MILLING PROCESS

Milling can be described as an end mill, (a tool similar to a drill bit) rotating into a piece of material to achieve a certain shape. For the purpose of this project imagine a train running around a track in a circle. The train represents the end mill and the inside of the circle would be your finished product. Your job is to calculate the starting and end points of this track using trigonometry, geometry and mathematics. These points are created using a Cartesian Coordinate system.

HINT: Your starting point is at "zero zero" on the print.

HINT: Keep in mind that the diameter of the end mill is .500, so your calculations will have to reflect this to maintain the correct dimensions of the part!

MILLING INSTRUCTIONS

After you complete your calculations, you will need to decide if you want a 2 or 4 flute end mill. Two flute end mills provide good chip carrying capacity. They are an excellent choice where the tool is buried in the work (price: $10.08 per half inch end mill). Four flute end mills last longer, provide finer finishes, and have higher metal removal rates than two flute end mills (price: $12.98 per half inch end mill). Please justify your decision.

HINT: This will not affect your "x" and "y" coordinates.

HINT: It does not matter what direction you go from the starting point!

For an advanced understanding of how a milling machine operates, imagine a pencil being held vertical in your hand over a piece of paper. This represents the end mill. With your other hand move the paper around in a circle. Theoretically, you can draw a circle without moving your pencil. In milling, the table moves to your x and y coordinates and your end mill stays in one spot. This is the basic operation of milling.