MATERIAL SCIENCE & ENGINEERING

20 Jan 2022

Milling Machine And Its Operations.

Lab Report 3

NAME:
Muhammad Abtahee
200301032

COURSE INSTRUCTOR:
Sir Danish Shafique

Total Pages 18
 Table of Contents
1 Abstract……………………………………………………………………………………1

2 Milling Machine…………………………………………………………………………...1

2.1 Methods of milling……………………………………………………………………….3

2.2 Types…………………………………….…………………………………………...……4

2.3 Parts of Horizontal milling machine…….……………………………………………...5

3 Cutting tools..………………………………………………………………………………7

3.1 Parts of Vertical milling machine…..………………………………………………….8

4 Milling operations.………………………………………………………………………..10

4.1 Plain milling…………………………………………………………………………….10

4.2 Face milling……………………………………………………………………………10

4.3 Side milling……………………………………………………………………………...11

4.4 Straddle milling………………………………………………………………………..11

4.5 Angular milling………………………………………………………………………..12

4.6 Gang milling.…………………………………………………………………..…….12

4.7 Form milling………………………………………………………………………..…13

4.8 Profile milling…………………………………………………………………………13

4.9 End milling…………………………………………………………………………….13

4.10 Saw milling……..…………………………………………………………………...13

4.11. T-SLOT milling……………………………………………………………………14

4.12. Gear milling…….………………………………………………………………….14

5 Conclusion……………………………………………………………………………...12

6 References………………………………………………………………………………..16
 1. ABSTRACT

A milling machine is one of the most influential and versatile kinds of machines found in the
manufacturing industry. Milling is the most widely used machine used in machine shops and
modern manufacturing industries all over the world.

It is a type of machining process in which a cutter having multiple cutting edges is used to
remove the material from the workpiece. This machine tool makes up about 85 percent of the
all material removal process.

Drilling Machine:
The drilling machine or drill press is one of the most common and useful machine employed
in industry for producing forming and finishing holes in a workpiece. The unit essentially
consists of:
• A spindle which turns the tool (called drill) which can be advanced in the workpiece
either automatically or by hand.
• A work table which holds the workpiece rigidly in position.

Working Principle:
The rotating edge of the drill exerts a large force on the work piece and the hole is
generated. The removal of metal in a drilling operation is by shearing and extrusion.

Drilling machine is used to drill blind and through holes in work pieces.

2. Milling Machine:

Milling is a metal cutting operation in which the excess material from the work piece is
removed by rotating multipoint cutting tool called milling cutter.
A milling machine is a machine tool that removes metal as the work is fed against a rotating
multipoint cutter. The milling cutter rotates at high speed and it removes metal at a very fast
rate with the help of multiple cutting edges.
One or more number of cutters can be mounted simultaneously on the milling machine. This
is the reason that a milling machine finds wide application in production work.
Used for machining flat surfaces, contoured surfaces,external and internal threads.

• As the workpiece moves against the cutting edges of milling cutter, metal is removed
in form chips.
• Machined surface is formed in one or more passes of the work.
• The work to be machined is held in a vice, a rotary table, a three jaw chuck, an index
head, in a special fixture or bolted to machine table.
• In many applications, due to its higher production rate and accuracy, milling machine
has even replaced shapers and slotters.
 2.1. Two basic methods of milling:
I. Up-milling or conventional milling.
II. Down-milling or climb milling.

Up-milling or conventional milling:

• Metal is removed by cutter rotating against the direction of travel of the workpiece.
• Needs stronger holding of the job.
• Chip thickness is minimum at the start of cut and maximum at the end of the cut.

Disadvantage: Tendency to lift work from the fixtures and poor surface finish.

Down-Milling or Climb Milling:

• Metal is removed by cutter rotating in the same direction of travel of the workpiece.
• Teeth cut downward instead of upwards.
• Chip thickness is maximum at the start of cut and minimum at the end of cut.
• Less friction involved.
• Better surface finish.
• Less power consumption.
2.2. Types of Milling Machines:
• Horizontal Milling Machine.
• Vertical Milling Machine.

Horizontal Milling Machine:

• Milling head can be adjusted manually by 45 degree.
• The spindle sleeve can be manually micro-injected.
• Workable X,Y,Z three way monetarized speed.
• The rectangular guide rail has good strength and stability.
• Has less accuracy.
2.3. Parts of Horizontal Milling Machine:
➢ Column:

The column houses the spindle, the bearings, the gear box, the clutches, the shafts, the
pumps, and the shifting mechanisms for transmitting power from the electric motor to
the spindle at a selected speed.

➢ Knee:

Knee is the first moving part of milling machine. If is mounted on the column and
moves along the slide ways situated over the column. It is made by cast iron and moves
vertically on slide ways. It moves up and down on sideways which change the distance
between tool and workpiece. It is driven by mechanically or hydraulically.

➢ Saddle:
• The saddle consists of two slide ways, one on the top and one at the bottom
located at 90º to each other, for providing motions in the X or Y axes by
means of lead screws.
• The main function of it is to provide motion in horizontal direction to work
piece.
➢ Table:
• The table is mounted on top of the saddle and can be moved along the X axis.
On top of the table are some T-slots for the mounting of workpiece or clamping
fixtures.
• It can provide three degree of freedom to work piece.
I. It provides vertical motion by moving the knee up and down.
II. It provides horizontal motion by the feed screw.
III. It provides horizontal (transverse) motion by moving the saddle.

➢ Arbor:
It is a mechanical part on which is used as extension part of the spindle in horizontal
milling machine. It is fitted on the spindle whenever required. It holds the tool and
moves it in correct direction.
Arbor Support:
This are used to support Arbor at right place. One end of this support is jointed at
the overhanging arm and another is jointed with Arbor.
➢ Overhanging arm:
It is situated over the column on horizontal milling machine. It is overhang over the
column surface and other end supports the Arbor. It is made by cast iron.
➢ Spindle:
• The spindle holds the tool and provides the actual tool rotation.
• It is motor driven and drives the tool. It has a slot on the front end of it.The
cutting tool fix in that slot.
➢ Spindle Reverse Lever:
The position of this lever determines the spindle direction. The three positions of
the handle are:
• In.
• Middle.
• Out.
The middle position is the neutral position. Never move the spindle reverse lever
when the spindle is turning.
➢ Spindle Speed Selection Lever:
The spindle speed selection lever is used to change the spindle R.P.M. setting. This
type of machine has a geared head so the spindle speed can only be changed when
the spindle is stopped.
➢ Spindle Clutch Lever:
The spindle clutch lever engages the spindle clutch to the motor. By manipulating
the spindle clutch lever the operator can start and stop the spindle.
➢ Feed Rate Selection Lever:
The feed rate selection lever is used to change the feed rate setting. The feed rate
settings are expressed in inches per minute.
➢ Motor Start and Stop Buttons:
The motor start and stop buttons control the power to the main motor for the
machine.
3. Cutting Tools:
Cutting Tools for Horizontal Milling.
Slab Mills: For heavy cutting of large and flat surfaces.

Side and Face Cutters: This type of cutters has cutting edges on the
periphery and sides of the teeth for cutting shoulders and slots.

Slitting Saws: For cutting deep slots or for parting off.

Vertical Milling Machine:

• The vertical milling machine is a precision tool used for shaping and
fabrication by the removal of stock typically from metallic work pieces.
• Workable X,Y,Z three way monetarized speed.
• The rectangular guide rail has good strength and stability.
• Has more accuracy.
 3.1. Parts of Vertical Milling Machine:
• Vertical milling machine which is of similar construction to a horizontal milling
machine except that the spindle is mounted in the vertical position.
• Its additional features are:
I. Milling Head:
The milling head consisting the spindle, the motor, and the feed control unit is mounted
on a swivel base such that it can be set at any angle to the table.
II. Ram:
The ram on which the milling head is attached can be positioned forward and backward
along the slide way on the top of the column.

Cutting Tools for Vertical Milling:

End Mills: Commonly used for facing, slotting and profile milling.
Rough Cut End Mills: For rapid metal removal.

Slot Drills: For producing pockets without drilling a hole beforehand.

Face Milling Cutters: Used For heavy cutting.

Involute gear cutter: There are 7 cutters (excluding the rare half sizes) that
will cut gears from 12 teeth through to a rack (infinite diameter).

Hobbing cutter: These cutters are a type of form tool and are used in hobbing
machines to generate gears.
 4. Milling Operations:
❖ Plain Milling Operation.
❖ Face Milling Operation.
❖ Side Milling Operation.
❖ Straddle Milling Operation.
❖ Angular Milling Operation.
❖ Gang Milling Operation.
❖ Form Milling Operation.
❖ Profile Milling Operation.
❖ End Milling Operation.
❖ Saw Milling Operation.
❖ Milling Keyways, Grooves and Slot.
❖ Gear Milling.
❖ Helical Milling.
❖ Cam Milling.
❖ Thread Milling.
4.1. Plain Milling Operation:

Plain milling is the milling of a flat surface with the axis of the cutter parallel to the machining
surface. It can be carried out either on a horizontal machine or a vertical machine.

4.2. Face Milling Operation:

• The face milling is the simplest milling machine operations.
 • This operation is performed by a face milling cutter rotated about an axis perpendicular
to the work surface.
• The operation is carried in plain milling, and the cutter is mounted on a stub Arbor to
design a flat surface.
• The depth of cut is adjusted by rotating the cross feed screw of the table.

4.3. Side Milling Operation:

• The side milling is the operation of producing a flat vertical surface on the side of a
workpiece by using a side milling cutter.
• The depth of cut is set by rotating the vertical feed screw of the table.

4.4. Straddle Milling Operation:

In straddle milling, a group of spacers is mounted in between two side and face milling
cutters on the spindle Arbor as shown in figure 19. For the milling of two surfaces parallel to
each other at a given distance.
 4.5. Angular Milling Operation:
• The angular milling is the operation of producing an angular surface on a workpiece
other than at right angles of the axis of the milling machine spindle.
• The angular groove may be single or double angle and may be of varying included
angle according to the type and contour of the angular cutter used.
• One simple example of angular milling is the production of V-blocks.

4.6. Gang Milling Operation:

Gang milling is a horizontal milling operation that utilizes three or more milling cutters
grouped together for the milling of a complex surface in one pass. As illustrated in figure 18,
different type and size of cutters should be selected for achieving the desire profile on the
workpiece.

4.7. Form Milling Operation:

• The form milling is the operation of producing the irregular contour by using form
cutters.
• The irregular shape may be convex, concave, or of any other shape. After machining,
the formed surface is inspected by a template gauge.
• Cutting rate for form milling is 20% to 30% less than that of the plain milling.
 4.8. Profile Milling Operation:
• The profile milling is the operation of reproduction an outline of a template or
complex shape of a master dies on a workpiece.
• Different cutters are used for profile milling. An end mill is one of the widely used
milling cutters in profile milling work.

4.9. End Milling Operation:

End Milling is the milling of a flat surface with the axis of the cutter perpendicular to the
machining.

4.10. Saw Milling Operation:

• Saw-milling is the operation of producing narrow slots or grooves on a workpiece by
using a saw-milling cutter.
• The saw-milling also performed for complete parting-off operation.
• The cutter and the workpiece are set in a manner so that the cutter is directly placed
over one of the T-slots of the table.
4.11. T-Slot Milling:
• A dovetail slot or T-slot is manufactured by using special types of cutters designed to
give the required shape on the workpiece.
• The second slot is cut at right angles to the first slot by feeding the work past the
cutter.
• The cutter is set exactly at the centre line of the workpiece and then the cut is taken.

4.12. Gear Milling:

• The gear cutting operation is performed in a milling machine by using a form-relieved
cutter. The cutter may be a cylindrical type or end mill type.
• The cutter profile fits exactly with the tooth space of the gear.
• Equally spaced gear teeth are cut on a gear blank by holding the work on a universal
diving head and then indexing it.
4.13. Helical Milling:
• The helical milling is the operation of producing helical flutes or grooves around the
periphery of a cylindrical or conical workpiece.
• The operation is performed by rotating the table to the required helix angle. And then
by rotating and feeding the workpiece against rotary cutting edges of a milling cutter.
• Production of the helical milling cutter, helical gears, cutting helical grooves or flutes
on a drill blank or a reamer.

4.14. Cam Milling:

• The cam milling is the operation of producing cams in a milling machine by the use of
universal dividing head and a vertical milling attachment. The cam blank is mounted at
the end of the dividing head spindle and an end mill is held in the vertical milling
attachment.
• The axis of the cam blank and the end mill spindle should always remain parallel to
each other when setting for cam milling. The dividing head is geared to the table feed
screw so that the cam is rotated about its axis while it is fed against the end mill. The
 axis of the cam can be set from 0 to 90° in reference to the surface of the table for
obtaining a different rise of the cam.
4.15. Thread Milling:
• The thread milling machine operations are used to produce threads by using a single or
multiple thread milling cutter. Thread milling operation is performed in special thread
milling machines to produce accurate threads in small or large quantities.
• The operation requires three driving motions in the machine. One for the cutter, one for
the work and the third for the longitudinal movement of the cutter.

5. Conclusion:

CNC Milling Machines provide the technology, precision, accuracy, and consistent flow of
procedures for a high production rate. They have the features that make them fast, with low to
zero human errors. You can save time and money and lessen the risk of wastage of materials.
CNC machining offers a reliable solution for rapidly manufacturing the parts. The current
approach, using an indexable tool, managed to eliminate multiple set-ups of the workpiece.
The visibility programme is an effective method to identify orientations for finishing
operations.

6. References:
• Research J. Engineering and Tech. 3(4): Oct-Dec. 2012
• S. S. K. Deepak. Milling Operation and its Optimization – A Literature Review.
Research J. Engineering and Tech. 3(4): Oct-Dec. 2012