table moves along guides on the bed itself, which stands on the foundation.

A cantilever CNC machine is better balanced than a non-cantilever one, which, however, is not significant when we are talking about an industrial machine weighing 200 kg or more.

It can provide greater rigidity and processing precision. In it, the spindle head simultaneously acts as a cutter speed box and moves vertically along the guides.

The spindle and sleeve can be moved along the axis to accurately position the cutter of the desired size. A boring machine (with or without CNC), by the way, also performs the functions of a milling machine.

Also, and vice versa, you can install a boring bar, a countersink, a reamer on a milling machine and it will become a boring machine. The workpiece is secured to the machine with all kinds of grips, squares, vices and prisms.

But if we are talking about mass production, then you need to attach several blanks at once and process them in one batch.

To do this, special “canopies” are assembled in the form of a continuous row of clamps, which allow several workpieces to be processed equally at once.

The dividing head is of great help, as it rotates the part to the desired angle. The dividing head has a spindle and a rotating drum.

The spindle gear is connected to the worm. The handle transmits torque to the spindle; in one revolution, the spindle rotates only 1 tooth out of all in the wheel.

There is a thread on the spindle for attaching the leash. There is also a limbo attached to the spindle, dividing the parts into parts.

To position the limbo, a folding sector is provided, the legs of which are placed under a certain number of holes.

Milling cutter: types and purpose

The main working part of a machine for metal milling is a milling cutter made of durable steel.

The teeth of the cutter are made by welding plates of durable steel.

There are composite cutters in which the plates are inserted into the body rather than welded:

• End mill. The blade is made of 3 parts: main, transition and auxiliary blades. The cutter tooth is located at an angle, which is formed from the projection of the main blade and the feed axis onto the plane. The angle of the auxiliary blade is only 10 degrees. The smaller it is, the better the smoothness of the finished plane. The angle of the transition blade is equal to half the angle of the main blade. The cutter can be cast or assembled, with inserted or welded knives. Placed to the surface of the workpiece at an angle of 90 degrees. In contrast to the cylindrical cutter, in which the entire cutting edge is responsible for the shape of the cutter, the end cutter profiles only the tops of the edge. All the milling work is done by the outermost edges. The edge appears in the form of a circle or a curved line. The smaller the cutter, the better its resistance to vibration. Unlike cylindrical milling, end milling is more productive - the angle of pressure on the surface is independent of the allowance, but depends only on the width of the milling;
• Disc cutter. The disk one is needed to prepare grooves and manholes. It is equipped with teeth along the surface of the cylinder and works on small grooves. During operation, the thickness of the cutter on the outside is greater than that of the hub. Allow 0.05mm error for thickness. When the teeth are ground down, the thickness of the cutter decreases, but the amount is very small. The teeth in two- and three-sided cutters are located along the entire cylindrical surface and both ends. The side edges are not significantly involved in cutting. More often, cutters with angled or multi-directional teeth are installed on machines. In this case, all the teeth on the cylinder work;
• Angle cutter. Installed for cutting beveled edges and angled grooves. In a single-angle cutter, the edges are located on the end and conical end, in a double-angle cutter - on adjacent faces. A corner cutter is mainly used to create chip flutes. The double-angled one works more stable than the single-angled one due to the symmetry of the force along the axis when adjacent tooth faces operate;
• End mill. Needed for cutting out deep grooves, contour grooves, and all sorts of ledges. Secure with a shank. All the excavation work is done by the leading cutting edges on the cylindrical surface, while the auxiliary ones only clean the bottom of the groove. Equipped with inclined or helical teeth;
• Key cutter. It is also an end drill, which works like a drill, burrowing into the workpiece material and then moving along the groove. When feeding along the axis, cutting occurs along the end edges;
• For T-slot. A frangible cutter with teeth directed at different angles. Due to difficult chip removal (a tooth passes 2 times per 1 revolution of the cutter), chamfers on the teeth are often sharpened at an angle of 30 degrees on both ends;
• Shaped cutter. Works only with shaped surfaces; they can have backed or pointed teeth. The latter produce a smoother surface and are more durable in comparison with a backed cutter. Both types of cutters are used only in mass production.

In general, the control of any vertical milling machine is intuitive, with the exception of CNC models - they require a specialized specialist who knows how to program.

Let's say there is a machine in front of you. On the table in front of you there will be clamps for the workpiece. Place the workpiece, set the gear and slowly lower the cutter down, then draw it along the line - that’s the whole difficulty.

A little more knowledge will be needed to understand the operation of a CNC-equipped unit.

But still, to become a master, you will have to spend hundreds of hours at the machine.

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Vertical milling machine - basics and principles

A vertical milling machine is a very popular technique that has found application in the engineering industry. The main feature of the equipment is that it allows the production of complex-profile parts, such as stamps, copiers, etc.

All functions assigned to a vertical milling machine can be divided into drilling, milling and boring. The accuracy of performing a task on such equipment is quite high. At the same time, the decent performance of the equipment is also not in doubt. Vertical machines, as a rule, are distinguished by high drive power, which, in combination with carbide tools, create a very productive tandem.

Among design features In such units, experts note the presence of a so-called dividing head, which is used to rotate the workpiece to the required angle. In addition, the rotation of the part facilitates the processing of helical grooves, which is also very important for increasing labor productivity.

The vertical milling machine is designed to process metal structures with a variety of cutters and drills. The technique can be used to process any planes, various kinds of spirals, and molds. Moreover, as a rule, such machines are designed for processing parts made of non-ferrous and ferrous metals, as well as alloys, which makes them multifunctional, wide-profile equipment.

The vertical machine is distinguished by the absence of a so-called console. The table moves along special guides of the foundation frame, which guarantees maximum rigidity of the equipment. Of course, this is reflected in the accuracy of workpiece processing when compared with alternative types of milling machines. This technique also copes with parts of large dimensions and weight without any problems.

In the design of a vertical milling machine, the spindle head acts as a gearbox, which can be regarded as an additional feature. The head moves vertically along the rack guides. The spindle with the sleeve can also be moved along the axis.

A craftsman who wants to acquire such equipment will undoubtedly be pleased by the fact that its functionality can be expanded with the help of additional components, such as a vertical or universal head, a round dividing table, comb cutting devices and other options. Thus, by purchasing such a unit, if necessary, the list of tasks it performs can be expanded.

Technical specifications

In order to clearly understand what requirements a particular machine meets, it is important to have an idea of ​​its main parameters. Today, the range of such equipment is truly huge. Companies produce equipment in a variety of sizes and with different power ratings. The market offers both desktop units aimed at domestic use and professional milling machines capable of operating in harsh production conditions.

When choosing the ideal unit for yourself, a master should focus on such key characteristics as:

• Power is perhaps the main parameter that gives an idea not only of the performance of the equipment, but also of the scope of its use.
• Characteristics of the workspace. This includes the dimensions of the desktop, distance from the spindle, spindle stroke and other parameters.
• The spindle speed is a characteristic that clearly demonstrates the processing speed of the part and determines the equipment option.

Today, there are 3 main types of universal vertical milling machines, depending on the type of control. Manual machines are the most “ancient”, but irreplaceable units in small workshops. Automatically controlled or numerically controlled equipment are more complex structures that require the appropriate level of qualifications to operate them effectively. This is especially true for CNC machines.

Let's look at some of the popular models to understand what types of equipment are potentially available to the master today.

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Vertical milling machine: description, characteristics, scope of application.

Currently, parts containing complex profile surfaces are widely used in mechanical engineering: forming surfaces of stamps, molds, copiers and many others.

The main methods for producing parts with such surfaces include casting, stamping, and cutting. However, only cutting, in particular milling, makes it possible to obtain surface parameters close to the specified ones and reduce the time for subsequent finishing. Very often this method is the only possible method; this is especially important at the moment, since most mechanical engineering enterprises have switched to mass or small-scale production. Producing parts by milling, with this type of production, is the most economically justified.

A typical technological process for processing complex-profile surfaces includes the following operations: blanking, milling, finishing. The latter is performed manually, and the complexity of the operation is determined by the output parameters of the surface after milling. Therefore, by ensuring a high roughness class at the milling stage, it is possible to reduce the time for finishing, which is the most labor-intensive part of the technological process. Vertical milling machine.

Designed to perform a variety of milling work using cylindrical, corner, face, shaped and other cutters. The machines process horizontal and vertical planes, grooves, frames, corners, gears, stamp models, molds and other parts made of steel, cast iron, non-ferrous metals, their alloys and plastics.

The power of the drives and the high rigidity of the machines allow the use of carbide tools. The frame 1 houses a gearbox 2. The spindle head 3 is mounted in the upper part of the frame and can be rotated in a vertical plane. In this case, the axis of the spindle 4 can be rotated at an angle to the plane of the worktable 5. The main movement is the rotation of the spindle. The table on which the workpiece is secured has longitudinal movement along the guides of the slide 6. The slide has transverse movement along the guides of the console 7, which moves along the vertical guides of the frame. Thus, the workpiece installed on the table 5 can receive feed in three directions. A feed box 8 is mounted in the console. The following types of cutters are used on vertical milling machines: face cutters (Figure 1.1), end cutters (Figure 1.2), keyed cutters (Figure 1.3). The cutters are made as one piece (Fig. 1.1, 1.2, 1.3) or assembled (Fig. 1.4) with brazed or inserted knives. Solid cutters are made of tool steels, brazed cutter bodies are made of structural steels; Plates made of high-speed steels and hard alloys are soldered onto the working parts of the cutter teeth. In prefabricated cutters, the teeth (knives) are made of high-speed steels or equipped with plates made of hard alloys and secured in the cutter body using various mechanical methods. The cutting blade of an end mill consists of a main cutting blade 8, a transition blade 9 and an auxiliary blade 10. The tooth of an end mill has a leading angle j, measured between the projection of the main cutting blade on the axial plane and the feed direction. The auxiliary plan angle j 1 is 5-10o. The smaller this angle, the lower the roughness of the machined surface. Plane angle on the transition cutting blade j 0=j /2. To secure workpieces on milling machines, universal and special devices are used. Universal devices include clamps, squares, prisms, and machine vices.

When processing a large number of identical workpieces, special devices are made that are suitable only for installing and securing these workpieces on a given machine. An important accessory of milling machines are dividing heads. They serve for periodic rotation of workpieces to the required angle and for their continuous rotation when milling helical grooves.

The dividing head consists of a housing 1, a rotary drum 2 and a spindle 4 with a center. A worm gear (usually with 40 teeth) is rigidly fixed in the housing on the spindle and meshes with a single-thread worm. The spindle is rotated by handle 6. Therefore, with one revolution of the handle, the spindle will make 1/40 of a revolution. The front end of the spindle is threaded for screwing on a jaw chuck or driver. The dividing dial 5 with holes is fixed on a hollow shaft, inside of which the shaft of the handle 6 is located. For ease of use of the dial 5, there is a sliding sector 7, consisting of two legs, which are installed so that between them there is the required number of holes on the dial. A dial 3 is attached to the spindle 4 for directly dividing the workpiece into parts. Helical grooves are milled with continuous rotation of the dividing head spindle, which it receives from the longitudinal feed screw of the milling machine table through replaceable wheels. The workpiece is installed in the centers of the dividing head and tailstock. During processing, the workpiece receives two movements - rotational and translational along the axis. Both movements are coordinated so that when the helical groove being cut moves one step, the workpiece makes one revolution. Milling mandrels are used as an auxiliary tool to secure cutters and transmit torque from the spindle to the cutter. The base for attaching the cutter to the mandrel can be its center hole or shank (conical or cylindrical). According to the method of fastening, in the first case the cutters are called mounted, in the second - tail cutters. Figure 1.5 shows a mandrel for attaching end mills. The mandrel is secured with a conical shank 10 in the spindle 1, and at the other end of the mandrel a mounted milling cutter 11 is secured using a key 12 and a screw 13. Mills with a conical shank 15 are secured in the conical hole of the spindle 1 directly or through adapter bushings 14 (Figure 1.6). Mills with a cylindrical shank are secured in a collet chuck. The conical shank of the chuck is inserted into the machine spindle and secured with a bolt. The pictures show schemes for milling surfaces on a vertical milling machine. The movements involved in the formation of surfaces during the cutting process are indicated by arrows in the diagrams. Horizontal planes are milled on vertical milling machines using end mills (Figure 2.1). This is more convenient due to the greater rigidity of their fastening in the spindle and smoother operation, since a large number of teeth operate simultaneously. Vertical planes are milled on vertical milling machines using end mills (Figure 2.2). Inclined planes and bevels are milled with face (Figure 2.3) and end (Figure 2.4) cutters on vertical milling machines, in which the milling head with spindle rotates in a vertical plane. The shoulders are milled on vertical milling machines using end mills (Figure 2.5). Grooves on vertical milling machines are milled in two passes: a rectangular groove with an end mill, then bevels of the groove with a single-angle end mill for a dovetail groove (Figure 2.6); and for a T-shaped groove (Figure 2.7), a rectangular profile groove is milled with an end mill, then the lower part of the groove is milled with a T-slot cutter. Closed keyways are milled with end mills (Figure 2.8), and open ones with end or keyway cutters (Figure 2.9). The accuracy of obtaining a keyway is an important condition when milling, since the nature of the fit of the parts mating to the shaft on the key will depend on it. Milling with a key cutter ensures a more precise groove; When regrinding along the end teeth, the diameter of the cutter practically does not change. Milling of cylindrical gears on vertical milling machines is carried out using a finger cutter (Figure 2.10). Complex profile surfaces can include convex, concave and straight sections. Moreover, a single-tooth or multi-tooth cutter can be used as a tool. In addition, the required profile can be obtained by turning or only by translational movement of the cutter, i.e. The following methods can be distinguished for obtaining complex-profile surfaces:

- concave cylindrical surface obtained

A) due to rotation of the cutter axis by an angle; b) due to the translational movement of the cutter; - a convex cylindrical surface obtained a) by rotating the cutter axis through an angle; b) due to the translational movement of the cutter. The work [1] provides formulas for calculating roughness for all of the above methods for producing surfaces. However, calculations using these formulas showed that they require clarification. The refined dependencies have the following form: Roughness of a concave cylindrical surface obtained by rotating the cutter axis through an angle (Fig. 1.a.) where h is the height of the ridge obtained during milling, r is the radius of curvature of the machined surface, R is the radius of the cutter, s - feed, a - angle of rotation of the cutter axis Roughness of a convex cylindrical surface obtained by rotating the cutter axis through an angle (Fig. 1.c.) From the dependencies shown above, it is clear that the roughness depends on the radius of curvature of the surface, the radius of the cutter and feed. The last two quantities have the greatest influence.

The given dependencies did not take into account random variables, such as elastic deformations, vibration of technological system components, temperature factor and some others, which have a lesser impact on the roughness model during milling.

Vertical milling machines

Cantilever vertical milling machines 6K11 6K12 Cantilever vertical milling machines 6K11 6K12 are designed to perform all types of milling work, drilling, countersinking and boring holes on parts made of ferrous and non-ferrous metals, their alloys and plastics in single, small-scale and mass production. The presence of a tool clamping mechanism and a number of additional devices and accessories can significantly expand the technological capabilities. Specifications vertical cantilever milling machines 6K-11 6K-12 Cantilever vertical milling machines FSS350R FSS450R - The main components of cantilever vertical milling machines FSS350R, FSS450R are made of SCh25 cast iron, have an optimal shape and greater rigidity.

The fluoroplastic coating of the table and stand guides has good anti-friction properties and anti-scuff ability, which allows for the stability of precision parameters for a long time.

The presence of automatic processing cycles (pendulum milling, milling with accelerated hopping, milling along a rectangular cycle in three planes) allows them to be used not only in small-scale, but also in large-scale production. Technical characteristics of vertical cantilever milling machines FSS-350R, FSS-450R Cantilever milling machine VM127M Cantilever milling machine VM127M is an analogue of machines 6Р13, 6Т13, FSS450R and is designed to perform milling operations of various parts made of ferrous and non-ferrous metals and their alloys in serial and small-scale production. The powerful main drive and carefully selected gear ratios ensure optimal processing conditions under various cutting conditions and full use of the cutting tool's capabilities. Technical characteristics of the cantilever milling machine VM-127M Vertical milling machines KM-80 KM-100 KM-150 KM-180 with CNC. (Taiwan) CNC-SITEK (Taiwan). Standard equipment: - Closed table, - Automatic lubrication system, - Coolant, - Lamp

Additional equipment: - Closed cabin, - Magazine for 16 tools, - Spindle 8000 or 10000 rpm, - TFT display, - 4 and 5 axes

Vertical milling machines

Scope of application of vertical milling machines Vertical milling machines are designed to perform all types of milling work using cutters. Milling machines of this type are mainly used for drilling, countersinking and boring holes, processing horizontal and vertical planes, grooves, frames, corners, gears, spirals, die models, molds and other parts. Vertical milling machines allow you to work with parts made of steel, cast iron, non-ferrous metals, their alloys and other materials. In this case, the cutter of the milling machine, together with the milling spindle, makes a rotational (main) movement, and the workpiece, fixed on the table, makes a linear or curved feed movement - called milling. The control of milling machines can be manual, automated, or carried out using a CNC system - see CNC milling machines.

In milling machines, the main movement is the rotation of the cutter, and the feed movement is the relative movement of the workpiece and the cutter.

A vertical cantilever milling machine, unlike a horizontal milling machine, has a vertically located spindle. Milling machines of some models allow displacement along their axis and rotation around a horizontal axis, thereby expanding the technological capabilities of the machine.

Vertical milling machines without cantilevers are designed for processing vertical inclined surfaces and grooves in large parts. Unlike cantilever milling machines, these machines do not have a console, and the slide and table move along the guides of the frame mounted on the foundation. This design of the machine ensures higher rigidity and processing accuracy compared to cantilever-type machines, and allows processing parts of large mass and size. The spindle head of milling machines of this type, which is also a gearbox, has an installation movement along the vertical guides of the rack. In addition, the spindle together with the sleeve can be moved in the axial direction when accurately setting the cutter to the required size.

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These specialized metalworking machines do not have a console, and the table moves along the guides of the foundation bed. This design ensures high rigidity of the machine, and therefore high processing accuracy (compared to other types of machines), which allows processing of parts of large mass and size. The spindle head is also a gearbox and has an installation movement along the vertical guides of the rack. The spindle together with the sleeve can be moved in the axial direction.

Equipment characteristics

Manufacturers produce equipment of different sizes, power and, accordingly, purposes: from desktop metal milling machines to professional high-performance machines for long-term hard work. When choosing a vertical milling machine, you need to pay attention to the following characteristics:

• power, kWt
• Working area parameters, mm
• Work table dimensions, mm
• Table movement along the X/Y/Z axis, mm
• Table rotation range, degrees
• Maximum drilling diameter, mm
• Maximum diameter of end mill, mm
• Maximum diameter of end mill, mm
• Distance to spindle, mm
• Spindle stroke, mm
• Spindle speed, rpm
• Spindle taper, ISO (DIN)
• Machine dimensions, mm
• Weight, kg

The machine control can be:

• manual;
• automatic;
• with CNC.

There are also two types of vertical metal milling machines:

• A vertical milling cantilever machine has a vertically located spindle. Some models allow displacement along their axis and rotation around a horizontal axis, thereby expanding the technological capabilities of the machine.


• vertical milling machine without cantilever for metal is designed for processing vertical inclined surfaces, grooves in large parts. These machines do not have a console, and the slide and table move along the guides of the frame mounted on the foundation. This design of the machine ensures higher rigidity and processing accuracy compared to cantilever-type machines, and allows processing parts of large mass and size. The spindle head of milling machines of this type, which is also a gearbox, has an installation movement along the vertical guides of the rack. In addition, the spindle together with the sleeve can be moved in the axial direction when accurately setting the cutter to the required size.