MILLING

On completion of this topic, you would be able to :

Differentiate milling from turning and shaping.

Know the working principle of milling machine.

Define the basic milling operation Classify the milling machines Indexing in milling and various method of milling

Milling : It is a machining operation in which the work is fed

against a revolving cutting tool.

Turning : It is a machining method in which a single point

cutting tool is fed against a revolving work, the work being held
in a chuck.. Only cylindrical objects are handled.

Shaping : It is a machining method in which a clamped work is

fed against a reciprocating single-point cutting tool. Only flat surfaces are generated . Low speed of operation.

Working Principle in milling

The work is rigidly clamped on the table of the machine, or held between centres and revolving multi teeth cutter mounted either on a spindle or an arbor. The cutter revolves at a fairly high speed and the work fed slowly past the cutter. The work can be fed in a vertical, longitudinal or cross direction. As the work advances ,the cutter teeth remove the metal from the work surface to produce the desired shape. CUTTER

FEED

WORK PIECE

Types of Milling Machines

1.COLUMN AND KNEE TYPE : a) Hand milling machine b) Plain milling machine

c) Universal milling machine

d) Omniversal milling machine

e) Vertical milling machine

Types of Milling Machines

2. Fixed bed type milling machine. 3. Planer type machines. 4. Special purpose type: a) Rotary table milling machine b) Planetary milling machine

c) Cam milling machine

d) Profile milling machine

Column and Knee Type milling machine

General purpose machines having a single spindle only Column and Knee type means The work table is supported on knee like casting, which can slide in vertical direction along a vertical column. These machines depending upon the spindle position and table movements.

Hand milling machine

Cutter revolves on an arbor by power. Table is fed manually against the cutter.

Size of the machine is limited.

Useful in producing small components like hexagonal or square heads on bolts, cutting slots or screw heads, cutting key ways.

Hand milling machine

Plain milling machine

More rigid and heavier in construction .

Table is given three directional linear feed.

Table movements are either manual or by power.

Capable to handle huge sized jobs.

Plain milling machine

Main parts of a plain milling machine

Universal milling machine

Similar to plain milling machines except the table can

be given one more additional movement.

Work table can be swiveled in horizontal plane and fed at an angle to the spindle. Intended for diversified line of work with high accuracy machining.

Universal milling machine

It can be used as a vertical milling machine with proper

attachments(over ram can be removed and a vertical

milling head can be fitted in place of arbor). Adaptable to various milling attachments.
Compact in size than plain milling machine but more accurate. More suitable for tool room works and special operations. Cannot handle heavier machining operations

Universal milling machine

Over arm

Movable jaws

Swivel base

Elevating screw

Universal milling machine

Omniversal milling machine

It is specially a tool room machine. In addition to the horizontal swivel, the knee can be swiveled in a vertical plane. Suitable for more complicated machining beyond the reach of universal machine. Performs operations with more precision than universal machine. It should be kept in conditioned rooms.

Vertical milling machine

This is also a column and knee type.

It carries a vertical column on a heavy base.

Column And overarm ( carries a housing at its front ) is a integral part. This housing , called head, can be fixed or swiveled. In fixed type , the spindle always in vertical position, can be

adjusted up and down.

In swiveling type, the head can be swiveled to any desired angle to machine the inclined surfaces.

Vertical milling machine

Knee carries an enclose screw jack by means of which it is moved up and down along the parallel vertical guide ways provided on the front side of the column. The saddle is mounted on the Knee and can be moved towards or away from the column along the horizontal guide ways on the knee. Table is mounted on gideways (normal to the direction of guideways provided on knee) provided on the saddle. Lead screw provide the longitudinal direction to the table. The work gets up and down movement bye knee, cross movement by saddle and longitudinal movement by the table. Mostly face milling cutters and shell end type cutters are used Very useful in production work.

Vertical milling machine

Vertical milling machine with fixed head

Vertical milling machine with swiveling head

Fixed Bed-type milling machine

More rugged than column and knee type.

The table is mounted on a fixed bed instead of the saddle and knee
and travel in longitudinal direction only It can neither move up and down nor crosswise . A rigid vertical column carries parallel vertical ways on which the adjustable spindle head or spindle carrier is mounted. This spindle head carries the spindle to which the arbor can be fitted to carry the cutter. Table is provided with longitudinal motion.

Fixed Bed-type milling machine

Fixed Bed-type milling machine

Duplex head fixed bed-type milling machine

Carries two vertical column Each columns carry parallel vertical ways on which two adjustable spindle heads or spindle are mounted.

Each spindle head carry a horizontal spindle on which cutters can be mounted
The spindle head can be adjusted vertically up and down The table has longitudinally movement only This machine enables machining of two surfaces simultaneously.

Duplex head fixed bed-type milling machine

Planer type milling machine

Very much similar to a double housing planing machine ,the only difference being in the tool heads In this case the spindle carriers are mounted ,in place of the planer tool post which are operated by individual motor. Consists of a fixed bed on which the table has a longitudinal movement only Consists four spindles (two vertical and two horizontal) each with its own drive motor. All the four cutter can be operated simultaneously to machine four surfaces on the work at a time

Used for high metal removal rate.

Planer type milling machine

Planer type milling machine

Work can be machined in four different ways
1. By moving the table , the cutters rotating in position 2. By keeping the table stationary and feeding the cutters by moving the milling heads 3. By moving the table and the milling heads simultaneously 4. By keeping the table stationary ,moving the cross-rail downwards and the side cutters up and down Used in heavy duty work Milling head can be of fixed type or swiveling type to facilitating machining of inclined surface also

Planer type milling machine

Special purpose machines

1.Rotary table or continuous milling machine :

Heavy and robust

Process of machining is continuous and there is no idle

machine time.
Used in mass production

Three times more production rate.

Work and table rotates about a vertical axis.

Rotary table or continuous milling machine

Drum Type milling machine

Heavy duty production machine Two end faces of the work pieces are machined simultaneously Upper two spindle carry roughing cutters and lower two finishing cutters Fixtures are mounted on the periphery of the drum to carry the jobs to be machined Production rate double than the rotary table milling machine

Drum Type milling machine

Tracer controlled milling machine

Also known as duplicator, diesinker, contour or keller milling machine Improved design of a vertical milling machine The contact finger of hydraulic tracer head makes a light contact with the contours of the template and guides the cutter movement Specific use in the production of dies used in press work , die casting , forging etc.

Tracer controlled milling machine

Thread milling machine

Used to cut threads, worms etc Two types of cutters are generally used one of these consists of a single row of teeth mounted on the periphery of a cylinder

Thread milling machine

Second one consist of a number of such rows, spaced at a distance equal to pitch from one another The single cutter is used for cutting threads of coarse pitches and on long screwed parts such as lead screw and worms etc Multi cutter teeth used for comparatively shorter lengths

Planetary milling machine

Cutter adopt circular path during the operation The work is held stationary Used for heavy and delicate type of work which can not be rotated and fed against the cutter Also used to produce external and internal threads in different holes whose centre lie on a circle in a single setting without disturbing the workpieces.

Planetary milling machine

Turret type milling machine

Basically column and knee type vertical milling machine The ram carrying the milling heads can b rotated about vertical axis and locked in any desired position Both the tool swivel about a horizontal axis while the their spindle rotate and also move inwards and outwards Two different type of cutter used Used in tool and die making

Turret type milling machine

Cam milling machine : Used for making profiles of cam on disc. The movement of table is

controlled by a master cam.

Profile milling machine : For duplicating the template attached, the cutter movement is regulated by guide pin.

Construction of milling machine

Main parts:
1. Base 3. Saddle 5. Work table 7. The arbor 2. Column 4. Knee 6. Over hanging arm 8. Spindle

9.Yokes /Movable jaws 10. Elevating screw

11. Spacing collars

13. Swivel base

12. Motor and transmission

14. Feed cranks

Base:
Made of grey cast iron capable to withstand entire weight of the machine. Supports the column at one end. Accommodates coolants.

Column:
A casting mounted vertically on the base. The front portion provides guide ways to support knee. Over hanging arm is held on its top. It houses driving mechanism for the spindle and table feed.

Saddle:
Provides cross feed for the work by moving away or towards the face of the column.

Machined and ground on the top to support the work table.

Knee:
A grey cast iron structure, attached to the face of the column
,moves on slides. Table can be moved up and down . Supports the saddle on its top.

Work table:
T-slots are provided on its top for direct mounting of the work. Provides longitudinal feed .

Capable to withstand cutting loads.

Facilitates a rigid clamping mechanism

Over arm:
Located on top of the knee. Supports the cutter holding and driving mechanism.

Provides more rigidity to the machine. Movable jaws and arbor are supported.

Arbor: Fixed in a spindle nose . Locates the cutters in position. Transmits power to cutters from spindle.

Available in different standard sizes.

Spindle:

It receives power from motor through gears .

Holds arbor and drives cutters.

Rotates at high speeds in different ranges.

Yoke: Clamped to the guide ways provided on the over hanging arm. Supports the arbor at number of sections and ensures vibration-free machining. It houses bearings on which arbor is mounted. Elevating screw:

Located on the top of the base and supports the knee.

Ensures free elevation of knee on the guide ways.

Also improves the rigidity of the machine.

Spacing collars
Multiple cutters at different sections on an arbor can be placed with
spaces. Available in different lengths.

Driving mechanism
It supplies the driving torque to the spindle in particular and other
mechanisms of the machine. Transmission done through gears and belts are housed. Coolant supply, lubricating-oil circulation and auto-feed needs power.

Feed Cranks
Hand driven cranks are used to effect all feed movements Viz., longitudinal, cross and vertical.

Kinematic system of common type milling machine

S5 C3 S6

Nut

B1 B2

S4 S2
S1

S3 C2

C1

Worm and worm wheel

Telescopic shaft

Milling cutter
Multi cutting-edged rotating tool. Most of them are made with high speed steel or special alloy steels.

A carbide inserted tool permits very high cutting

speeds. All cutters generally have two types of cutting teeth, straight or spiral teeth and form relieved teeth.

Milling cutter
Each milling cutter is identified by the

outer diameter,
thickness, no. of teeth and

the bore diameter,

apart from the material of the cutter.

Classification of Milling cutter

Profile sharpened cutters : Producing only flat surfaces irrespective of tool shape Slab or plain milling cutter : straight or helical fluted Side milling cutters disc type Slotting cutter :- disc type Slitting (saw) or parting tools :- disc type End milling cutters with straight or helical fluted Face milling cutters large cutter

Classification of Milling cutter

Form relieved cutters : job profile is the replica of the tool form

Form cutters
gear (teeth) milling cutters

spline shaft cutters

tool form cutters T-slot cutters Thread milling cutter

1.Plain milling cutter

It has straight or helical cutting edges only on the periphery. Produces flat surfaces parallel to the cutter axis. Do not carry cutting edges on its sides. With more width it becomes a slab mill.

Plain milling cutter

Plain milling cutters are hollow

straight HSS cylinder of 40 to 80

mm outer diameter having 4 to 16 straight or helical equi-spaced flutes or cutting edges and are used in horizontal arbor to

machine flat surface as shown in figure.

Plain milling cutter

Plain milling cutters are divided into:
a) Light duty cutter : Remove less material. Face width less than 20mm straight teeth parallel to the axis.

Face width more than 20mm, helical teeth with 25 degree helix angle.

Plain milling cutter

b) Heavy - duty plain milling cutter: With wider face width and helical teeth, removes more material.

Helix angle 250 to 450 , better shearing takes place.

Gives a fine surface finish.

Plain milling cutter

c) Helical plain milling cutter

Has an helix angle between 450 to 600 .

Due to better shearing, provide better surface

finish. Adapted for taking light cuts on soft materials.

Side and slot milling cutter

These arbor mounted disc type cutters have a large number of cutting teeth at equal spacing on the periphery. Each tooth has a peripheral cutting edge and another cutting edge on one face in case of single side cutter used to produce steps comprising two flat surfaces at right angle as shown in Fig.

parallel facing by two side (single) cutter

Side milling cutter

Double sided cutters are used for
making rectangular slots bounded by three flat surfaces. These cutters may be made from a single piece of HSS or its teeth may be of uncoated or coated carbide inserts for high production machining. Diameter of the cutter ranges from 50mm to 200mm. Width range is 5mm to 32mm.

slotting by side (double sided) milling cutter

Side milling cutter

Slitting saw or parting tool

having only one peripheral cutting edge on each tooth larger in diameter and much thin i.e Face width is very small.

possess large number of cutting teeth but of small size

used only for slitting or parting Standard saws are made thinner at the center than at the outer edge to provide clearance Used to mill thin deep slots and cut-off
Parting by slitting saw

operations.

Metal slitting saw

End milling cutter

Designed for accurate cutting of slots,pockets,key ways and contours. Cutting edges are provided on the

end face and on the periphery.

Teeth may be straight (parallel to axis of rotation ) and helical Used to machine both horizontal and vertical surfaces.

End milling cutter

mostly made of HSS but some time carbide inserts (coated and uncoated) 4 to 12 straight or helical teeth on the periphery and face diameter ranges from about 1 mm to 40 mm

A - mill size or cutting diameter B - shank diameter C - length of cut or flute length D - overall length

very versatile and widely used in vertical spindle type milling machines

End milling cutter

End milling cutter

Shell type end mill

Larger and heavier than other end mills Teeth on periphery and the end both Helical teeth are provided At the end face a recesses provided to receive a cap screw and They are held in stub arbor . Diameter ranges are more than 50 mm. Used for heavy duty work. Used for Milling of flat surfaces ,cutting slots etc

Shell type end mill

Face milling cutters

usually large in diameter (80 to 800 mm) and heavy used only for machining flat surfaces in different orientations mounted directly in the vertical or horizontal spindles coated or uncoated carbide inserts are clamped at the outer edge of the carbon steel body as shown generally used for high production machining of large jobs.

Form relieved cutters

form of the tool is exactly replica of the job-profile to be made clearance or flank surfaces of the teeth are of archemedian spiral shaped instead of flat. teeth are sharpened by grinding the rake surface only used for making 2-D and 3-D contour surfaces

Form relieved cutters

Such disc type HSS cutters are generally used for making grooves or slots of various profiles as indicated in Fig. Form cutters may be also end mill type like T-slot cutter as shown in Fig.

Form relieved cutters

They have cutting edges of different profiles in order to generate required

contours.
a) Convex milling cutter: Teeth curved outwards on the

circumference.
Used to produce concave grooves. Diameter ranges from 50mm to 125mm. Width varies from 3.2mm to 40mm.

Form relieved cutters

b) Concave milling cutter:

Generates

convex

surfaces and rounded corners. Diameter ranges from 56 mm to 110mm .

Minimum radius that

can be milled is

1.5mm- 20mm.

T-slot milling cutter

It has cutting edges on periphery and on both sides of the cutter. Used with a vertical spindle . Used for machining the portion of T- slot.

Gear teeth milling cutter

Gear milling cutters are made of HSS and available in disc form only like slot milling cutters and also in the form of end mill for producing teeth of large module gears. The form of these tools conform to the shape of the gear tooth-gaps bounded by two involutes as shown in Fig.
Such form relieved cutters can be used for producing teeth of straight and helical toothed external spur gears and worm wheels as well as straight toothed bevel gears.

Spline shaft cutters

These disc type HSS form relieved cutters are used for cutting the slots of external spline shafts having 4 to 8 straight axial teeth.

Tool form cutter

Form milling type cutters are also used widely for cutting slots or flutes of different cross section e.g. the flutes of twist drills ,milling cutters, reamers etc., and gushing of hobs, taps, short thread milling cutters

Thread milling cutter

Such shank type solid HSS or carbide cutters having thread like annular grooves with equispaced gushings. Used in automatic single purpose milling machines for cutting the threads in large lot production of screws, bolts etc. Both internal and external threads are cut by the tool as shown in Fig. The milling cutter and its use in long thread milling(lead screw, power screws, worm etc. )

Short thread milling

Long thread milling

Straddle milling
For faster and accurate machining two parallel vertical surface at a definite distance, two separate side milling cutters are mounted at appropriate distance on the horizontal milling arbour as shown in Fig.

Gang milling
In gang milling, being employed where feasible for quick production of complex contours comprising a number of parallel flat or curved surfaces a proper combination of several cutters are mounted tightly on the same horizontal milling arbour as indicated in Fig.

Angle milling cutter

These cutters carry sharp angular teeth which are neither parallel nor

normal to their axes.

Used for cutting V groves , notches chamfers, dovetails, helical flutes etc; a) Single angle milling cutter: Have teeth on both the angled face and sides of the cutter. Made with angles of 30 to 45 degree and 60 to 85 degree in steps of 5 degree with one side of the angle at 90 degree to the axis of the cutter.

Single angle cutter

Angle milling cutter

Double angle milling cutter: The face of the cutter is formed into V- shape(two angular faces join and

form V shape).
Cutting edges are included at 45, 60 and 90 degree.

It is not necessary the angle of both the faces should be equal.

Adapted for cutting spiral grooves on a blank, bevels.

Slot drill
Used for machining a sunk key way in a shaft. Similar in action to twist drill. Has two cutting edges .

Cutting edges

Woodruff key milling cutter

Small type of end milling cutter which resembles with plain and side mill.

Cutting edges may be straight (smaller size) or

staggered (larger size).

They are made in shank style and in arbor style.

Smaller sizes up to 50 mm diameter. Used for cutting key-seats to fit woodruff keys.

Fly cutter
Single point cutting tool attached to stub arbor or held in bar. Exactly same way as a boring tool in boring bar.

Cutting edge of the tool can be ground to any desired shape. Thus be considered as form tool.
Generally used for experimental purpose. Used to reproduce contoured surface.

Elements of a Plain milling cutter

Rake surface

Types of rake angle

Milling operations
Process of removing metal with a rotating cutter. Usually flat or form surfaces are produced.

Using number of types of milling cutters various

operations are obtained.

Milling operations
The direction of rotation of the cutter is important. Some of the commonly performed operations are as follows 1. Plain milling 3. Straddle milling 5. Angular milling 7. Profile milling 2. Face milling 4. Gang milling 6. Form milling 8. End milling

9. Key way milling

11. Cam milling

10. Gear cutting

12. Saw milling

Plain milling
Machining a flat surface parallel to the axis of the cutter. They are also referred as slab milling or peripheral milling.

Plain milling

Plain milling
Plain milling operation can be carried out in two methods. 1. Up milling or conventional milling 2. Down milling or climb milling

Up milling or conventional milling

Also referred as conventional milling.

The rotation of the cutter is opposite to the

direction of the work feed. The resultant cutting force acts upwards.

Tendency is to lift the work piece off the table.

Up milling or conventional milling

Up milling or conventional milling

Fixtures and holding devices are to be selected carefully. Chip thickness is minimum at the start of the cut and maximum at the end. A lower impact on the cutter at the start of the cut.

Difficulty in chip removal and coolant application is experienced.

Reduced tool life and surface finish.

But safety in operation .

Feed in Back lash is compensated by the direction of the milling force.

Down milling or climb milling

Also referred as climb milling.

Rotation of the cutter is in the same direction of the feed.

No tendency for the cutter to oppose the feed motion. Resultant cutting force is downward. Fixtures and holding devices are simpler and less costly. Cutters with high rake angle can be used. Less power is needed .

Down milling or climb milling

Down milling or climb milling

Chip disposal is easier and better surface finish.

Chip thickness is maximum at the start of the cutter and minimum

at the end. Less tool wear. Preferred for slitting thin sheets. Preferred on rigid machines only. Higher speeds and feeds can be employed.

Conventional (Up) Milling Vs Climb (Down) Milling

Face milling
Cutting of a flat surface at right

angles to the axis of the cutter.

Face milling cut can be either vertical or horizontal. Side milling cutter or shell type end mill is used .

Straddle milling
Used for cutting two or more horizontal and

vertical surfaces simultaneously by mounting

number of cutters on the arbor. Cutters are separated by spacing collars.

Metal removal rate is higher.

Straddle milling

Gang milling
Operation of machining several surfaces simultaneously by different types of cutters. All cutters are mounted on the same horizontal arbor. No spacing collars are used. Generally Side and plain milling cutter are used

Gang milling

Angular milling
Cutting a flat surface at an inclination to the axis of the cutter. Achieved by angular milling cutter( either by a single and double angle cutter). Swiveling the work or the spindle can also provide angular milling.

Form milling
Cutting the surface having a regular or irregular outline. The contours are convex ,concave or a gear tooth

cutting.

Profile milling
Operation of machining complex shapes with the help of template on a tracer

machine.
Movement of the cutter is guided by contact finger .This finger runs in contact with the outline to be duplicated and the tracer mechanism guides the tool

movement accordingly. The end mill is mostly used for profile milling.

End milling
Operation of machining horizontal or vertical surfaces by end mill. Generally performed on a vertical

milling machine.

Saw milling
Machining narrow slots or grooves using metal slitting saw. Also used for parting off operations.

Key-way milling
Cutting key-ways , groove and slots using a special cutter, key-cutter. T slots can be cut with the help of T- slot cutter.
Rough machined rectangular slot
Rough machined Dovetail slot

Dovetail cutter

Gear cutting
Spur gears and helical gears are cut on milling machine with help of gear cutters. Profile is identical with tooth space of gear to be cut. It involves indexing operation.
Gear milling cutter

Gear cutting

Cam milling
Milling a cam profile on milling machine using dividing head. End milling cutter is held in vertical attachment such

that axis of the spindle and blank remain parallel.

The movement of blank is controlled by dividing head. Also, using CAM software, milling can be performed.

Cam milling

Milling machines attachment

1. 2. 3. 4. 5. 6. Universal milling attachment Indexing and dividing head Rotary table Vertical milling attachment Slotting attachment Rack milling attachment

Universal milling attachment

The universal milling attachment is shown in fig .
The rotation of the horizontal spindle is transmitted into rotation about vertical and also in any inclined direction.

This attachment extends the processing capabilities and application range of the milling machine.

Universal milling attachment

Amongst the knee type conventional milling machines, horizontal arbor type is very widely used, where various types and sizes of milling cutters like plain or slab milling cutters and disc type cutters including single and double side(s) cutter, slot cutter, form cutters, gear milling cutters, slitting cutter etc. having axial bore are mounted on the horizontal arbor. For milling by solid end mill type and face milling cutters, separate vertical axis type milling machines are available. But horizontal arbor type milling machines can also be used for those operations to be done by end milling and smaller size face milling cutters by using proper attachments.

Indexing or Dividing heads

Used to change the angular position of the work in relation to the cutter Possible to divide the periphery of the workpiece in to any number of equal parts. Work can be mounted on the dividing head which is bolted with the table Work can be held in a chuck or between centres of dividing head and foot stock (similar to tail stock) This attachment is used for cutting gears, flutes on twist drills Three types of dividing head 1. Plain dividing head 2. Universal dividing head 3. Optical dividing head

Circular milling attachment

This device may be considered both accessory or attachment and is generally used in milling machines for both offline and online indexing / rotation of the job, clamped on it, about vertical axis. Fig visualises such a rotary table which is clamped or mounted on the machine bed / table. It provides a rotary motion to the workpiece in addition to longitudnal ,cross and vertical motion.

Circular milling attachment

Vertical milling attachment

Used to convert a horizontal milling machine into a vertical one . It can be mounted on the face of the column of a knee and column type milling machine. Spindle head can be swiveled to any degree for angular milling. Operation to be performed Face milling, grooving, T slot cutting etc.
Eye bolt for lifting

Slotting attachment
Used for converting a milling machine into a slotter (rotational motion of the horizontal spindle machine in to up and down vertical reciprocating motion) The slotting head is fitted to the spindle and used for cutting slots. The tool slide (reciprocating movement like the ram of a slotter ) driven from the main spindle of the milling machine by an eccentric.

Slotting attachment

Rack milling attachment

Bolted to the face of the column The cutter is mounted on the arbor provided in this attachment. The arbor remains parallel to the longitudinal transverse of the machine table on which the workpiece is held for cutting the teeth The attachment has a gear train which enables the spindle axis to be set at right angles to the machine spindle in the horizontal plane to help cutting the teeth. Used for cutting rake teeth and cutting worm.