Milling machines are an important industrial tool for machining solid materials like wood and

metal. They can perform a vast number of functions ordinarily done by hand, thus speeding up
and facilitating a faster and more efficient workflow. In order to be better informed about what
type of milling machine is best for ones needs, it is best to learn what the different
classifications of mills are and what each is best intended for. Knowing the difference between
horizontal and vertical machines is particularly useful. Milling machines can be purchased from
a machinery shop or warehouse. Mills can also be purchased used from warehouse liquidators or
even from local sellers. The Internet provides a vast selection of milling machines through
authorized dealers or on auction sites like eBay. Whether it be new or used, prospective buyers
should consider their budget and needs before buying one particular type of mill because,
although these machines are very useful, they can also be a substantial financial investment.

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.

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 Mill

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 Mill

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.
 A milling machine is categorized as vertical and horizontal. There are many tasks that a milling machine
can perform such as shaping, boring, drilling, and routing among others. Although this machine is most
commonly used for shaping metals, other solid materials can be shaped as well.

What is a Milling Machine

In manufacturing, one of the most important machine tools is the milling machine. Basically, a
milling machine is used in shaping solid materials, specifically metals. More than anything else,
the milling machine is used in shaping flat and irregular surfaces. Aside from this main function,
the milling machine can also perform other tasks such as drilling, routing, planning, cutting
gears, boring, and producing slots among others. There are some milling machines that are most
effective in performing specific tasks. In order to identify the most appropriate milling machine
to use, it is helpful to distinguish each type of milling machine. Generally, there are only two
categories of milling machines which are the vertical mills and the horizontal mills. The vertical
mills have a vertical orientation of the spindle axis, while the horizontal mills employ a
horizontal orientation of the spindle axis.
Vertical Mills
There are two popular types of the vertical mill. One of these is the bedmill which is set up in
such a way that the spindle is allowed to move parallel to its own axis only, while the table is
contrastingly allowed to move perpendicular to the axis of the spindle. On the other hand, the set
up the turrent mill is such that the spindle stays stationary during cutting operations while the
table is allowed to move in both the perpendicular and vertical directions to the axis of the
spindle. Although this mill is smaller than the bedmill, this is considered as the more versatile
type.
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What is a Milling Machine

written by: jaychris edited by: Lamar Stonecypher updated: 1/8/2010

A milling machine is categorized as vertical and horizontal. There are many tasks that a milling machine can perform
such as shaping, boring, drilling, and routing among others. Although this machine is most commonly used for
shaping metals, other solid materials can be shaped as well.

What is a Milling Machine

In manufacturing, one of the most important machine tools is the milling machine. Basically, a milling machine is used
in shaping solid materials, specifically metals. More than anything else, the milling machine is used in shaping flat
and irregular surfaces. Aside from this main function, the milling machine can also perform other tasks such as
drilling, routing, planning, cutting gears, boring, and producing slots among others. There are some milling machines
that are most effective in performing specific tasks. In order to identify the most appropriate milling machine to use, it
is helpful to distinguish each type of milling machine. Generally, there are only two categories of milling machines
which are the vertical mills and the horizontal mills. The vertical mills have a vertical orientation of the spindle axis,
while the horizontal mills employ a horizontal orientation of the spindle axis.

Vertical Mills
There are two popular types of the vertical mill. One of these is the bedmill which is set up in such a way that the
spindle is allowed to move parallel to its own axis only, while the table is contrastingly allowed to move perpendicular
to the axis of the spindle. On the other hand, the set up the turrent mill is such that the spindle stays stationary during
cutting operations while the table is allowed to move in both the perpendicular and vertical directions to the axis of the
spindle. Although this mill is smaller than the bedmill, this is considered as the more versatile type.

Horizontal Mills
The horizontal mills have the cutters mounted horizontally on an arbor across the table. With this set up, the
workpieces can be fed from three axes. Although side milling can be done by these mills, these are most commonly
used in end and face cutting. One of the major disadvantages of these mills though is the great number of controls
which make the operation of these mills relatively slower.

There are some important factors to consider in choosing milling machines. These include the milling feed direction,
cutting speeds, feed rates, and lubrication. The feed direction is important because it affects the performance of the
mill and the quality of the workpieces. Cutting speeds have to match accordingly with the type of material and cutter.
Moreover, cutting speeds should also match the type of work done by the mill such as finishing. A recommended list
of feeding rates is also provided by various manufacturers for the proper operation of milling machines. It is worth
noting that the recommended feeding rates vary for every type of milling cutter used. Finally, proper lubrication should
be provided when milling metals and alloys.

Today, there are various types of milling machines available in the market. Although there are still a lot of machinists
that prefer the traditional manual operated and the mechanical automated milling machines, the computer numerical
control (CNC) milling machines are also gaining popularity worldwide.

The vertical knee mill is the most common milling machine found in machine shops today.
Therefore it will be used as an example to describe the general parts of all mills.

Take a look a the milling machine parts and, as you read the text below, see if you can find
the bold names in the image.
 The head (drive) is that part of the drive system that transforms electrical power from a
motor to mechanical power in the spindle. The drive system also allows the machinist
to change the speed of the spindle (RPM) and therefore the cutting tool. The quill moves
vertically in the head and contains the spindle in which cutting tools are installed.. The
quill feed hand wheel moves the quill up and down within the head as does the quill
feed lever. The knee moves up and down by sliding on ways that are parallel to the
column.

The saddle sits on the knee and allows translation of the worktable. Sitting on the base
is the column whose main function is to hold the turret. The turret allows the milling
head to be rotated around the column's center. The overarm (ram) slides on the turret
and allows the milling head to be repositioned over the table.

The longitudinal traverse hand wheel moves the worktable to the left and right, the
cross traverse hand wheel moves the work table in and out, the vertical movement
crank moves the knee, saddle, and worktable up and down in unison.

The principle parts of milling machine are given:

Base

The base of the machine is Grey iron casting accurately machined on its top and bottom surface
and serves as a foundation member for all the other parts which rest upon it. It carries the column
at its one end. In some machines, the bage is hollowed and working as a reservoir for cutting
fluid.

Column

The column is the main supporting frame mounted vertically on the bage. The column is box
shaped. Heavily ribbed inside and houses all the driving mechanisms for the spindle and table
feed. The front vertical face of the column is accurately machined and is provided with dovetail
guide ways of supporting knee. The top of the column is finished to hold an over-arm that
extends outward at the front of the machine.

Knee

The knee is the rigid gray iron casting that slides up and down on the vertical way of the column
face. The adjustment of height is effected by elevating screw on the base that also supports the
knee. The knee houses the feed mechanism of the table, and in different controls to operate it.
The top face of the knee forms slid way for the saddle to provide cross travel of the table.

Saddle
The saddle is placed on the top of the knee, which slides on guide ways set exactly at 90 to
column face. A cross feed screw near the top of the knee engages a nut of the bottom of the
saddle to move it horizontally, by hand or power, to apply cross feed. The top of the saddle is
accurately machined to provide guide ways for the table.

Table

The table rest on ways on the saddle and travels longitudinally. The top of the table is accurately
finished and T-slots are provided for clamping the work and other fixtures on it. A lead screw
under the table engages a nut on the saddle to move the table horizontally by hand or power. The
longitudinal travel of the table may be limited by fixing trip dogs on the side of the table. In
universal machines, the table may also be swiveled horizontally. For this purpose the table is
mounted on a circular bage which in its turn is mounted on the saddle. The circular bage is
graduated in the degree.

Over hanging arm

Over hanging arm is mounted on the top of column extends beyond the column face and serve as
a bearing support may be provided nearest to the cutter. More than one bearing support may be
provided for the arbor.

Milling Machine
Milling Machine

Front Brace

The front brace is an extra support that is fitted between the knee and over arm to ensure further
rigidity to the arbor and the knee. The front brace is slotted to allow for adjustment of the height
of the knee relative to over arm.

Spindle

The spindle of the machine is locates in the upper part of the column and receive power
from the motor through belts, gears and clutches and transmit it to the arbor the front end
of the spindle just projects from the column face and it is provided with a tapered hole
into to which various cutting tools and arbors may be inserted. The accuracy in metal
machining by the cutter depends on primarily accuracy, strength and rigidity of the
spindle.

Arbor

An arbor is considered as an extension of the machine spindle on which cutters are

securely mounted and rotated. The arbors are made with taper shanks for proper
 alignments with machine spindles having taper hole on their nose. The taper shank of the
arbor conforms to the Morse taper or self release taper whose value is 7:24. The arbor
may be supported at the farthest end from the over hanging arm or may be of cantilever
type which is called stub arbor.

Milling Machine Construciton

Milling Machine Construciton
Milling machine may be defined as the type of machine in which the metal is removed by
causing the job to be fed against a revolving cutting tool called the milling cutter, which
has one or more cutting...