Milling Operation001

Milling operation
Module 4
Milling
Milling is a machining operation in which work is fed past
a rotating tool with multiple cutting edges.
• Axis of tool rotation is perpendicular to feed direction.
• Creates a planar surface and other geometries possible

either by cutter shape or path.
• Other factors and terms:

– Milling is an uninterrupted cutting operation
– Cutting tool called a milling cutter, cutting edges called "teeth"
Figure ‑ Two forms of milling:
(a)peripheral milling, and (b) face milling
Slab Milling
The basic form of peripheral milling in which the cutter
width extends beyond the workpiece on both sides
Figure
(a) slab milling
Conventional
Face Milling
Cutter overhangs
work on both
sides
Figure
(a) conventional face milling
Slotting
• Width of cutter is less than workpiece width, creating a slot
in the work
Figure
(b) Slotting
End Milling
Cutter diameter is
less than work
width, so a slot is cut
into part
Figure (c) end milling

Profile Milling
Form of end milling

in which the
outside periphery
of a flat part is cut
Figure (d) profile milling

Pocket Milling
Another form of
end milling used to
mill shallow
pockets into flat
parts
Figure (e) pocket milling

Surface Contouring
Ball‑nose cutter is
fed back and forth
across the work
along a curvilinear
path at close
intervals to create a
three dimensional
surface form
Figure (f) surface contouring
Types of milling machines
• Column and knee type
1. Horizontal milling
2. Vertical milling
3. Plain milling
4. Universal milling
• Special type
1. Rotary table
2. Drum milling
3. Planetary milling
4. Profiling and tracer type
5. CNC milling
Column and Knee type
milling machine:
• In this machine a vertical column is attached to the

bed which consist all gear drives which rotate the
knee and saddle.
• A knee is situated on the base which can provide
vertical motion to the work piece or which can move
up and down.
• A saddle is attached to the upper section of the knee
which can move in transverse direction.
• The table is placed over the which can hold the work
piece by use of climbing bolts.
Horizontal Knee-and-column Milling Machine
• As the name implies

the spindle is
situated horizontally.
• The spindle rotates
horizontally.
• A arbor is attached
to the machine
which holds the
cylindrical disk shape
cutter which cuts the
metal work piece.
Main parts of horizontal milling m/c
1. Base
2. Column
3. Knee
4. Table
5. Overhanging arm
6. Spindle
7. Arbor
8. Arbor bracket
Arbor
Vertical Knee‑and‑Column Milling Machine
• This is one of the types
of knee and column
milling machine.
• The spindle of this
machine is in vertical
position.
• No arbor is required in
this machine.
• The cutter tool has
cylindrical shape and
the cutting edges are
situated at the
circumference of the
cylindrical face.
Vertical v/s Horizontal
Universal milling machine
• The universal milling

machine is same as
horizontal milling
machine except there is
a arrangement of swing
up the table to 45
degree in either
direction.
• This is advantageous
when milling spirals
and helical gears.
Omniversal Milling Machine
• In this machine, the table having all the movements of a
universal milling machine, and can be tilted in a vertical
plane by providing a swing arrangement at the knee.
• The entire knee assembly is mounted in such a way that
it may be fed in longitudinal direction horizontally.
• The additional swivelling arrangement of the table
enables it to machine taper spiral grooved in reamers,
bevel gears etc.
• It is essentially a tool room and experimental shop
machine.
Planner milling machine
• Planner milling machine is
mostly used for facing
operation in mass
production.
• These machine are similar to
the bed type milling
machine except it can
mounted with various
cutters and spindle heads to
the machine.
• These cutters can perform
the facing operations
simultaneously.
CNC Milling machine
• CNC is most versatile milling machine which is
control by a computer.
• It is upgrade version of bed type milling machine in
which the spindle can move in all three direction and
the table can rotate 360 degree.
• These all movement is hydraulically controlled which
is command by a computer. Any difficult geometry
can make on it.
• A sketch of the work piece is loaded to the computer
which is cut on work piece by the cutters
automatically.
Principle of CNC Milling Operation
The following are the principles of CNC milling
operation:
1. Movement of X, Y, Z axis are controlled by motor supplied
either with AC or DC.
2. Movement of machine part is done by giving commands.
3. All the operations are carried out by codes like speed,
feed, depth of cut etc.
4. For each operation separate code is available.
5. Warning system is available to safe guard the various
operations and components.
Types of milling cutters
Types of cutters
a) Peripheral
b) Slitting
c) Slab milling
d) Angular milling
e) Profile milling
f) Side milling
g) Straddle milling
h) Pocket milling
End mill cutter
Milling cutters
Straddle Milling
• When two or more
parallel vertical surfaces
are machined at a single
cut, the operation is
called straddle milling.
• Straddle milling is
accomplished by
mounting two
side milling cutters on
the same arbor, set apart
at an exact spacing.
Nomenclature of a Plain Milling Cutter
Milling cutter nomenclature.
• The pitch refers to the angular distance between adjacent teeth. The pitch is
determined by the number of teeth.
• The cutting edge is the angle on each tooth that performs the cutting.
• The land is the narrow surface behind the cutting edge on each tooth.
• The rake angle is the angle formed between the face of the tooth and the
centerline of the cutter. The rake angle defines the cutting edge and provides a
path for chips that are cut from the work piece.
• The primary clearance angle is the angle of the land of each tooth measured
from a line tangent to the centerline of the cutter at the cutting edge. This angle
prevents each tooth from rubbing against the workpiece after it makes its cut.
Side milling cutter
Selection of Milling Cutters
• High-speed steel, stellite, and cemented carbide cutters have a distinct
advantage of being capable of rapid production when used on a machine that can
reach the proper speed.
• The harder the material, the greater will be the heat that is generated in cutting.
Cutters should be selected for their heat-resisting properties,
• Use a coarse-tooth milling cutter for roughing cuts and a finer-toothed milling
cutter for light cuts and finishing operations.
• Some operations can be done with more than one type of cutter such as in
milling the square end on a shaft or reamer shank. In this case, one or two side
milling cutters, a fly cutter, or an end milling cutter may be used.
• The milling cutter should be small enough in diameter so that the pressure of
the cut will not cause the workpiece to be sprung or displaced while being
milled.
Cutter holding devices
1. Arbor
2. Collets
3. Adapter
4. Quick change tooling adapter
1. Arbor
Taper used for arbors
Types of arbor
2. Collet
Collets
Collets
• A collet is a form of a sleeve bushing for

reducing the size of the hole in the milling
machine spindle so that small shank tools can
be fitted into large spindle recesses
3.Adapters
Adapters
1. Spindle Adapters
• A spindle adapter is a form of a collet having a

standardized spindle end.
• They are available in a wide variety of sizes to
accept cutters that cannot be mounted on arbors.
• They are made with either the Morse taper shank
or the Brown and Sharpe taper with tang having a
standard spindle end
Chuck Adapter
• A chuck adapter is used to attach chucks to milling
machines having a standard spindle end.
• The collet holder is sometimes referred to as a

collet chuck.
• Various forms of chucks can be fitted to milling

machines spindles for holding drills, reamers, and
small cutters for special operations.
Chuck adapter
Quick-Change Adapter
• The quick-change adapter mounted on the spindle nose is
used to speed up tool changing.
• Tool changing with this system allows you to set up a number

of milling operations such as drilling, end milling, and boring
without changing the setup of the part being machined.
• The tool holders are mounted and removed from a master

holder mounted to the machine spindle by means of a
clamping ring.
Quick-Change Tooling adaptor
Holding cutter
Work holding devices
1. T-bolts
2. Table vise
3. Parallels
4. V blocks
Clamp and parallel
Table vise
Angle plate
Circular table
Universal table
V block
T bolt and fixtures
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Milling operation

• Axis of tool rotation is perpendicular to feed direction.

• Creates a planar surface and other geometries possible

• Other factors and terms:

Figure (c) end milling

Form of end milling

Figure (d) profile milling

Figure (e) pocket milling

• In this machine a vertical column is attached to the

• As the name implies

• The universal milling

• A collet is a form of a sleeve bushing for

• A spindle adapter is a form of a collet having a

• The collet holder is sometimes referred to as a

• Various forms of chucks can be fitted to milling

• Tool changing with this system allows you to set up a number

• The tool holders are mounted and removed from a master

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