The machine is vertically milling cantilever. Modern milling machines for metal - types, features, purpose

In the manufacture of various metal parts, it is almost impossible to do without the use of. Conveniently, a milling machine for metal work is equally successfully used in working conditions and in home workshops. It should be noted that the equipment of this category is the most common in the field of metalworking.

Almost all modifications of milling equipment work on a similar principle and have a similar design. The differences between the models of such machines may lie in their functionality, which is formed by adding additional components and systems to their design.

Varieties of milling machines

We list the main types of milling machines, each variety of which sometimes differs significantly from its counterparts and has a lot of differences in design and in its working purpose.

Vertical milling

A fairly common type of machine in this category is a vertical milling machine. The working tools for such machines are shaped, cylindrical, end mills, and drilling operations can also be performed. A vertical milling machine allows you to perform the following technological operations: processing gears and various grooves, corners, frame elements, vertical and horizontal surfaces on parts made of various metals.

Milling machines of this type do not have consoles in their design, and their desktop moves along guides located on the equipment bed. Due to the peculiarities of its design, the vertical type machine is characterized by high rigidity, which makes it possible to process metal parts on it with high level quality. The gearbox of such a milling machine is located in the spindle head.

Vertical- milling machines are divided into two categories, differing in the presence of a console in the design. Their names are respectively:

• consoleless vertical milling machines;
• vertical console milling machines.

With the console, it differs in that its spindle and sleeve can move relative to the axis of the equipment. The differences in their design can be clearly seen in the photo.

Horizontal milling

The horizontal milling machine is notable for the fact that its spindle is located in a horizontal plane. The equipment of this group allows you to process parts that have small dimensions. The versatility of this machine is ensured due to the fact that it uses cutters of end, cylindrical, shaped, end and angular types as a working tool. The horizontal milling machine in its standard configuration does not allow processing the part along the helical surface, for this it must be equipped with auxiliary devices.

The device of the machines of the horizontal milling group allows you to install their desktop in parallel, as well as perpendicular to the spindle axis. All working and power units of this equipment are located on the frame, and the gearbox, which controls the speed of rotation of the spindle, is located in its inner part.

Drilling and milling

Machines belonging to the category of drilling and milling are designed for processing not only horizontal and vertical surfaces, but also inclined ones. With their help, grooves of large-sized parts are also processed.

Such a metal milling machine has a drilling and milling head that allows you to perform tilted drilling operations and machine surfaces located at an angle to the horizontal axis. A distinctive feature of such a machine is that its working head can operate in reverse mode.

Due to their versatility, due to the ability to carry out the two most popular operations, such machines are very beneficial from an economic point of view, as well as in terms of saving space in the production area. Few of the home craftsmen will refuse to have such a machine at home, since such an apparatus combines several effective and useful devices in its design at once.

Universal

Such metalworking machines are very convenient to use to equip private workshops or medium-sized workshops specializing in mechanical repair work. Universal machines allow processing of horizontal and vertical planes, as well as surfaces of a spiral type and stamps.

Such a machine for metal differs next design features: spindle assembly, box, as well as the main nodes are located in the inside of the bed. The design of the machine provides vertical and horizontal guides along which its console and desktop move. The working surface, in addition, can be set in relation to the equipment spindle at the desired angle, which makes it possible to process metal parts with even the most complex configuration with it.

Desktop

Such a very compact equipment installed at home, in workshops educational institutions and in small production shops, it allows you to perform various technological operations: cut threads, drill holes, process all kinds of parts and materials with various types of milling cutters, etc.

This type is distinguished by good accuracy, since their design has exceptional rigidity (of course, with proper installation). Such console milling machines are distinguished by high productivity, which makes it possible to use them for the production of products in serial batches. Despite their high performance and wide functionality, such machines are distinguished by low power consumption and compact size, which allows them to be conveniently placed even in a small area.

CNC milling

Such devices are actively used in various industries in the mass production of high-quality parts. CNC machines are highly productive and capable of providing unsurpassed quality not in a single copy, but on a stream, which makes them indispensable equipment in any serious production. The differences between such machines from all other types of milling machines are so significant that they require detailed analysis in a separate article.

CNC machines that process parts from various metals with high productivity and accuracy have one big drawback: a decent cost, but it is fully compensated by the following positive factors:

1. reducing the need for qualified specialists in production;
2. high productivity relative to manual machines;
3. term reduction production cycles;
4. accelerate the transition to the production of new products.

CNC

The difference between such devices and the previous type of milling machines lies in even greater versatility, even higher accuracy and speed. The range of work that such devices can perform includes a huge list of operations and processes that are in demand in the most high-tech and responsible industries. Contemporary software for machining centers are produced by large global companies. The work of machining centers will be discussed in detail in a separate article.

Desktop CNC

A separate category is made up of types of milling machines equipped with CNC (computer numerical control). Such equipment belongs to the category of professional, its operation is controlled by special controllers that must be connected to a computer device. Like other types of milling machines, CNC models can perform various technological operations on metal: drilling, countersinking, boring, etc.

Widely versatile

Having at your disposal such a machine, you can perform any kind of milling operations with almost any material. If we compare a horizontal milling machine and a universal type machine, then its main difference is that its design provides for an additional spindle head, which is mounted on a special movable trunk and can be rotated at any angle with respect to the workpiece.

Conveniently, both spindles of such a machine can process parts both jointly and offline. Another overhead milling head can also be installed on the swivel head, with which you can process metal parts of an even more complex configuration - drilling, boring, countersinking, and so on.

There are also models of wide-purpose machines that do not have a console panel in their design. Instead, a carriage is installed that moves along vertical guides. On the vertical slide of this carriage, various devices can be used (for example, a dividing table). Such machines are somewhat cheaper, but are also capable of performing a fairly large list of technological tasks.

When choosing a milling machine, first of all, you need to decide what it is for. This approach to choosing equipment will give you the opportunity to purchase it in full accordance with your needs, and also not to overpay for features that you will never need.

The principle of operation of milling machines

Almost all milling machines work on the same principle. Differences can only be in their functionality.

The main structural elements of such machines are: a supporting frame, a work table, clamping elements, a collet and a collet chuck in which a working tool is fixed, a portal with a spindle fixed on it, which can move, a drive motor.

The working tool of any milling machine is a cutter, the design and dimensions of which depend on the configuration of the part to be processed. The working tool is fixed in the collet chuck with the help of a shank, and the rotation is transmitted to it from the drive motor through the gear system. The main purpose of the cutter is to remove an excess layer of metal from the workpiece, which, in fact, is the essence of processing on such a machine.

The machine spindle is located on a movable portal, the movements of which are controlled by special controllers, if we are talking about CNC equipment. Electronic system such equipment includes CNC controllers (numerical program control), auxiliary elements of the system and connecting parts. The principle of operation of CNC machine models is as follows: a special program reads the drawings of the part to be obtained as a result of processing, generates electronic commands that are transmitted to the working body of the machine.

Special attention should be paid to universal machines, which are a hybrid of horizontal and vertical models. Their design also has a collet, collet chuck and clamps, but the gearbox of such machines transmits all movements from one electric motor. Their distinctive feature is the presence of a manual mode, with which you can control the operation of the running block.

Example of a kinematic diagram (cantilever milling machine)

Additional elements have five-coordinate and engraving equipment in their design. Such equipment is equipped with additional clamping elements that allow you to install an engraver on it. The tool of such equipment rotates due to the cardan shaft, with which it is directly connected to the electric motor.

The simplest in design are manual milling machines for metal. Such equipment has low power, and its design consists of a collet with a collet chuck, a rotor, a drive head and an electric motor. Naturally, functionality such a machine is also limited: it can be used to perform only the most simple milling operations.

The resource of work, which the machine of the milling group of a manual type has, is also low and amounts to no more than 10,000 hours. The weakest components in such equipment, which are the first to fail, are the collet and collet chuck, clamps, attachment and spindle. But its low reliability and durability is fully compensated by the low cost. It makes sense to acquire it if you plan to use it irregularly.

Machine cost

The classification of milling machines according to their cost is quite extensive. Naturally, the cheapest models on this list are models from Chinese manufacturers. You can save even more on the purchase of such equipment if you buy it not through intermediaries, but directly from manufacturers. What is convenient, manufacturers from China offer both the simplest manual machines and professional ones equipped with CNC. If we consider the minimum range of prices, then it varies between 7000-35000 rubles.

Chinese desktop drilling and milling machine Triod MMS-20E (cost about 60 thousand rubles)

It will cost you dearly enough vertical machine, the cost of such equipment starts from 20,000 rubles. Moreover, at this price you will purchase a machine with the simplest configuration: collet and collet chuck, clamps, attachment, spindle.

If you are considering purchasing for your manufacturing enterprise wide universal machine, then get ready for the fact that the price of such equipment starts from 250,000 rubles. Milling machines for metal work, which are equipped with CNC, cost starting from 2 million rubles.

In any case, if you set a goal, you can purchase a high-quality milling machine for metal of a serial model at a very attractive cost.

A good option to save money on purchasing a milling machine is to purchase a used model. By the way, high-quality equipment of serial models (for example, TV-3 or TV-6) can be purchased at a cost starting from 20,000 rubles. Such a low price is explained by the fact that industrial enterprises, updating their technical base, sell old machines at a price corresponding to 20-30% of the original cost.

Milling machines are a type of equipment used to process various materials by milling. It is used to perform operations such as:

• cutting material;
• cutting grooves, grooves;
• production of gears and gear wheels;
• and other operations that basically require the removal of the source material from the surface of the workpiece.

A striking example of a part made by milling, as mentioned above, is a gear.

When processing a workpiece on a milling machine, the working tool (milling cutter) is rotated, which distinguishes it from a lathe in which the part rotates. A metal milling machine is equipment that allows you to process workpieces from various types of metals and alloys, which is difficult to replace. From Promo you can buy milling machines to work with any size of workpieces: from small-sized milling machines to machines for processing large-sized parts. Any size: from a small machine for home and individual use to large-sized routers for small-scale production.

Vertical milling machine for metal

The most popular in its class is the vertical milling machine. It is called vertical due to the location of the spindle. The salient features of this type of equipment are:

• the possibility of processing any metals and alloys. Naturally, it is necessary to take into account the strength of the cutting tool.
• standard design, facilitating the repair and maintenance of equipment;
• due to a relatively simple design, brought to perfection during use, high reliability and unpretentiousness;
• a wide range of types of processing: boring, drilling, milling. At the same time, after the introduction of the rotary head, it became possible to manufacture parts with an inclination of up to 45 degrees relative to the plane of the table.

Vertical milling machines for metal can be without a console (consoleless) and with it (console milling). The latter are characterized by the presence of a console on which the table is located, moving horizontally and vertically, as well as allowing the workpiece to be rotated relative to the processing plane. To ensure high precision and processing speed in mass production, CNC vertical milling machines are provided.

Universal milling machine

Universal milling machines are a development of vertical milling machines. They differ in that they are equipped with a rotary table that allows you to set the workpiece at the required angle to the tool. At the same time, there are its varieties: a universal vertical milling machine and a universal cantilever milling machine. You can buy a universal milling machine for metal at Proma.

The presence of an additional head, in which another cutter is fixed, is a sign of a wide-purpose milling machine. At the same time, it can be used both simultaneously with the main one, and separately from it. Such machines are indispensable in the manufacture of parts of complex shape. Some types of such equipment do not have a cantilever panel: instead, there is a movable column on which the carriage is movably fixed.

The Promo company delivers machines to any region. New machines have a 12 month warranty.

In these specialized metalworking machines, there is no console, and the table moves along the guides of the foundation frame. This design provides high rigidity of the machine and, consequently, high machining accuracy (compared to other types of machines), which makes it possible to process parts of large mass and size. The spindle head is at the same time a gearbox, and has an installation movement along the vertical guides of the rack. In the axial direction, the spindle can also be shifted together with the sleeve.

Equipment characteristics

Manufacturers produce equipment of various sizes, capacities 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
• Desktop dimensions, mm
• Table movement along the X/Y/Z axis, mm
• Table rotation range, hail
• Maximum drilling diameter, mm
• Maximum end mill diameter, mm
• Maximum end mill diameter, mm
• Spindle distance, mm
• Spindle stroke, mm
• Spindle speed, rpm
• Spindle taper, ISO (DIN)
• Machine dimensions, mm
• Weight, kg

Machine control can be:

• manual;
• automatic;
• with CNC.

There are also two types of vertical milling machines for metal:

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


• vertical milling non-console metal machine is designed for processing vertical inclined surfaces, grooves in large-sized parts. In these machines there is no console, and the sled and table move along the guides of the bed, installed on the foundation. This design of the machine provides its higher rigidity and processing accuracy compared to cantilever type machines, 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 shifted in the axial direction with the exact setting of the cutter to the required size.

CNC vertical milling machines for metal are distinguished by the vertical position of the spindle, which moves up and down. They allow to carry out a complex of operations for roughing, semi-finishing and finishing of metals, wood and other materials. With their help, you can easily produce parts of various shapes in small, medium and large series.

The CNC vertical milling machine consists of a movable cross part, a vertically moving headstock and a stationary column.

Some models are distinguished by the fact that they have a console that provides movement of the cross table from top to bottom. By the direction of movement of the shaft and the console, you can determine the types of cutters used and the specialization of the machine as a whole. Additional equipment of milling and processing centers with rotary tables with the addition of 1-2 controlled axes is done in order to expand the technological capabilities of this equipment.

CNC vertical milling machines for metal are of great interest for medium and large production shops, because they allow in the shortest possible time to process the surfaces of large quantities of products of a sufficiently complex profile. A vertical milling machine with DRO makes it possible to sharpen, drill, countersink horizontal and vertical surfaces of parts, among which are:

• gears;
• molds of different sizes;
• stamped blanks; spiral figures;
• corners and grooves of various sizes.

Taps and cutters are used for threading. The presence of a system for quick automatic tool change allows you to consistently perform all kinds of transitions on the vertical milling center. The necessary tooling is located in the drum or chain magazine, as well as in the turret.

CNC vertical milling machine for metal: advantages

CNC control allows you to simplify and speed up operations associated with the processing of complex parts. From the operator of a vertical milling machine with DRO, you only need to select and configure the necessary program, set the processing coordinates, and the main process will be done by the machine. Only minor intervention is required to set up the workpiece and control the processes.

CNC vertical milling machines for metal are widely used in many Moscow and Russian machine-building industries.

In the event of malfunctions due to accidents, manual control can be carried out. For the manufacture of stationary parts and tables of the machine, cast iron of the highest degree of rigidity and resistance to vibration is used. In this case, the workpiece is fed into the cutting area automatically.

The 6t12 machine is a unit for performing vertical milling work, which has been produced on the territory of the Gorky Combine since the mid-80s of the last century. The design of the 6t12 machine strongly resembles the products of the P line, but the main difference lies in greater uniformity.

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.

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

The spindle bearings 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 contributes to the performance of power cutting with high quality processing. If stock lubrication is used and the structural elements themselves are at the correct tension, bearing life will be longer than the amount of time before overhaul. To determine the class of bearings, you must familiarize yourself with the technical data sheet.

In the screw pair, the backlash is eliminated with the help of a specially provided movable nut, which is included in the axial clearance control mechanism. Bimetallic materials are used in the production of all running nuts. Parts subject to more accelerated wear at friction points are produced using steel with a surface HDTV hardening. Gears are strengthened in exactly the same way of heat treatment. As a result, the equipment works for a long period of time without the need for after-sales service. And when the time comes to do it, the cost of spare parts will be minimal.

The composition of a centralized efficient lubrication system includes two groups. The first includes lubrication for the mechanisms in the console, and the second - the oil supply system for the mechanisms that are located in the bed. Each of them, respectively, provides separate meals from its own plunger-type pump.

If the machine 6t12 1 is used every day in two shifts, the overhaul cycle will be at least 11 years. But to achieve such indicators is possible only on the condition that the user complies with the operational requirements and mainly mills steel.

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

Achieving additional time savings becomes 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 model of equipment are the following: constituent parts:

• a device for slowing down the feed rate (the machine uses a proportional scheme);
• a mechanism to protect the operator and others from getting metal chips;
• an electromagnetic type clutch that effectively brakes the spindle assembly in a horizontal plane;
• clutch to protect the electric motor of the main feed from overload;
• a device that allows you to adjust the gap in the screw pair (when performing feed 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 the metal workpiece.

Location of components

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

1. Coolant pump start system.
2. The system controls the direction in which the spindle rotates - right or left.
3. Electric motor for table drive.
4. Limb, the surface of which has a scale indicating the amount of feed.
5. Mushroom for switching feed.
6. Handle for moving the table in manual mode and vertical direction.
7. A handle holding the sled against the console.
8. A handle designed to control the operation of the longitudinal stroke of the table.
9. Electric motor for spindle drive.
10. Duplicate handle, including the longitudinal course of the table.
11. Flywheel for moving the table in manual mode and in the transverse direction.
12. Cams for turning off the system of longitudinal feed of the table in automatic mode.
13. Crane for supplying coolant.
14. Trigger keypad mounted on the front of the sled.
15. Duplicate handle for engaging vertical or transverse gear.
16. Switch for the workspace lighting system.
17. Switch for the whole machine.
18. Handle for selecting the spindle speed.
19. Limb, the scale of which indicates the number of revolutions.
20. Pointer for gearbox.
21. Start button panel on the spindle box.
22. Cams that automatically turn off the vertical feed of the table.
23. Cams that automatically turn off the cross feed of the table.
24. Handle, including vertical and transverse table feed.

Location of controls

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

How is the rotary head of the machine?

The image above shows the current drawing of the rotary head, which is used in the 6T12 machine. It is centered in an annular groove located in the neck of the bed, fixed with 4 bolts that enter into a 1-different groove of the bed flange.

The spindle consists of a two-bearing shaft, which is integrated into the sliding sleeve. The adjustment of axial play is reduced 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, 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 bevel wheels that are mounted in the head. The gears and bearings mounted in the swivel head are lubricated by a pump in the frame. bearings responsible for correct work the mechanism of sleeve movement and spindle rotation - by injection method.

Kinematic scheme

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 by means of a flexible coupling. The number of revolutions can be changed by moving three gear blocks along special splined shafts.

The feeds are driven by a flanged electric motor mounted in the console. Thanks to two three-ring blocks and a moving gear wheel, 18 different feeds are available, which are transmitted to the console via a ball safety clutch.

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

Wiring diagram

A scan of the drawing of the electrical circuit is given in the figure above. The equipment is optimized for operation in a three-phase network with a voltage of 380 volts with alternating current with a frequency of 50 Hz. The control circuit operates under a voltage of 110 volts with alternating current. In the 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 the efficiency of operation, each machine is equipped with a set of auxiliary circuits - bearings, slings, lubrication, kinematics, and so on. The rest of the guide includes electrical equipment. Here is a schematic diagram of the connection of electrical appliances, as well as a set of specifications for the selection of spare parts.

On the basis of 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

As part of the work, it is necessary to adhere to general requirements safety technology. Each specialist must check the following working bodies:

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

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