Capabilities of milling cutters: Which set best represents what can be performed on a milling machine using appropriate cutters and setups?

Difficulty: Easy

Correct Answer: All of these (keyways, external threads by thread milling, and spur gear teeth)

Explanation:


Introduction / Context:
Milling machines are versatile. With the correct cutters, arbors, and indexing/gear trains or CNC interpolation, they can produce a wide range of features beyond simple slots and faces.



Given Data / Assumptions:

  • Availability of standard and form cutters (end mills, side-and-face, woodruff, involute gear cutters).
  • Thread milling possible using single-form cutters or multi-tooth thread mills with synchronized motion.
  • Dividing head (indexing) or CNC control for gear cutting and helical threads.


Concept / Approach:
Keyways are cut with end mills or woodruff cutters; external threads can be milled helically; spur gears are cut with involute gear cutters using indexing. The same platform supports complex profiles by coordinated toolpaths.



Step-by-Step Solution:

Keyways: center cutting end mill to required width and depth; maintain alignment.External thread milling: synchronize feed to create the helix lead; choose appropriate pitch-form tool.Spur gear cutting: mount dividing head; select involute cutter matching module/DP and tooth number.Verify dimensions with gauges and micrometers.


Verification / Alternative check:
Finished parts are checked using keyway gauges, thread plug/ring gauges, and gear tooth verniers or span measurements confirming feasibility on milling machines.



Why Other Options Are Wrong:
Each single-operation choice understates milling capability; claiming none is incorrect because all listed operations are routine with proper setup.



Common Pitfalls:
Poor fixturing or ignoring indexing accuracy during gear cutting; neglecting cutter selection per module or pitch.



Final Answer:
All of these (keyways, external threads by thread milling, and spur gear teeth)

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