Milling

INTRODUCTION-Milling

•The tool is spinning.

•One or more linear movements
N
may have the tool or the part.
ap
F ae

DC

N Spindle speed (rpm)

N Vc Cutting speed (m/min)

Dc Tool diameter (mm)

F Feed rate (mm/min)

A milling cutting tool is similar to the ap Axial cutting depth (mm)
turning cutting tool, but many tools called
“teeth” integrate it. ae Radial cutting depth (mm)
 INTRODUCTION

Z
Y

X
 INTRODUCTION: MILLING TYPES
Side or Peripheral Shoulder Milling
Face Milling
Milling (Face & Side Milling)

Cutting mov.
Cutting mov.

Feed mov. Feed mov.

Cutting mov.
Feed mov.

• Cutting depth in axial • Cutting depth in radial • Cutting depth in axial and
direction. direction. radial direction.

• It uses mainly the cutting edges • It uses mainly the cutting edges • It uses the cutting edges on the
on on the periphery of the tool. on the periphery of the tool. face and periphery of the tool.

• Surface roughness created by • Surface roughness created by • Surface roughness created by

face teeth. side teeth. face and side teeth.
 INTRODUCTION: MILLING TYPES

Up milling Or conventional Down milling or Climb Milling

1. Work piece is fed in opposite direction of 1. Work piece is fed in same direction of
that of cutter. that of cutter.
2. Chips are progressively thicker. 2. Chips are progressively thinner.
3. Strong clamping is required since the 3. Strong clamping is not required since the
cutting force is directed upwards and tends cutting force is directed downwards and
to lift the work piece. keeps work piece pressed to table.
4. Poor surface finish and used for hard 4. Good surface finish and used for soft
materials. materials.
MACHINE TYPES
 MACHINE TYPES
Horizontal and Vertical Milling machines
According to their main rotational axis…

Rotational axis
direction
Rotational axis
direction

Vertical Milling Machine Horizontal Milling Machine

 MACHINE TYPES
Horizontal and Vertical Milling machines
According to their main rotational axis…

Cutting Cutting Cutting depth

movement Cutting depth movement movement
movement

Feed
Feed
movement
movement

Vertical Milling Machine Horizontal Milling Machine

MACHINE TYPES
 MACHINE TYPES
Conventional milling machines

Column and knee type

• Manual movements execution.

• Manual tool and part change.
• Machine may have or not an overarm: Spindle mounted to a movable
housing on the column to permit positioning the milling cutter forward or
X rearward in a horizontal plane.

Machine principal components:

Y 1. Column: supports the spindle. The tool has no linear movements,
just the rotational cutting movement.
2. Knee: supports the work table. It has all the linear movements: X, Y
Z & Z.

Machine types:
1. VERTICAL MACHINE
VIDEO 2. HORIZONTAL MACHINE
3. UNIVERSAL MACHINE
 MACHINE TYPES
Conventional milling machines
Column and knee type

VERTICAL MILLING MACHINE 2 HORIZONTAL MILLING MACHINE

1 • Arbor supports the cutter and an overarm
• Cutter is directly mounted in the spindle.
• Typical for face and end milling operations. the arbor.
• Typical for side or peripheral milling
operations.
 MACHINE TYPES
Conventional milling machines
Column and knee type

UNIVERSAL MILLING MACHINE

3 • It is a vertical and horizontal milling machine at the same time.
• Types:

Hure spindle:
It has a swiveling spindle that allows to swivel the
Vertical & horizontal spindle at different angles. Vertical milling
spindle attachment

VIDEO VIDEO
 MACHINE TYPES
Conventional milling machines

Bed type
➢ The tool has the perpendicular movement. Z
➢ The worktable has the X & Y movements.
➢ Greater rigidity. Used for voluminous and
heavy parts.

A special machine type:

ROTARY TABLE TYPE

» It has a roughing spindle and a
finishing spindle.
Z
 MACHINE TYPES
CNC Machines

CNC Milling machine

➢ Automatic movements execution.

➢ Manual tool change.
➢ Manual part change.
➢ Usually, it is not needed any special workholding
device.

• Machining time: less than in an universal milling.

• Idle time: very short
• Set-up time: slightly important (programming)
• Series: 10 to 1000 parts, or more.
• Precision: IT7/8, Ra ~ 0.8 -1.6 µm.
 MACHINE TYPES
CNC Machines

Bed type
Z

X
1 BRIDGE TYPE OR PLANER MILLING MACHINE

➢ The part has the longitudinal axis movement.

➢ Spindle carriers are mounted on cross-rails (bridge structure).
➢ Large size milling machines.
➢ Suitable for flat surfaces of heavy components.
➢ May use several spindle heads (vertical or horizontal).
VIDEO
 MACHINE TYPES
CNC Machines

Bed type Z
Z
Y
Y
X
X

GANTRY MILLING MACHINE TRAVELLING COLUMN MILLING MACHINE

2 3
➢ Similar to the bridge type machine, but ➢ The part has no movement at all.
the workpiece has no movement at all.
➢ Typically used for large size parts.

VIDEO VIDEO
 MACHINE TYPES
CNC Machines tool magazine CNC

Machining Centre
➢ It is a CNC milling machine equipped by an
automatic tool changer.
➢ Automatic tool changer using tool magazine or
carousel.
➢ Automatic part changer using pallets (optional).

Machining time: similar to CNC Milling machines.

Idle time: smaller than in CNC Milling machines.
Set-up time: slightly important (programming &
setting-up)
Series: 10 to 1000 parts, or more
Precision: IT7/8, Ra ~ 0.8 -1.6 µm.

tool magazine tool carousel

 MACHINE TYPES
CNC Machines

4 AXIS
Machining Centre
Machine has CNC controlled X,Y & Z linear movements
+ 1 rotational movement.
3 AXIS
a) Horizontal rotary table
b) Vertical rotary table
➢ Machine has CNC controlled
c) Rotary spindle
X,Y & Z linear movements.
To obtain surfaces with a cylindrical pattern (e.g. gears,
polygonal geometries,…).

Integrated vertical rotary table

(C axis)

VIDEO VIDEO Horizontal rotary table (A axis)

19
 MACHINE TYPES
CNC Machines

Machining Centre

5 AXIS

➢ Machine has CNC controlled X,Y & Z linear movements

+ 2 rotational movements.
Types:

2 Swiveling head VIDEO

▪ Heavier parts can be machined.
▪ Shorter tools are needed.

3
Vertical machine Horizontal machine

Trunnion table VIDEO

1 A larger working volume.
More powerful spindle Heavier removal Combination type
rates. Higher versatility (part can be clamped
Bigger rotational movement capability. on the rotary table or out of it).
 MACHINE TYPES
CNC Machines
MULTITASKING MACHINE – HORIZONTAL (I)
Machining Centre
• Several technologies are integrated into one machine:
turning, milling, drilling,…
• It has evolved from turning machines.
• The heart of the machine is the tool spindle (B
spindle), which even can be tilted. It provides milling,
drilling and tapping capability along with turning,
facing, grooving and threading.
• This spindle is serviced by an automatic tool changer
that resides outside the cutting zone.
• It may have a double spindle and one/two tool turrets.
• Application: very complex parts.

VIDEO
WORKHOLDING DEVICES
 WORKHOLDING DEVICES
Vise

The most common type of workholding

device for small parts.
Part is hold by pressure driven:
Mechanically
Pneumatically
Hydraulically
Types based on the degree of freedom:
Plain vise
PNEUMATIC VISE HYDRAULIC VISE
Plain vise with swivel base
Universal vise with swivel base
MECHANICAL VISE VIDEO

Plain vise Plain vise with swivel base Universal vise

 WORKHOLDING DEVICES
Clamps

Used for big size or irregular parts.

Part is hold using clamps, t-slot bolts, screws, washers, nuts, parallels, step blocks,… VIDEO
It is important to keep in mind the efforts/deformations produced on the part.

T-slot bolt
T-nut Washer

Angle plate
Toe mold clamp

Step block Swing clamp Cam clamp C clamp V block

 WORKHOLDING DEVICES
Modular fixturing system

Based on a drilled and/or grooved baseplate.

It allows to build different workholding systems from a set of standard

components (clamps, positioners,…).

VIDEO VIDEO
 WORKHOLDING DEVICES
Indexing head / Rotary table

MOTOR DRIVEN

Commonly used for machining angularly equidistant surfaces.

The chuck allows to hold and rotate the part working at different
angles.
Similar clamping possibilities to the turning process:
Jaw chuck
Between chuck and center
Between centers
VIDEO
MANUALLY OPERATED

VIDEO
 WORKHOLDING DEVICES
Magnetic Chuck

Ideal for ferromagnetic parts.

Powerful workholding system.
Usually electronically activated.
Part centering may be time consuming.

VIDEO
 WORKHOLDING DEVICES
Vacuum Chuck

Ideal for thin and flat metal sheets, non-porous surfaces.

Hold down forces are not extremely high.
Uniform holding pressure on the entire workpiece surface.

VIDEO
TOOLHOLDING DEVICES
 TOOLHOLDING DEVICES
Toolholder

Weldon / Whistle Notch Collet chuck

Weldon Whistle Notch VIDEO VIDEO

Power chuck Hydraulic chuck Shrink fit (thermal)

VIDEO VIDEO VIDEO

 TOOLHOLDING DEVICES
Tool holder

Safe Lock Polygonal clamping

Pull out protection

Clamping steps

VIDEO
 TOOLHOLDING DEVICES
Extension adaptor

Overhangs should be minimized.

MACHINING OPERATIONS
 MACHINING OPERATIONS
1.Face Milling
Face Milling:
Operation carried out for producing a flat
surface, which is perpendicular to the axis
of rotating cutter.
Cutter: Face milling cutter.
Machine: Vertical Milling Machine

High feed
Low cutting depth
 MACHINING OPERATIONS
2. Shoulder Milling

Roughing

Finishing

VIDEO
 MACHINING OPERATIONS
3. Slot Milling
Slot Milling:
Operation of producing slots like T-slots, plain slots etc.,
Cutter:
End milling cutter, T-slot cutter, side milling
1 END MILLING
cutter Machine:
Vertical Milling Machine
 MACHINING OPERATIONS
4. T-shape Slot Milling

It requires a previous slot milling operation of width

bigger than the T-shape tool shank.
The use of air flow is highly recommended in order
to evacuate the chip continuously.

5. Helical Slot Milling

It requires a coordination between the rotational

speed (N) and the feed per revolution (fn).
 MACHINING OPERATIONS
6. Dovetail Milling 7. Form Milling

VIDEO VIDO

Form Milling:
Operation of producing all types of angular cuts
like V-notches and grooves, serrations and
angular surfaces.
Cutter: Double angle cutter.
Machine: Horizontal Milling Machine
 MACHINING OPERATIONS

8. Gang Milling

Two or more milling cutters mounted on the same

arbor.
Displacing the cutters half a pitch in relation to
each other assists in avoiding vibration.
High productivity, high removal rate.
Medium/big series.
The use of a fly-wheel reduces torsional vibrations.
 MACHINING OPERATIONS

9. Chamfering

10. Corner rounding

 MACHINING OPERATIONS
11. Profile Milling

ROUGHING

VIDE
O
VIDE
O

FINISHING
 MACHINING OPERATIONS
12. Gear Milling

TYPE OF GEARS

External & Internal gears Splines Bevel gears and pinions

VIDEO
Hobbing (productivity ↑)
 MACHINING OPERATIONS
13. Turn Milling

A curved surface is milled while rotating

the workpiece around its centre point.

2 METHODS:

Main method for external machining. Used mainly for internal features.
Same principle as for circular milling /
ramping, but with component rotating.

Face turn milling – 4/5 axes Periphery turn milling – 3/4 axes
 MACHINING OPERATIONS
14. Boring

Excellent dimensional
tolerances and surface
roughnesses.

a a a >a

ROUGHING FINISHING VIDEO

BORE FACE GROOVING

It is a productive alternative way to produce

circular grooves.
Increased productivity.
Diameters from 47mm to 1275mm.
It can be done in vertical or horizontal machines.
 MACHINING OPERATIONS
15. Drilling
 MACHINING OPERATIONS
16. Thread Milling

TAPPING

Synchronization of the feed movement and rotational movement is a must.

1
If the machine spindle is not prepared for direct threading, a special
toolholder needs to be used.
 MACHINING OPERATIONS
17. Reaming
Objective: To achive a good surface roughness and good
dimensional tolerances (H7) in a pre-drilled hole.
High penetration rates and small depths of cut.
The tool is called “reamer”.

The reamer never should be

spinned counterclockwise.

RIGHT WRONG

Spiral flute Straight flute

Lateral coolant supply Axial coolant supply
For through holes For blind holes
MILLING APPLICATIONS
 BIOMEDICAL APPLICATIONS

MONOBLOCK PROSTHESIS – BONE PLATE –

Titanium Titanium
VIDEO VIDEO

MOULD FOR PILLS – DENTAL BRIDGE PROSTHESIS – IMPLANTABLE MEDICAL PORT

Steel Titanium OR DRUG DELIVERY SYSTEM
– Titanium
 BIOMEDICAL APPLICATIONS

LAB ON A CHIP (Blood plasma separator) – Steel

SPINAL CROSS CONNECTOR – Stainless steel

AEROSPACE APPLICATIONS

3 – BLISK –
Titanium
 AEROSPACE APPLICATIONS

1 – WING RIB – Aluminium

3 – ENGINE MOUNT – Titanium

1 – WING – Composite 8 – VERTICAL TAIL –

Composite 5 – FLAP TRACK – Stainless steel
 AUTOMOTIVE APPLICATIONS

TURBO CHARGER – CYLINDER HEAD –

Stainless Steel Cast iron or aluminium

STEERING KNUCKLE –
Cast iron or steel
DIE & MOULDS APPLICATIONS

OPERATION OVERVIEW
1. Face milling
2. Shoulder milling
3. Profile milling
4. Drilling
5. Hard part finishing
6. Semi finishing - Roughing
7. Semi finishing - Roughing

STAMPING DIE –
Steel
POWER GENERATION APPLICATIONS

GAS TURBINE BLADE –

Stainless steel or Titanium
 WIND POWER APPLICATIONS

OPERATION OVERVIEW
OPERATION OVERVIEW 1. Face Milling
1. Face milling 2. Shoulder Milling
2. Boring 3. Helical or Circular Interpolation
3. Back facing 4. Finish Boring
4. Drilling 5. Back Facing
5. Thread milling 6. Drilling
7. Threading
8. Chamfering

GEARBOX HOUSING HUB

Cast iron Cast iron
MACHINING TIME
 MACHINING TIME
Peripheral or side milling

L
L

L
 MACHINING TIME
Face milling

L
L

L
 CUTTING PARAMETERS: MILLING
WORKPIECE TOOL MATERIAL OPERATION Vc fz Ap Ae
MACHINE
MATERIAL (m/min) (mm/tooth*rev) (mm) (mm)

MILLING STEEL HIGH Face milling D 20 - 25 0.05 – 0.1 D 1-2 D (~2/3)Ø

MACHIN SPEED A 25 - 30 0.01 – 0.05 A 0.2-0.5 A (~2/3)Ø
E STEEL Side milling D 20 - 25 0.05 – 0.1 D (50%- D (10%-25%)Ø
(HSS) A 25 - 30 0.01 – 0.05 80%)Ø A A (5%-10%)Ø
(50%-80%)Ø
Other milling D 15 - 20 0.05 – 0.1
A 20 - 25 0.01 – 0.05
HARD METAL Face milling D 80 - 100 0.05 – 0.1 D 1-2 D (~2/3)Ø
A 100 – 120 0.01 – 0.05 A 0.2-0.5 A (~2/3)Ø
Side milling D 80 - 100 0.05 – 0.1 D (50%- D (10%-25%)Ø
A 100 – 120 0.01 – 0.05 80%)Ø A A (5%-10%)Ø
(50%-80%)Ø
Other milling D 70 - 90 0.05 – 0.1
ALUMINIUM A 90 – 100 0.01 – 0.05
HIGH SPEED D 50 - 70 0.05 – 0.1 D 1-2 D (~2/3)Ø

A 70 - 90 0.01 – 0.05 A 0.2-0.5 A (~2/3)Ø

Side milling D 50 - 70 0.05 – 0.1 D (50%- D (10%-25%)Ø
STEEL
A 70 - 90 0.01 – 0.05 80%)Ø A A (5%-10%)Ø
(HSS) (50%-80%)Ø
Other milling D 40 - 60 0.05 – 0.1
A 60 - 70 0.01 – 0.05
HARD METAL Face milling D120 - 150 0.05 – 0.1 D 1-2 D (~2/3)Ø
A 150 – 180 0.01 – 0.05 A 0.2-0.5 A (~2/3)Ø
Side milling D120 - 150 0.05 – 0.1 D (50%- D (10%-25%)Ø
A 150 – 180 0.01 – 0.05 80%)Ø A A (5%-10%)Ø
(50%-80%)Ø
Other Other
milling: slot milling,
milling t-shape
D100 - 130milling,0.05
dovetail
– 0.1milling, form milling.
D: Roughing operation A 130 – 150 0.01 – 0.05
A: Finishing operation