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
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!
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"
HINT: It does not matter what direction you go from the
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.