The past few years have seen an unusually rapid development in the art of milling. We have carried out some very exhaustive experiments in cutter design, cutter and work cooling, and other branches of the art, which have led to marked improvements, not only in these particular branches, but in the Milling Machine itself.

Although some of the data pertaining to these developments have already appeared in various publications, we believe that their compilation in complete form, as found in this book will make them of much more general use to those interested in, and responsible for, efficient production from Milling Machines. A more complete knowledge of the action of milling cutters, the effect that action has on production, a familiarity with the different constructions and types of milling fixtures and holding devices, the cause of unsatisfactory Milling Machine performance and the basic principles of cutter sharpening, are all necessary for the intelligent application of the modem Milling Machine.

We have in this book given considerable space to various phases of these subjects, and to this end are presenting some matter never before published.

The mathematical chapters dealing with the computations involved in cutting spur, bevel, spiral and worm gears, present these subjects in a simple, detailed manner, which will, we believe, make them clear and useful to those for whom the usual method of presentation of this matter has always been too much involved.

The arrangement of the various formulas and mathematical tables will prove of convenience to all who have occasion to use them.

The formulas and diagrams in the chapters on gearing have been adapted from Machinery's Handbook and are printed by permission of the publishers.

The mathematical chapters, especially the chapters on Shop Trigonometry, Continued Fractions, Spiral and Bevel Gears, are based on material prepared by Mr. A. L. DeLeeuw, while Chief Engineer of The Cincinnati Milling Machine Company.

Before entering into an analysis of the process of milling, the design of milling cutters, jigs, fixtures, etc., and the mathematics involved in the setting up of the machine for some classes of milling, it may be best to first examine into the construction of the machines and attachments available.

Classification of Machines. In this book we will confine ourselves to the Column and Knee Type Milling Machines and the smaller sizes of Manufacturing Millers in most general use. These comprise the types of machines with which everyone is more or less familiar. They are the machines that are used in the tool room, in the jobbing shop, for model work, repair shops and for manufacturing.

Universal Milling Machines, so called because of the great range of work that they will accommodate, are arranged with a swiveling table, and regularly equipped with a dividing head. They can thus be used, in addition to a general line of milling, for all sorts of indexing and milling work between centers, such as spur and spiral gears, and also on angular work, such as bevel and mitre gears. Each tool room should contain one or more of these Universal Machines.

Plain Milling Machines are similar to the Universals, differing only in that the Plain Machines do not have a swiveling table, and that their equipment does not include index centers of any sort. They are used both in the tool room and for regular manufacturing.

Vertical Milling Machines are similar to the Plain Milling Machines, with this exception — that the spindle is in a vertical position, and at right angles to the plane of the table. They are particularly adapted for the use of face and end mills in the manufacturing department, for the milling and boring of jigs in the tool room, and for the machining of dies.

Manufacturing Millers are particularly adapted for repetition work produced in large quantities. They are, generally speaking simpler in construction than the Knee Type Millers, and are used in large quantities in the manufacture of firearms, typewriters, automobiles, etc. All of these machines will be briefly described in the following pages.

The Selection of a Milling Machine. The selection of the type of Miller best adapted for the economical production of a given class of work cannot be given too careful consideration. The quantity and quality of work that the machine will produce mast justify the investment.

We have gone far towards helping our customers in the solution of their milling problems and have thus gained a wider knowledge of the economic field of milling than can be obtained from the limited experience of one shop on one class of work.

We are prepared to make complete time studies of all the milling operations on any piece of work, suggest methods, fixtures, etc., and furnish the complete equipment for doing it.

Our wide experience in this work and the great variety of milling machines made by us, enable us to recommend and furnish that size. style and type of machine which will prove most economical in view of all the conditions attendant upon its installation and use.

It would hardly be appropriate to attempt to deal here with all the considerations upon which an intelligent selection of a machine depends, but mention of the most important factors will, we believe, prove helpful.

Whether it should be a Cone-Driven or a High-Power Constant Speed Drive type machine depends on -

-    The quantities in which parts are made.
-    The kind of work to be milled.
-    Power required.
-    Method of transmission used, whether by line shaft, group drive or individual motor drive.

Whether it should be Plain, Universal or Vertical depends on -

-    Whether it will be one of many machines or the only Milling Machine in the department.
-    The amount of time it will be used for spiral cutting.
-    Whether it will be used for jobbing or manufacturing.
-    Whether for machining flat surfaces, die sinking or gang work.
-    Whether it should be an Automatic depends on the quantities in which the parts are made.

The suggestions contained in the illustrations of machines in operation will be helpful in the selection of the proper machine.


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A treatise on milling and milling machines