INTRODUCTION

Milling is the machining process of using rotary cutters to remove

material from a workpiece by advancing (or feeding) in a direction
at an angle with the axis of the tool. It covers a wide variety of
different operations and machines, on scales from small individual
parts to large, heavy-duty gang milling operations. It is one of the
most commonly used processes in industry and machine shops
today for machining parts to precise sizes and shapes.
Milling can be done with a wide range of machine tools. The
original class of machine tools for milling was the milling machine
(often called a mill). After the advent of computer numerical
control (CNC), milling machines evolved into machining centers
(milling machines with automatic tool changers, tool magazines
or carousels, CNC control, coolant systems, and enclosures),
generally classified as vertical machining centers (VMCs) and
horizontal machining centers (HMCs). The integration of milling
into turning environments and of turning into milling
environments, begun with live tooling for lathes and the
occasional use of mills for turning operations, led to a new class of
machine tools, multitasking machines (MTMs), which are purposebuilt to provide for a default machining strategy of using any
combination of milling and turning within the same work
envelope.

Types of Milling Machines

There are several types of milling machines, but usually they are
classified by the orientation of their spindles, which are positioned
either horizontal or vertical. Each type of mill has its own
attributes depending on what type of work one is doing, so it is
essential to familiarize oneself with the differences between these
two before purchasing one for use.

Horizontal Milling
Horizontal milling machines have a spindle or cutters mounted on
a horizontal arbor above an X-Y table. Some horizontal mills have
a table, known as universal table, that features a rotary function
for machining at different angles. Horizontal mills are optimal for
machining heavier pieces because the cutters have support from
the arbor, as well as a bigger cross-section area than a vertical
mill. The design of the horizontal milling machine allows for the
rapid removal of material off of the piece one is machining. These
types of milling machines can range in size from something small
enough to fit on a tabletop to room-sized machines.

Vertical Milling
Vertical milling machines have a spindle that moves in a vertical
orientation over the table, working on the top and bottom sides of
the object being machined. Vertical milling machines lend
themselves to standing machinists and detailed work. These
machines tend to be taller than they are wide since their
operation is vertical, which works well when dealing with die
sinking. Die sinking is when a cavity of a particular size and shape
is machined into a steel block. The opening can then be used for

molding plastic or for forging, coining, or die-casting. Below are

the two types of vertical milling machines most commonly used.

Turret
Turret milling machines are classified as vertical milling machines
because the spindle is positioned vertically; it is considered a
versatile machine since it can create a wide selection of shapes.
Like a drill press, this milling machine features a quill that when
lowered or raised can create different cutting depths; the quill
works in conjunction with a part under the table called a "knee" to
machine a piece. The table on this machine moves both parallel
and perpendicular to allow the machinist to make easier cuts, but
this maneuverability can add stress on the table. Turret milling
machines also tend to be smaller since it is difficult to move a
quill on a larger machine.

Bed Mill
With bed milling machines, the table moves against the axis of
the spindle. This machine does not create as much flexibility in
shape cutting like a turret milling machine, but this type of
configuration is often used on larger machines.

Milling Machine Lubricants

Since machining solid materials, especially metal, can create a lot
of friction, it is extremely important for milling machines to be
properly lubricated. Lubricants help reduce friction and cool the
machine while it performs its intended functions, which prevents
failure and damage to the mill and the piece it is machining. Each

milling machine comes with a built-in lubrication system, but it is

up to the user to maintain the lubricant for it to function correctly.
Most mill manufacturers indicate what kind of lubricant to use, but
if one is unsure, it is a good idea to try and find a manual online
or ask a professional to make sure what the proper lubricant is
needed for the particular machine being used.

History of Milling Machines

The milling machine performs a variety of operations, so it has
numerous historical predecessors, from the drill to the lathe. The
first milling machines were developed to shape wood in the 19th
century, and as technology and the knowledge of metallurgy
advanced, these wood mills were modified to cut and shape
metal. These machines helped fuel the pace of the Industrial
Revolution, when precise machining became increasingly
important. Since so many machinists were making adjustments
and developments in their own shops, it is difficult to credit one
person with the invention of the mill. A mill of note, however, is
one built in the 1830s by James Nasmyth; his milling machine
could mill the six sides of a hex nut. Over time, milling machines
have become synonymous with industry and manufacturing.
Modern mills employ the use of computer numerical control (CNC)
for even more ease of use and precision.

OBJECTIVE:
1.To understand the function and feature provided by the indexing
milling machine.
2.To learn the tool and equipment needed while operating the
machine.
3.To understand the safety precaution when operate and handling
of indexing milling machine.
4. Introduction and working principle of milling machine,
5. Different type of milling operations,
6. Different type of milling machine and their main parts,
7. Specifications of milling machines

SAFETY RULES
1.Safety glasses worn at all times,by everyone in the shop.
2.No long sleeves,no gloves,no open toe shoes,and no jewelry or
watches.
3.Long hair must be secred behind your head.
4.Become thoroughly familiar with the machine before operating
it.
5.When in doubt,always ask a supervisor or shop manager.
6.Never use the mill (or any other equipment) when tired or
rushed for time.
7.Only attempt work that you have been approved to do and are
comfortable doing.
8.Get additional training,refresher courses and approval as
necessary. ASK FOR HELP.
9.Never reach anywhere over,around or near any rotating cutter.
10.Stop the machine every time the cutter is not cutting,not being
used , or you are changing tools/parts.

11.Only remove chips using gentle air blasts or chip brushes, be

aware of cutting tools.
12.Use a chip shield to keep chips from hitting you and other in
the area.
13.Keep ALL rags and tools away from the machine and off
machine table during use.
14.Be sure the holding device and workpiece are both securely
clamped.
15.Always make sure that the cutting tool is sharp,at the correct
height and has the proper clearance.
16.Do not be distracted or talk to other when operating the
machines.
17.Do not walk way from running machines.Turn them off every
time.

Conclusion
Milling machines are important for cutting and shaping wood and
metal, among other solid materials. These machines are an
invaluable resource for any business or individual seeking to
create precision pieces in a work or personal shop environment.
There are several different types of milling machines, but the two
main types are classified by the orientation of their spindle:
horizontal and vertical. Since milling machines are a big
investment, it is best to research which kind best fits one's budget
and needs before purchasing one particular kind of mill over
another. Milling machines can be purchased at machinery shops
or dealers. They can also be bought second hand and at reduced
prices from warehouse liquidation sales or previous owners,
although it is important to check the working condition of a used
mill before purchasing it. Mills can also be found online through
any authorized dealer or on auction sites like eBay. Milling
machines are an integral part of the industrial world, so owning

one can be a valuable asset to one's business or home workshop;

it is only a matter of finding the right mill for the right machining
job, and determining the right orientation is a step in the right
direction

WORKING PRINCIPLE OF MILLING MACHINE

Working of a milling machine is based on the fact that milling
cutter is fed against workpiece. This is achieved by developing
relative motion with precise control between workpiece and
rotating milling cutter. Feed motion is generally given to the
workpiece through its holding device. Cutting mechanism of the
workpiece in milling operations is Milling cutter work piece
Conventional Partial Face Milling End Milling Work piece Milling
cutter Work piece Feed direction Profile Milling work piece Milling
cutter Work piece Pocket Milling cutter Pocket Milling Milling cutter
Work piece same as that in turning operation on lathe. This
cutting takes place due to plastic deformation of metal by the
cutting tool. Milling machine can also hold more than one cutter
at a time. The holding device is supported by mechanism that can

offer a selective portion of the workpiece to milling cutter for its

processing. Indexing is one of the examples of this type of
processing.

PRINCIPAL PARTS OF A MILLING MACHINE

Generally columns and knee type milling machine is considered
as typical milling
machine. Principal parts of a typical milling machine are described
as below.

Base
It provides rest for all parts of milling machine including column. It
is made of

grey iron by casting.

Column
It is a type of rigid vertical long box. It houses driving mechanism
of spindle, table
knee is also fixed to the guide ways of column.

Knee
Knee can be adjusted at a height on the column. It houses the
feed mechanism of
the table and other controls.

Saddle
Saddle is placed at the top of the knee. Saddle provides guide
ways for the
movement of the table.

Table
Table rests on the saddle. It consists of T shaped slots for
clamping the
workpiece. Movements of the table (feed motions) are given in
very controlled
manner be lead screw.

Overhanging Arm

Overhanging arm is mounted on the column and serves a bearing

support for the
arbor. This arm is adjustable so that the bearing support may be
provided near to
the milling cutter. There can be more than one bearing supports
to the arbor.

Arbor
It holds rotating milling cutters rigidly and mounted on the
spindle. Sometimes
arbor is supported at maximum distance from support of
overhanging arm like a
cantilever, it is called stub arbor. Locking provisions are provided
in the arbor
assembly to ensure its reliability.

Front Brace Milling

Front base is used to adjust the relative position of knee and
overhanging arm. It is also an extra support fixed between the
knee and overhanging arm for rigidity.

Spindle
Spindle is projected from the column face and provided with a
tapered hole to
accommodate the arbor. Performance of a milling machine
depends on the

accuracy, strength and rigidity of the spindle. Spindle also

transfer the motive
power to arbor through belt or gear from column

MILLING MACHINE

USING THE MACHNE

1 Tramming the Head with the help of a Supervisor or Shop
Manager.
The head of a vertical milling machine can be tilted from side to
side and from front to back. This allows for versatility of the
machine,but these adjustments can drift. Occasionally, one
should check and adjust the head so that the spindle will be
normal to the plane of the table.To check, install a dial indicator
into the tramming bar,and install the dial indicator on the other
end of the bar. The indicator face should be facing up and the
probe at 45 degree to the table. Lower the spindle until the dial
indicator contacts the table then registers about one half of a
revolution. Set the dial indicator is toward you and set the bezel
to zero. Rotate the spindle by hand 180 degrees. If the dial
indicator still reads zero, the spindle is aligned front to back. If
not, adjust the head until the dial reads half of the original
reading and iterate the entire process until the error falls within
acceptable limits. Repeat the process with the dial displaced left
and right to alight the head side to side.
2.Squaring the Vise. Check before every job, dont assume its
aligned or tightened
Work on a milling machine is most often held in a vise clamped
onto the bed. To make sure the parts we make are square and
parallel, the vice must be aligned with the X travels of the
machine. To do this, mount the vise on the bed and secure it with
T-bolts, but only lightly so as to permit adjustment of the
orientation of the vise. Mount a dial indicator in the spindle of the
machine with the probe facing away from you. Lower the spindle
and run the bed of the table back until the fixed (back) jaw of the
vise is in contact with the indicator and further until the indicator

registers one half of a revolution. Set the bezel to zero. Use the
manual cross feed to run the indicator across the face of the vise.
If the vise is squared, the indictor will remain at zero. If the dial
indicator does not read zero, tap lightly with a soft hammer to
realign the vise. Repeat this procedure until the dial indicator
reads zero through the full travel across the face of the vise jaw.
Tighten down the T-bolts be careful not to change the vise
orientation.
3. Setting Spindle Speed & High/Low Gearing
Spindle speed is set by turning the speed crank on the right side
of the spindle. The spindle must be on and rotating to adjust the
speed. There is a manual display (dial) on the head of the
machine that shows the speed in rpm. The spindle speed dial has
two scales, one for low range, and one for high range. The
machine is switched between ranges with SPEED RANGE lever
on the right side of the machine head. Switching this lever must
be done with the spindle not running! Sometimes, the spindle
must be rotated slightly (by hand) to allow the

4. Using an Edge Finder

Before doing precise work on a milling machine, one must locate
the edges of a part accurately. An edgefinder is designed to do

this on edges with flat vertical surfaces. An edgefinder is

composed of two concentric cylinders, spring loaded together. To
use it you must first insert it into the machine with the
appropriate collet. The big end of the edgefinder is held in the
collet at least way in. Start the spindle and set the speed to
approximately 1,000rpm. Flick the bottom of the edgefinder to
induce a wobble in the smaller diameter. The smaller diameter is
usually .200 diameter. Then, move the part into the tool very
slowly. The edge finder will center up, then break out of
concentricity suddenly. At that point, reset the dial indicator or
digital readout for that axis of the machine to a value equal the
radius of the edgefinder. Repeat the process at least twice to
make sure your edge finding was correct.

5. Using the Digital ReadOuts commonly known as DROs

The mills are equipped with electronic display for accurate
positioning. These DROs have a 4 place display (.0002accuracy)
for the X and Y axes. The Z axes is still read off the mechanical
dial on the Z-axis handle with a .001 accuracy. There are two
systems of measurement that the DROs can supply, Incremental
and Absolute. Absolute should be used for the zero corner of
your part and not be changed during the job. The incremental
setting can be zeroed as necessary for use between any two
locations, features, holes, etc.

6. Cutting Fluids and their applications.

Different applications and/or materials require slightly different
cutting fluids. These fluids are designed to provide the correct
amount of lubricity, cooling, better surface finish, increased tool
life and more. All cutting fluids (especially WS11) should be
thoroughly cleaned / removed from the machine when finished!
The machine should be dry and a light misting of WD40 applied
to the entire vice, tables and machine ways to prevent corrosion.

USING PARALLELS in a Kurt vice.

Parallels are used to raise the work above the vice jaws for
machining, drilling or other operations. They can set the part
height so the vice jaws will not be hit by your cutting tools and
that any drilling operations will not cut into the bottom of the
vice. Make sure you use a matching (height) set. Also be aware of
running into the parallels, and constantly check to see that they
have not moved unintentionally. It is a good idea to always check
that no chips have fallen on toip of or underneath the parallels, as
this will greatly effect the accuracy of your parts.
SQUARING STOCK & FACE MILLING First step in accurate parts
To create a square corner on a part, first orient an already finished
edge vertically in the vise and clamp lightly onto the part. Set a
machinist's square against the finished edge and the bottom of
the vise. Lightly tap the part with a plastic hammer to align it with
the square. Clamp the vise down securely. Now the top edge of
the part is ready to be milled to horizontal. It is often necessary to
create a flat face on a large part. This is called face milling. Select
a sharp, flat bottom, end mill cutter a little wider than the
workpiece so that the facing can be accomplished in one pass.

This can work for end mills up to .750 diameter in size. Beyond
that size, you will have to make multiple passes or use a
flycutter.Fly cutting, which is also called single point milling, is
one of the most versatile milling operations. It is done with a
single-point cutting tool shaped like a lathe tool bit. It is held and
rotated by a fly cutter arbor. You can grind this cutter to almost
any form that you need. It is more economical to grind the desired
form on a lathe-type tool bit than to buy a pre-ground form cutter,
which is very expensive and usually suitable only for one
particular job. For milling slots, end mills are an idea tool. They
will produce a slot to within two one-thousandths of an inch in one
pass. If greater accuracy is required, use an end mill a little
smaller than the desired slot. Measure the slot you produced and
then open it to the desired dimension with a second pass. Note
that the depth of cut should not exceed three times the diameter
of the cutter.

DRILLING, BORING & REAMING Much more accurate than a

drill press
The milling machine may be used effectively for drilling, since
accurate location of the hole may be secured by means of table
positioning. Spacing holes in a circular path, such as the holes in
an index plate, may be accomplished by indexing with the index
head positioned vertically. Twist drills may be supported in drill
chucks fastened in the milling machine spindle or mounted
directly in milling machine collets or adapters. The workpiece to
be drilled is fastened to the milling machine table by clamps,
vises, or angle plates. For boring, there are various types of
boring tool holders may be used for boring on the milling
machine, the boring tools being provided with either straight
shanks to be held in chucks and holders or taper shanks to fit
collets and adapters. The two attachments most commonly used
for boring is the offset boring head, also known as the Criterion
Boring Head The single-edge cutting tool used for boring on the

milling machine is the same as a lathe cutter bit. Cutting speeds,

feeds, and depth of cut should be the same as that prescribed for
lathe operations. Boring is usually used for holes bigger than .
500 diameter. The most accurate way to finish a hole smaller
than .500 diameter is the process of reaming. Reaming is a
process which slightly enlarges a pre-existing hole to a tightly
toleranced diameter. A reamer is similar to a mill bit in that it has
several cutting edges arranged around a central shaft. Reaming is
always done after hole drilling. If the hole is drill crooked, the
reamer will follow the crooked hole. Reaming should not be relied
upon to correct the location or alignment of a hole. Reamed holes
should not intersect with drilled holes. Its primary purpose is to
fine-tune the diameter of the hole. Reaming is most accurate for
axially symmetric parts produced and reamed on a mill. Reamers
come in a multitude of sizes.

Maintenance and servicing of milling

machines
Like any other machine, milling machines are subject to wear and
tear. The physical wear is a result of the use of the machines and
of the abrasion caused by friction during use. Such wear can be
reduced by regular maintenance and servicing of the milling
machine by the operator:
The degree of wear depends on:

- maintenance and servicing of the milling machine,

- properties of coolants and lubricants,
- environmental conditions (dust, temperature variations, etc.)
-operating conditions (single or multi-shift operation, volume of
metal removed, proper operation).

Advantages
1. The metal is removed at a faster rate as the cutter has got
multiple cutting edges and rotates at a higher speed.
2. It is possible to perform machining by mounting more than one
cutter at a time.
3. The table of the machine can be moved to an accuracy of
0.02mm.
4. It is very useful since various cutters and precise tools can be
machined.

5. Special attachments can be mounted on the machine to

perform operations that are performed in other machine tools.
6. The quality of the shop is enhanced with the presence of this
machine.

Disadvantages
1. The cost of the milling machine is high.
2. As milling cutters cost high, the investment for procuring tools
is more.
3. The production cost will increase if we carry out the operations
performed in a shaper or a drilling machine with a milling
machine.

Indexing heads
Cross-section of an indexing head
A dividing head mounted on the table of a small milling machine.
The direct indexing plate and center are visible facing the camera.
An interchangeable indexing plate is visible on the left side.
Indexing is an operation of dividing a periphery of a cylindrical
workpiece into equal number of divisions by the help of index

crank and index plate. A manual indexing head includes a hand

crank. Rotating the hand crank in turn rotates the spindle and
therefore the workpiece. The hand crank uses a worm gear drive
to provide precise control of the rotation of the work. The work
may be rotated and then locked into place before the cutter is
applied, or it may be rotated during cutting depending on the
type of machining being done.
Most dividing heads operate at a 40:1 ratio; that is 40 turns of the
hand crank generates 1 revolution of the spindle or workpiece. In
other words, 1 turn of the hand crank rotates the spindle by 9
degrees. Because the operator of the machine may want to rotate
the part to an arbitrary angle indexing plates are used to ensure
the part is accurately positioned.
Direct indexing plate: Most dividing heads have an indexing plate
permanently attached to the spindle. This plate is located at the
end of the spindle, very close to where the work would be
mounted. It is fixed to the spindle and rotates with it. This plate is
usually equipped with a series of holes that enables rapid
indexing to common angles, such as 30, 45, or 90 degrees. A pin
in the base of the dividing head can be extended into the direct
indexing plate to lock the head quickly into one of these
angles.The advantage of the direct indexing plate is that it is fast
and simple and no calculations are required to use it. The
disadvantage is that it can only be used for a limited number of
angles.
Interchangeable indexing plates are used when the work must be
rotated to an angle not available on the direct indexing plate.
Because the hand crank is fixed to the spindle at a known ratio
(commonly 40:1) the dividing plates mounted at the handwheel
can be used to create finer divisions for precise orientation at
arbitrary angles. These dividing plates are provided in sets of
several plates. Each plate has rings of holes with different
divisions. For example, an indexing plate might have three rows of
holes with 24, 30, and 36 holes in each row. A pin on the hand
crank engages these holes. Index plates with up to 400 holes are

available. Only one such plate can be mounted to the dividing

head at a time. The plate is selected by the machinist based on
exactly what angle he wishes to index to.
For example, if a machinist wanted to index (rotate) his workpiece
by 22.5 degrees then he would turn the hand crank two full
revolutions plus one-half of a turn. Since each full revolution is 9
degrees and a half-revolution is 4.5 degrees, the total is 22.5 (9 +
9 + 4.5 = 22.5). The one-half turn can easily be done precisely
using any indexing plate with an even number of holes and
rotating to the halfway point (Hole #8 on the 16-hole ring).
Brown and Sharpe indexing heads include a set of 3 indexing
plates. The plates are marked #1, #2 and #3, or "A", "B" and "C".
Each plate contains 6 rows of holes. Plate #1 or "A" has 15, 16,
17, 18, 19, and 20 holes. Plate #2 or "B" has 21, 23, 27, 29, 31,
and 33 holes. Plate #3 or "C" has 37, 39, 41, 43, 47, and 49 holes.
[citation needed]
Universal Dividing heads: some manual indexing heads are
equipped with a power drive provision. This allows the rotation of
the dividing head to be connected to the table feed of the milling
machine instead of using a hand crank. A set of change gears is
provided to select the ratio between the table feed and rotation.
This setup allows the machining of spiral or helical features such
as spiral gears, worms, or screw type parts because the part is
simultaneously rotated at the same time it is moved in the
horizontal direction. This setup is called a "PTO dividing head".

REFERENCES
https://en.wikipedia.org/wiki/Indexing_head
http://collections.infocollections.org/ukedu/en/d/Jgtz104ae/3.html
http://www.lathes.co.uk/index/