Conventional Milling

Lesson outcomes
By the end of this lesson, students should be
able to understand:
The concept of milling and its different
types
Guidelines and troubleshooting for milling
operations
Types of milling machines and their
components

Milling - definition
Milling: a machining process whereby a
rotating cutting tool is fed against a
workpiece that can travel along various axes

Types of milling operations

Axis of cutter rotation is

plain milling=peripheral
perpendicular to workpiece
milling = slab milling
surface

Axis of cutter rotation

Relative motion between
parallel to workpiece surface cutter teeth and workpiece
leave feedmarks on
Cutter usually HSS

machined surface
Straight or helical teeth
Surface roughness
Helical teeth requires less
dependent on insert corner

cutting force and torque

geometry and feed per tooth
less vibration

Spindle axis: vertical

Versatile: can produce
profiles, curved
surfaces

Cutter is called an
endmill (HSS or
carbide inserts)
Ball nose mill, hollow
end mill

2 types of slab milling

Max chip thickness is at the end of the

cut
Contamination on surface doesnt
affect tool life
Smooth process if cutter is sharp

Max chip thickness at the beginning of

cut
Scale/oxidation on surface will damage
cutter

Tool may chatter

Workpiece clamped down by cutting

forces less clamping requirement

Workpiece may be pulled up clamp

properly

Not suitable for irregular surfaces

Recommendations for
milling parameters

High speed machining

Important in machining aerospace
components
Spindle speed 20,000-60,000 RPM
High stiffness & accuracy machines

Troubleshooting for
milling operations

Milling Machine Types

Column-and-knee type machines
Bed type milling machine

Column and knee milling machines

Horizontal spindle

Vertical spindle

Column and knee milling machine

components
Worktable: surface on which the workpiece is
mounted. Table moves longitudinally.
Saddle: Supports the table and can move in
transverse direction
Knee: Supports saddle and provides vertical
movement
Overarm: Adjustable to accommodate different
arbor lengths
Head: Contains the spindle and cutter holders

Bed type milling machine

Knee is replaced by a
bed
Bed can move
longitudinally
Worktable mounted on
bed
High stiffness
Used for high speed,
high production work

Other types of milling machines

CNC milling machines
Machining centers
Etc.

Workpieces are held using:

Plain vise
Universal Vise
Angle Plates
Rotary Table

Plain vise

Universal vise

Angle Plate

Rotary Table

Milling cutters are held

using:
Arbor
Collet
Toolholder

Arbor

Collet

Toolholder

Summary
Milling is a machining process whereby a rotating cutting tool is
fed against a workpiece that can travel along various axes
Different types of milling (slab milling, face milling, end
milling) are characterized by the cutters relative motion to the
workpiece, cutter type and machining output
Calculations for cutting speed, material removal rate, power,
torque and cutting times are important before performing any
milling operation
Components should be designed with machining limitations in
mind
Troubleshooting can be performed by identifying the appropriate
machining parameter to change and modifying it in the correct
amount
Column-and-knee-type are suitable for general purpose milling
while bed-type milling machines are more suitable for high
volume production work