MILLING

 It is the machining process in which the removal of metal takes place due to
the cutting action of a rotating milling cutter.

 The cutter rotates at a high speed, and because of the many cutting edges, it
removes the metal at a very faster rate.

 The metal removal rate is higher as compared to a lathe machine, plannar

machine and a shaper machine.

 It has good accuracy and better surface finish.

 Milling machines are used for machining flat surface, contoured surfaces and
external and internal threads etc..

 Machine can hold one or more number of cutters at a time.

 As the work piece moves against cutting edges of the milling cutter, metal is
removed in the form of chips.

 Machined surface is formed in one or more passes of the work.

 The rotary of the speed of the cutting tool and the feed rate of the work
piece depend upon the type of material being machined.
Types of milling machine
1. Column and knee type
 Hand milling machine
 Plain milling machine
 Universal milling machine
 Vertical milling machine

2. Manufacturing or fixed bed type.

 Simplex
 Duplex
 Triplex

3. Planer type

4. Special type
1. Hand milling machine

 It is the simplest type of milling machine used to make light and simple milling
operations.

 The feeding movement of the table is controlled by hand control.

 The cutter is mounted on the horizontal arbor.

 This milling machine is very compact

2. Plain milling machine

 Much more rigid compared to hand milling machine.

 The milling machine table may feed by hand or power against

a rotating cutter on horizontal arbor.

 The plain milling machine has horizontal spindle, then it is

called as horizontal milling machine.
3. Universal milling machine

 The appearance of universal milling machine is similar to that of plain milling

machine.

 It is used to make very wide range of milling operations.

 The work table is mounted on circular swiveling base.

 The table can swilled to any angle up to 45 degree on either side of normal
position.

 This feature is used to make helical grooves by milling.

4. Vertical milling machine
 Vertical milling machine has a vertical spindle.
 Milling machine

 Base
 Column
 knee
 Saddle
 Table
 Overhanging arm
 Front brace
 Spindle
 Arbor
1. Base
 The base of the machine is a grey iron casting and serves as a foundation member
for all other parts which rest on it.
 The base carries the column at its one end.
 in some machine base will be hollow and works as reservoir for cutting fluid.

2. Column
 The column is the main supporting frame mounted on the base.
 It is box shaped and houses all the driving mechanism for the spindle and feed table.

3. Knee
 The knee is a fixed grey iron casting that slides up and down on the vertical ways of
the column face.
 The adjustment of height affected by an elevating screw mounted on the base that
also supports the knee.
 The knee houses the feed mechanism for the table.
 The top face of the knee forms a slide way for the saddle that gives cross travel to
the table.
4. Saddle
 On the top of the knee is places the saddle. Which slides on the guide ways set
exactly at 90 degrees to the column face.
 A cross feed screw is provided on the bottom of the saddle to move horizontally by
hand or power.
 The top of the saddle is precisely machined to provide guide ways for the table.

5. Table
 It rests on the guide ways of saddle and travels longitudinally.
 The top of the table is finished accurately and T –s lots are provided for clamping
the work.
 A lead screw is provided under the table, it helps to move the table horizontally by
hand or power.

6. Spindle
 Spindle of the machine is located in the upper part of the column and receives
power from the motor through belt and gears and transmit it to the arbor.
7. Arbor
 It is an extension of the machine spindle on which the milling cutters are securely
mounted and rotated.
 The arbor may be supported at the farthest end from the overhanging arm by stub
arbor.

8. Elevating screw
 The upward movement and the downward movement to the knee and the table can be
given by means of elevating screw which is operated either manually or Automatic.
 MILLING METHODS
 Generally milling operations can be classified as two major groups
 Peripheral milling
 Face milling
1. Peripheral milling
 In this operation axis of the cutter is parallel to the surface being
machined .
 Peripheral milling can be carried out in two methods
a) Up milling or conventional milling
b) Down milling or climb milling

2. Face milling
 Produces a flat surface perpendicular to the axis of rotation of the cutter.
Up milling
 In this case rotation of the cutter is in opposite to the direction of the feed.
 In up milling cutting force acts upwards; hence there is a tendency to lift the
work piece of the table.
 The chip thickness is minimum at the beginning of the cut and maximum at
the end.
 In up milling cutting force increases from zero to maximum value per tooth
movement of the cutter.
 There is a tendency for the tooth to rub on the work surface just before the
tooth makes contact.
 This contributes to reduced tool life and poor surface finish.
Down milling
 In this case rotation of the cutter is in the same direction of the feed.
 In up milling cutting force acts downwards; hence there is no tendency to lift
the work piece of the table.
 Thus more power is available for cutting.
 The chip thickness is maximum at the beginning of the cut and minimum at
the end.
 In up milling cutting force increases from maximum to zero value per tooth
movement of the cutter.
 Provide better surface finish.
 MILLING CUTTERS
 Milling cutters are rotating tools with number of cutting edges.
 Many type of milling cutters are used on milling machine.
 They are classified by the methods of mounting the cuter on the
machine, according to their general shape and the type of work they
will do.
 Cutters may have teeth on the periphery or ends only or on both.

1. Plain milling cutter

2. Side milling cutter
3. Metal slitting saw cutter
4. Angle milling cutter
5. End milling cutter
6. T slot cutter
7. Form milling cutter
1. Plain milling cutter
 Cutters are cylindrical in shape and have cutting teeth on periphery
only.

 These cutters are used for the production of flat surfaces parallel to
the rotation of the spindle.

 The cutter teeth may be straight or helical according to the size of the
cutter.

 Side face no cutting action is provided.

 3 types
1. Light duty plain milling cutter
2. Heavy duty plain milling cutter
3. Helical plain milling cutter
2. Side milling cutter
 Cutters have teeth on its periphery and also one or both of its sides.
 These cutters are employed for removing metals from the side of a work piece.
 It is used for straddle milling , face milling .
 Different types are
1. Plain milling cutters
 Cutters have cutting teeth on periphery and on both sides.
 Used for face milling or cutting slot

2. Staggered teeth side milling cutter

 Cutters have alternate teeth with have helix angle.
 Used for key way cutting.

3. Half side milling cutter

 Teeth on its circumference and one of its sides.
3. Metal slitting cutter
 Metal slitting cutters are also called as metal slitting saws.

 They appear like plain or side milling cutter but they are of very
small width.

 These type of cutters are mostly used for parting off operation and
for slotting.
4. End milling cutter
 End milling cutters have cutting teeth on the end as well as on the
circumference of the cutter.

 The teeth on the circumference may be straight or helical.

 These cutters are used for light milling operations such as cutting slots,
machining accurate wholes, profile milling and narrow flat surface.
5. T-slot milling cutters

 They are special form end mills for producing T- slots.

 The teeth are provided on the periphery as well as on the both sides of
the cutter.
 It looks like a side milling cutter with shank
6. Angle milling cutter
 The angle milling cutters are made of single or double angle cutter
and are used to machine angle other than 90 degree.

 the cutting edges of the angle milling cutters are formed at the conical
surface around the periphery of the cutter.

 Its angular teeth are neither parallel nor normal to their axis.

 They are mostly used in milling V-grooves, notches and other angular
surfaces.
7. Form milling cutter
 Also called form relieved milling cutters or radius cutters.
 The form cutters have irregular profiles on cutting edge, to generate
irregular outline of the work.
a) Convex milling cutters
 They have teeth curved outward on the circumferential surface to form
contour of a semi circle.
 It used to produce concave surface.

b) Concave milling cutters

c) Gear cutters