Together
to success
since 1997
INTECH GmbH
We are interested in cooperation with the manufacturers of milling machines, who are looking for an official and reliable distributor to supply their equipment to the industrial plants in Russia.
The company’s top management and sales team are well acquainted with the Russian market, its mentality and laws; they also understand industrial specifics of the financial and economic activities of the Russian customers. All our sales managers have a large customer database, extensive experience of successful sales and well-established connections with the potential buyers of your millers. This allows our managers to promptly set out the most promising directions for promotion and to ensure a rapid entry of the products into the promising Russian market. Our employees, who are fluent in English and German, are focused on working at the international market with the supplies of foreign equipment.
Our team of experienced engineers, who can handle the most serious technical problems, constantly keeps in touch with the Russian customers, holds meetings and delivers presentations regarding the latest achievements of our manufacturing partners. They point out the engineering challenges and actively communicate with all the departments at Russian plants. That is why the specifics of doing a business in the Russian Federation are well-known to us, and we also know the equipment of the local industrial plants and their up-to-date modernization needs.
Once we become your authorized representative in Russia, our marketing staff will carry out a market research in order to check the demand for milling machines, will submit a market overview for milling machines that you offer and evaluate the needs for this type of equipment at local plants. Our specialists will also estimate the potential and capacity of this market at local industrial plants. Our IT-team will start developing a website for your products in Russian. Our experts will assess the conformity between your milling machines and customer needs as well as analyze the common reaction to the new goods in general. We will look into the categories of potential customers, and pick out the largest and the most promising plants.
Upon becoming your authorized agent on the territory of Russia, ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will obtain certificates, if required, for a batch of the goods, for various types of milling machines in compliance with Russian standards. We can also arrange the inspection in order to obtain TR TS 010 and TR TS 012 Certificates. These certificates provides permission to operate your equipment at all industrial plants of the EAEU countries (Russia, Kazakhstan, Belarus, Armenia, Kyrgyzstan), including the hazardous industrial facilities. Our company is eager to assist in issuing Technical Passports for millers as per Russian and other EAEU countries’ requirements.
Our engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), collaborates with several Russian design institutes in various industrial segments, which allows us to conduct preliminary design as well as subsequent design works according to the standards, construction rules and regulations that are applicable in Russia and other CIS countries. It also enables us to include your milling machines into the future projects.
The Company has its own logistics department that can provide packing service, handling as well as the most efficient and cost effective mode of transportation of the goods (incl. over dimensional and overweight goods). The goods can be delivered on DAP or DDP-customer’s warehouse basis in full compliance with all the relevant regulations and requirements that are applicable on the Russian market..
Our company has its own certified specialists who will carry out installation supervision and commissioning of the delivered equipment, as well as further guarantee and post-guarantee maintenance of milling machines. They will also provide necessary training and guidance for the customer’s personnel.
Milling is a Machining operation, associated with surface machining using milling cutters.
Generally, during milling, a milling cutter rotates, while feeding is performed straightforwardly and perpendicularly in relation to the milling cutter, i.e. to its rotation axis. A billet is fixed on the milling-machine table using a jaw plate.
Functions of milling cutters differ from those of multiple blade tools available at drilling machines.
Due to perpendicular feed relative to the rotation axis of a milling cutter, each tooth of the milling cutter contacts the work piece being machined but, at the same time, it rotates only partially. Several milling cutter teeth work simultaneously, although only one tooth may work as well. A milling cutter has a lot of teeth and each of them works a short period of time. During the main part of its rotation, the milling cutter is cooled down, which ensures, in its turn, a very long service life of the milling cutter and efficiency of milling.
Geometrical structure of each cutting tooth is similar to the view of a cutting tool. However, milling has its own specific feature: the nature of how the milling cutter teeth contact the work piece surface is discontinuous. This has a positive effect on the process in terms of reducing of heat impact, generated during milling, on the milling cutter edge and causes not so calm and smooth process as during turning.
According to the tooth shape, milling cutters are divided into:
Milling cutters of the first type have the tooth profile which is made up of straight lines, the teeth are sharpened on the back side, and the form-relieved teeth of the milling cutters, on the contrary, are sharpened on the front face. When regrinding, a tooth profile of a profile-relieved milling cutter remains, which is a great advantage as compared to profile-relieved milling cutters which are used for milling at high speeds and therefore are made of hard alloys.
For machining of surface by milling, cylindrical milling cutters are applied when a machine table moves toward the milling cutter (opposed milling) or moves in the same direction (climb milling). Comma-shaped chips, are removed by each milling cutter tooth during these methods. In conventional milling, the chip thickness gradually increases, while on the contrary, in climb milling, it decreases during cutting. Conventional milling facilitates a smooth increase in the load on the tooth, which is an advantage. However, the disadvantage of this method is that a milling cutter attempts to pull the work piece from the table. During climb milling it is vice versa, therefore, the choice of the method depends on the specific operational conditions.
Parameters during milling
Cutting speed is a peripheral speed of a milling cutter rotation.
V = πD·n/1000, m/min,
Where D is a diameter of a milling cutter, mm,
n is a number of rotations, made by a milling cutter/min
Feed is a movement of a work piece being machined along the milling cutter axis per time unit.
Sm = Sz·z·n, mm/min,
Where z is a number of milling cutter teeth,
n is a number of rotations made by a milling cutter/min
Cutting depth is a metal layer removed by a milling cutter for 1 passage;
Milling width is a length of the surface contacting with a milling cutter in a direction perpendicular to feeding.
Chip thickness is a quantity of metal removed by each milling cutter tooth.
During cutting, a certain force impacts on each milling cutter tooth, the direction and magnitude of which vary depending on the nature of milling and feed direction. During end milling using milling cutters, in case of opposed feeding, cutting force P applied on the milling cutter tooth can be divided into two components: tangential Pz and radial Py. By radial force Py, mandrel containing a milling cutter is analyzed for bending. The total value Pz is determined as the sum of forces acting on the teeth:
Pzsum = Pz1 + Pz2 + Pz3kG
Torque for milling:
M = Pz·D/2 kG mm,
where D is the diameter of a milling cutter,
Power for milling:
N = M·n/974000 kW,
Where M is a torque value,
n is a number of rotations made by a milling cutter/min
A milling cutter is a milling machine tool designed for cutting and having several teeth. A tooth is neither more nor less than a cutter for chip removal.
Cutting in milling operations differ, however, from cutting process using a turning or a drilling machine. As we mentioned above, the teeth of a milling cutter are involved in cutting not all simultaneously but alternately. This increases the lifetime of a milling cutter and improves milling efficiency.
The figure below shows a variety of milling cutters, which vary according to different characteristics and features:
According to their design, milling cutters can be:
1. One-piece milling cutters are items 1, 2, 4 and 7 in the figure. They are a single piece of high quality material suitable for the manufacture of milling cutters and other cutting tools.
2. Brazed milling cutters are generally made of inexpensive structural steel. A piece of soldered plate made of high-quality metal is welded on the upper part of the tooth or a cutter.
3. A splicing milling cutter is item 3 in the Figure. It is a round case of alloy structural steel, where teeth are inserted and fixed with wedge or pin of conical shape. To sharpen, a splicing milling cutter is not disassembled and is machined in an assembled condition.
4. A milling head is item 15 in the Figure. The head is equipped with quick-change teeth, conventional cutters. To sharpen, one should not disassemble a milling head to process it in an assembled condition or it is possible to sharpen the teeth separately and then fix them in the case.
Depending on the type of fastening, the following types of milling cutters are distinguished:
Shaft-mounted cutters are items 1, 3, 4 and 7 in our figure, these are the cutters with a hole and a keyway, they are fixed directly on the spindle arbor.
Shank cutters, items 6 and 9, are a continuation of the rear portion (cylindrical or conical) and make a solid part together with a shank part.
Endmills, item 15, are fixed on the shaft end using bolts.
According to the scope of application, milling cutters are divided into the following main types:
The figure below shows the number of operations carried out using various types of milling cutters in the milling process.
Cylinder-type and end milling cutters, items 1 and 2 in figure 3, serve to mill plains. Application of disc, end, grooving and angular cutters, item 3 in the figure, is to create grooves and slots on a work piece being machined. Item 4 presents shaped cutters used to process shaped surfaces. Disc and involute end mills, items 5 and 6, cut teeth on gear wheels.
Main types of milling machines:
1) general-purpose machines: horizontal milling machines, multi-operated and vertical milling machines.
2) single-purpose machines and special.
Horizontal milling machines are equipped with base, where a knee with rails rides vertically. Along these rails, in their turn, transverse slides move parallel to spindle axis. A table with a gear box and a feed box moves in the direction perpendicular to the spindle axis.
Milling cutters are fixed in a mandrel. Shank cutters are inserted into the spindle and centered by tapered seat.
The table of a multi-operated milling machine, as opposed to the horizontal milling machine, can be swung in a horizontal plane by 45 degrees. So that the feed direction of the table can be changed in relation to the spindle axis 45 to 90 degrees, which is required for milling spiral.
At vertical milling machines, the spindle is vertical; otherwise they are the same as at horizontal milling machines.
Tables of peripheral milling machines can move only in the horizontal plane, perpendicular to vertical or horizontal spindle axes, thus providing for machining of parts at different sides at the same time. Machining is performed by milling cutters contacting with the spindles. The table does not slide or move in transverse direction and instruments are set using extending of spindles along their axes and movement of spindle headstocks along the guides.
Rotary-table milling machines used for continuous Machining of flat surfaces have large-diameter round tables, and the work pieces are removed while the table keeps on rotating.
Application of drum-type milling machines is the same as of the turret-type machines. The difference is that a drum-type milling machine processes parallel planes simultaneously from both sides. Within the base of the machine, the drum rotates, where work pieces to be machined are put and finished work pieces are removed. Milling cutters are in the headstocks, each pair of milling cutters makes consistently rough first, then finish milling. These machines have good rigidity and high performance.
Special milling machines process mostly large parts in mass production.
One of the types of universal instruments includes a milling machine. This is a machine with a cutting tool, called a milling cutter, with a variety of blades. The main movement of a milling cutter is its rotation. A milling cutter is mounted on a vertical shaft. However, the shaft can be set in a different way, so that it faces the billet at an angle. The machine table can be fed manually or by a drive, however, a mechanical one. At the same time, control on scales having optical zoom system is maintained quite precisely.
The milling machine shaft, or, as commonly called, the spindle, where a milling cutter is set, is horizontal. The work piece to be machined is fixed on the table. The table, in turn, is the simplest, moving along 3 axes. There are also universal tables. Those are able to turn at an angle.
Modern engineering allows to machine work pieces with complex surface profile: it may be the surface of dies, molds, where shaping is important, etc.
To get work pieces with such surfaces, such types of treatments as molding, punching, cutting are used. But only cutting allows obtaining surface parameters that are close to the target value (set point), and allows reducing the time for post-Machining. Mostly, milling is the only possible method to perform this type of treatment, as many engineering factories and plants have switched to a full-scale and small-scale production. And in the production of this kind to process details by milling is considered cost-effective.
The process of surface machining with a complex profile is based on the following operations:
1) blanking
2) milling
3) finishing.
Finishing is done manually. The complexity of this operation and labor costs for it are determined by the final surface parameters that take place after milling. If a high roughness class is provided at the stage of milling operation, it is possible to reduce the time allotted for finishing. Because finishing is the most time-consuming stage in the machining process.
Machining on milling machines can be applied to various forms of surface. It is both external and internal plane. One can process:
To process the last, special types of milling machines are used, as it is a work with complex spatial planes. Following lathes, milling machines take one of the leading positions on their popularity, since they are highly productive and quite versatile.
Types of milling machines:
Knee-type milling machines can be vertical, horizontal, universal and universal ones. The machine of this type is very popular. Availability of a knee distinguishes it from other types of machines. The knee moves along the guides on the base, the knee is rigidly fixed to the housing of the machine, and slides located above, move knee in the transverse direction. In contrast to the spindle, which practically does not move, a table moves in this type of machine. The billet is fixed on the table, with which it moves, making both perpendicular and angle motion relative to the spindle axis.
Milling Machining is connected with operations at details with different flatness and surfaces on milling machines. This operation is directly related to:
On universal milling machines, flat and shaped surfaces (internal and external), grooves, ledges, rotation bodies, holes, threaded joints, teeth gears are machined. This type of machines is widely used in maintenance departments, locksmith and carpentry shops and studios, is equipped with a digital measuring device in three axes: vertical of knee feed in an accelerated mode, table feed in both directions at an accelerated rate. These machines are equipped with working lights and cooling system.
Operations: drilling, milling, thread cutting, and etc.
Horizontal machining center equipped CNC belongs to a heavy series of this type of structure and designed for the following types of Machining: roughing, finishing and final. Working in difficult operational conditions of machining process of large-scale box-like work pieces with a complex structure made of cast iron, construction stainless heat-resistant steel and alloys, the center ensures high rigidity and resistance to vibrations.
Hydrodynamic guides guarantee the safety of the machine precision parameters, as well as the ability to cut hard materials.
Dimensions of machining table: 630х630 mm;
Movements along the axes X/Y/Z: 900/800/710 mm;
Spindle of rotation rate: 4500 rpm. (910 Nm - 1080 Nm);
Number of tools: 60;
CNC system;
Scope of work that can be performed on milling machines, is very diverse and large. These are procedures for milling planes, slots and grooves, shaped surfaces, revolution surfaces, thread cutting, gear teeth, and others.
Types of operation on milling machines and tools used:
1. Machining of plane by cylindrical milling cutter with helical teeth
2. Machining of plane by end mill with inserted teeth
3. Machining of side plane by disc cutter
4. Machining of two sides of open slot by two-way circular groove cutter
5. Milling of groove by disc side milling cutter
6. Milling of two sides of open slot by end mill
7. Milling of groove by end mill
8. Milling of ledge sides by set of two double-sided disc cutters
9. Milling of semicircular groove by semicircular shaped cutter
10. Milling of complex profile by ready-made kit of various types of mills.
Among the available tools for milling machines, there are universal, normalized, and special tools. They are divided, in turn, to single and shared tools, which include fixed, mobile and swivel for continuous milling.
Known to all of us dividing heads, machine vise, rotary tables, angular tables, rotary tables are universal milling fixtures.
Machine vise are usually supplied with conventional hand screw clamp (eccentric or pneumatic) for the installation of the work piece.
Pneumatic vises with rubber diaphragm are most commonly used. The billet is clamped between the jaws. At air supply to vise chamber the diaphragm moves with disc and stem, the stem makes the crank shaft rotate, and the billet is fixed with a force of 900 kg under air pressure of 4 atm.
Indexing heads change the work piece position angle with respect to the cutter and are divided into simple, universal, and optical ones. There are three methods of dividing with indexing heads: direct, simple and differential methods. The direct method is to simply turn head spindle (indexing) at a predetermined angle. For this purpose, simple and universal heads are suitable.
Areas of use for universal indexing heads are very diverse:
1. for rotating the billet from time to time at certain predetermined angles
2. for continuous rotation of the billet during spiral milling
3. to impart a predetermined angular position to a billet to be machined of predetermined angular position relative to the table plane of the machine.
If it is required to observe the exact rotation of the billet to the desired angle (margin of error max. 0.25 "), optical indexing heads are used, fitted with a limb. The limb scale is observed through the eyepiece of optical system inside the indexing head.
If necessary to rotate the billet in a horizontal plane universal rotary tables can be used. Such tables are fed manually or mechanically.
To place the work piece at a certain angle to the table plane of the milling machine, angular tables are given priority.
Rotary tables are selected for positional machining.
Knee-type milling machine
Kneeless-type milling machines are divided into:
Kneeless-type milling machines of vertical type serve to perform operations on the work piece of a fairly large size. Milling is performed at high speed in the automatic control loop. Automatic cycle provides:
On modern kneeless-type milling machines, a milling cutter is automatically removed from the surface of the work piece for the purpose of its protection. Milling is carried out at high speed on these machines, what makes their greatest value. The machine processes box-like work pieces with great machining allowances. The table does not move vertically, it moves only crosswise and longitudinally. The spindle headstock moves vertically. Spindle itself stands upright and has a large number of rotations to 1250 rpm, so that milling takes place at very high speed.
CNC-controlled milling machines are machines with an automatic control system. Automatics move the table and control the spindle speed. Sometimes, a spindle is arranged on a carriage or slide, which promotes for its movement in the axial direction and vertically. CNC-controlled machines of this type serially process work pieces with high-precision surface processing in three-dimensional space. For example, components for aviation and energy industries such as the propeller for aircrafts and helicopters, turbine blades and large industrial fans.
Speaking of copying milling machineы, once a thought arises about copying, creating a copy or reproduction of something, repeating the same script. Therefore, copying milling machineы provide for non-planar surfaces on details, machining curved surfaces of the matrix, punches used later for stamping work pieces from sheet steel. Thus obtained form is as if copied predetermined pattern, becoming similar to it. When machining the cutter shifts the template pattern to the billet.
If to install an automatic changer of the cutting tool on CNC milling machine, the machine will perform the functions of the machining center, making the variety of machining operations in automatic mode.
Numerical control contributes to the implementation of complex technological processes for work piece machining in automatic mode. Actions of the operator are not necessary in the process. Programs for different machining operations are loaded in the control system. The machining program is selected before the start of the process. The program is selected by the operator from a control station. From this post, the operator can operate the machine in manual mode and turn off the machine in case of emergency. The visual system displays all actions performed by the machine; the operator monitors the implementation of operations on the display.
CNC-controlled milling machine processes work pieces made of cast iron, steel and alloys of light metals. This equipment processes box-like work pieces with full operation complex in 3 coordinates (X, Y, Z) in the basic version of the machine, and in four or five coordinates - in optional version of the CNC machine, engineered in the context of the latest global technology needed for small-scale and individual production.
Machines equipped with CNC system, graphic display, which ensures high-precision performance of the commands. Servos, equipped with digital control, ensure accurate and rapid movement on three axes.
Perfect technical characteristics allow the machine to implement a lot of operations at one setting up: milling, boring, drilling, thread cutting. Table and slide equipment, made of special high-strength cast iron having a high rigidity and vibration resistance as well as the powerful design of the spindle and the automated system of coolant to the cutting area contribute to growth of machine high popularity.
Vertical milling machine can produce a variety of milling operations with different types of milling cutters.
Vertical milling machines are designed to perform operations of drilling, counterboring and reaming of holes, machining of horizontal and vertical planes, slotting and grooving, cutting frames, corners, gear teeth and so forth.
The machine can process steel, iron surfaces, process details of alloys, non-ferrous metals, plastics, etc. During machining, a milling cutter starts to rotate with the spindle, making rotational movements. The billet to be machined also moves. This straight- or curved movement is called milling. A work piece or a billet is fixed on the machine by the grip, machine vise.
A vertical knee-type milling machine has a spindle mounted vertically.
Vertical kneeless-type milling machines process vertical sloping surfaces. The base is mounted directly on the foundation. The carriage and the table ride along the base guides. This machine design ensures high rigidity of the machine; and rigidity ensures precision and the ability to work with dimensional billets.
Vertical milling machines are easy to use due to the rapid tool and device change.
In contrast to vertical milling machines, horizontal-type milling machines have a horizontal spindle. Horizontal milling machines can use almost all types of milling cutters.
To install a milling cutter, a mandrel is used with the length having proportional dependence on the width of the desktop.
In horizontal milling machines, feeding (in full) is perfumed through table movement. The table movement control can be either manual or mechanized. The work piece to be machined is fixed in the T-slots of the table. As a rule, the table moves in three directions. But in some cases vertical movement is provided not through the table movement but through the movement of the milling head.
Some horizontal-type milling machines have a table with a turning device which allows rotation of ± 45° upon the horizontal plane. This has an advantage: a billet may be fed at an angle to the shaft axis (spindle).
Milling machines of the above type are used to process vertical, horizontal, inclined surfaces, slots in larger detail. Typically, their case is made of cast iron and has a cast construction. The advantages of such rigid structure:
Like kneeless-type milling machines, these machines do not have a knee either. The base is mounted directly on the foundation. The carriage and the table ride along the base guides. This machine design ensures high rigidity of the machine; and rigidity ensures precision and the ability to work with dimensional billets and work pieces.
Vertical head of the vertical-horizontal milling machine has a U-turn at ± 45 degrees.
Control components are located on the local control panel. An opportunity to be in vicinity of the machine provides for additional convenience in control of the machine.
Horizontal and vertical milling machines belong to a superuniversal range of milling machines.
Upon becoming the official distributer of milling machines, our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), carries out the following: finds the buyers of your products on the market, conducts technical and commercial negotiations with the customers regarding the supplies of your equipment, concludes contracts. Should a bidding take place, we will collect and prepare all the documents required for the participation, conclude all the necessary contracts for the supply of your equipment, as well as register the goods (millers) and conduct customs clearance procedures. We will also register a certificate of transaction (Passport of Deal) required for all foreign trade contracts in the foreign currency control department of the authorized Russian bank so that currency transaction could be effected. If required, our company will implement an equipment spacing project in order to integrate your equipment into the existing or newly built production plant.
We are convinced that our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will become your reliable, qualified and efficient partner & distributor in Russia.
We are always open for cooperation, so let’s move forward together!
