Gang milling is a machining process in which two or more milling cutters are mounted on the same arbor (shaft) and used to remove material from a workpiece.
The gang milling cutters are arranged in a manner that allows them to cut simultaneously, which increases productivity and reduces the time required for machining.
It reduces the number of setups required as multiple cuts can be made at once, rather than having to change out a single cutting tool for each operation.
This milling process is used when a large number of workpieces are to be milled and similar types of pieces are to be created.
This milling process is particularly useful in the production of gears, as it allows multiple teeth to be cut at the same time, which increases efficiency and reduces the number of setups required.
Gang milling is commonly used in the manufacturing of gears, dies, and other precision parts. It is particularly useful in the production of gears, as it allows multiple teeth to be cut at the same time, which increases efficiency and reduces the number of setups required.
This milling process is used to machine a wide range of materials, including metals, plastics, and wood. It is used in many industries, including aerospace, automotive, and medical device manufacturing.
Parts of Gang Milling:
The parts of a gang milling setup typically include:
1) Base: The base of the gang milling machine is a heavy-duty casting that supports all the other parts of the machine.
2) Table: The table is the flat, horizontal surface that supports the workpiece during milling.
3) Spindle: The spindle is the rotating shaft that drives the cutting tools. The spindle is connected to an arbor that holds the cutting tools.
4) Arbor: This is the tool holder that holds the multiple cutting tools in place.
5) Cutting Tools: The gang milling machine uses multiple cutting tools mounted on the same arbor to remove material from the workpiece.
Working of Gang Milling:
1) The process of gang milling starts with the selection of the appropriate milling cutters for the job.
2) The cutters are then mounted on the arbor, which is typically a cylindrical rod that is supported by bearings. The cutters are positioned at a specific angle and distance from one another to achieve the desired cut.
3) The arbor is inserted into the spindle of the milling machine, and the workpiece is clamped in place.
4) The machine’s spindle rotates the arbor, which in turn rotates the milling cutters.
5) The cutters are positioned so that they are able to remove material from the workpiece simultaneously.
6) The material is fed into the machine, and the cutters rotate at high speeds to remove material and create the desired shapes on the workpiece.
7) The speed of the spindle and the feed rate of the workpiece is adjusted to achieve the desired finish and accuracy.
8) The finished part is then removed from the machine and inspected to ensure that it meets the desired specifications.
Types Of Gang Milling Cutters:
There are 3 milling cutters on the number. Two sides and one plain milling cutter in the center.
Two types Of Milling Cutters are used in Gang Milling:
1) Plain milling cutter present in the center.
2) Side Milling cutters present on the sides of the plain milling cutter.
Different types of milling cutters are used depending on the job to be done.
Combination of a milling cutters that can be used:
i) Side milling cutter + Plain milling cutter
ii) Side milling cutter + Side milling cutter
Plain Milling Cutters are of three types:
1) Light-duty plain milling cutter
2) Fine helical teeth slab mill
3) Coarse helical teeth slab mill
Types of Five types of Side Milling Cutters:
1) Plain Side milling cutter
2) LH Half Side milling cutter –
3) RH Half Side milling cutter –
4) Staggered teeth side milling cutter:-
5) Interlocking side milling cutter:
Advantages of Gang Milling:
- Increased productivity: Gang milling allows for multiple cutting operations to be performed simultaneously, thus increasing the overall productivity of the machining process.
- Reduced set-up time: With gang milling, multiple cutting tools can be mounted on a single arbor, reducing the time and effort required to change tools between different operations.
- Improved surface finish: Gang milling allows for multiple cutting tools to work together, resulting in a smoother and more consistent surface finish on the final product.
- Enhanced precision: Gang milling allows for tight tolerances to be achieved as multiple cutting tools work together to achieve a more precise final product.
- Cost-effective: Gang milling can be more cost-effective than using multiple machines or individual tools to achieve the same results.
- Flexibility: Gang milling can accommodate a wide range of materials and workpiece shapes, making it a versatile option for many different types of manufacturing operations.
- Reduced labor costs: Gang milling can reduce the number of operators needed to perform multiple cutting operations, thus reducing labor costs.
- Increased tool life: Gang milling can help to extend the life of cutting tools by distributing the cutting forces across multiple on-one tools to do all the work.
Disadvantages of Gang Milling:
- Complex set-up: Gang milling requires a complex set-up process, including aligning and adjusting multiple cutting tools, which can be time-consuming and challenging.
- Higher maintenance costs: Gang milling requires more frequent maintenance and tool replacement, which can increase overall costs.
- Limited accessibility: Gang milling can be difficult to access certain areas of the workpiece, making it less suitable for certain types of jobs.
- Reduced precision: Gang milling can be less precise than using a single cutting tool, as the alignment and adjustment of multiple tools can be more challenging to achieve.
- Limited material thickness: Gang milling is typically limited to a maximum material thickness, making it less suitable for thicker materials.
- Increased vibration: Gang milling can produce more vibration than using a single cutting tool, which can lead to increased wear and tear on the machine and the workpiece.
- Limited cutting angle: Gang milling is typically limited to a specific cutting angle, making it less suitable for cutting at different angles.