MILLING

MILLING
Milling is another basic machining process by
which surface is generated progressively by
the removal of chips from a work piece as it is
fed a rotating cutter.
Milling operations can be classified into two
broad categories
1. Peripheral Milling
2. Face Milling
2

Peripheral Milling

Face Milling

Peripheral Milling
The axis of the cutter rotation is parallel to the work piece
surface to be machined in peripheral milling.
Slab milling
Slotting (Slot milling)
Side milling
Straddle milling
Up milling
Down milling

Slab milling

Cutter width extends beyond the

work piece on both sides

Slotting (Slot milling):

Cutter width is less than the work

piece width, creating a slot. If the
cutter is very thin, it can be used to
cut a work part into two, called saw
milling.

Side milling and Straddle milling

Side milling:
Cutter, machines the side of the
work piece.
Straddle milling:
Similar to side milling, but cutting
takes on both sides of the work part
simultaneously.

Up milling
Also called conventional milling,
- Wheel rotation opposite of the feed
- The chip formed by each cutter tooth starts out very thin and increases its
thickness
- The length of the chip is relatively longer
- Tool life is relatively shorter
- Need more clamping force to hold the work part still.

Down milling:
Also called climb milling,
- Wheel rotation is parallel to the feed
- The chip formed by each cutter tooth starts out thick and leaves out thin
- The length of the chip is relatively short
- Tool life is relatively longer
- Need less clamping force to hold the work part still.

10

Face Milling
The generated surface is at right angles to the cutter axis and
is the combined result of actions of the portions of the teeth
located on both periphery and the face of the cutter. Most of
the cutting is done by the peripheral portions of the teeth, with
the face portions providing some finishing actions.
Conventional face milling:
Diameter of tool is larger than work parts width.
Partial face milling:
The cutter overhangs from one side of work part .
End milling:
Cutters diameter is less than the work parts width.

11

12

Continue...
Profile milling:
Outside periphery of flat part is cut.
Pocket milling:
Similar to end milling, but the shape created is a shallow
pockets in flat surfaces
Surface contouring:
A ball-nose cutter is fed back and forth across the work part to
create a contoured surface perpendicular to the cutter.

13

Face milling

Pocket milling

Profile milling

End milling

14

More Examples on Face Milling

15

Milling Cutters
The tool used in milling is known as a milling cutter, the
cutting edges called teeth. Types of milling cutters are related
to the milling operations can be classified as:
Plain milling cutters:
- Used in peripheral milling operations
- Cylindrical or disk shaped
- Have several straight or helical teeth on periphery
- Used to mill flat surfaces
Side milling cutters:
- Similar to plain milling cutters
- Teeth extend radial part way across one or both ends of
cylinder toward the center
- Relatively narrow

16

Milling Cutters

17

More Milling Cutters

18

Continue...
End milling cutters:
- Looks like a drill bit, but it cuts with peripheral teeth instead
of its end.
- Have multiple teeth
- Used in milling slots, profiling and facing narrow surfaces.

19

Continue...
Face milling cutters:
- Have teeth on periphery and both sides
- Made of HSS
T-slot cutters:
- Have teeth on periphery and both sides
- Used for milling the wide groove of a T-slot
- In order to use them, a vertical groove must first be made
with a slotting mill or an end mill to provide a clearance for the
shank
- T-slot cutter must be fed carefully, because it cuts in 5
surfaces

20

Face Milling Cutters

21

T-Slot Milling Cutters

22

Milling Machines
The milling machine supplies an accurate rotating spindle
for the cutter and a table (vise) to fix and position the work
part. There are two types of machines
Horizontal milling machines:
- Horizontal spindle
- Designed for peripheral milling operations
Vertical milling machines:
- Vertical spindle
- Designed for face milling operations
(In our Lab.s we have this type of machines)

23

Horizontal Milling Machine

24

Vertical Milling Machine

25

Classifications of milling machines

Column and Knee type:
- Column, spindle, cutter, table, knee, base are the common
parts of the vertical and horizontal milling machines
- In horizontal, arbor supports the cutter and an over arm
supports arbor
- In vertical, milling cutters can be mounted directly in the
spindle
- The milling machines having only the three mutually
perpendicular table motions (x-y-z axes) are called plain
column and knee type
-Vertical type is especially well suited for face and end milling
operations
26

Column and Knee Milling Machine

27

Continue...
-Two more special column and knee machines are called
universal and turret type.
Universal type:
Has a table that can be rotate in a horizontal plane to any
specified angle
Turret type:
Has duel heads that can be rotated about a horizontal axis. This
permits milling to be done horizontally, vertically or at any
angle.

28

Turret Type Milling Machine

29

Continue...
Bed type milling machines:
- Designed for mass production
- Greater rigidity
- Achieves heavier feed rates and depth of cuts, high MRR
-Work table is directly fixed on the bed of the machine tool
-The cutter mounted in a spindle head that can be adjusted
vertically along the machine column
-After machine set-up, little skill required to operate them,
therefore semi-skill operators can us this type of machines
Three types are available w.r.t. the count of spindles available
Simplex:
Has single spindle
30

Bed Type Milling Machine(1)

31

Bed Type Milling Machine(2)

32

Continue...
- Duplex:
Has two spindles, permitting simultaneous milling of two
surfaces at a single pass
Triplex:
Has three spindles, permitting simultaneous milling of three
surfaces at a single pass
Planer type milling machines:
- Utilize several milling heads
- Can remove large amount of metal while permitting the table
and work piece to move quite slowly
- Often, only single pass is required
- Good for heavy pieces
33

Continue...
Tracer mills (Profiling milling machines):
- Also called duplicators
- Designed to reproduce an irregular part geometry that can be
created on an template
- In two dimensions- tracer
- In three dimensions- duplicator
CNC milling machines:
- Cutter path controlled by numerical data
- Suited to profile, pocket, surface contouring.

34

CUTTING CONDITIONS IN MILLING

The rotational speed in milling is related to the
desired cutting speed at the surface of the work
piece by equation.

N = ------------D
N= rotational speed, rev/min
= cutting speed, ft/min (m/min)
D= Tool diameter, ft (m)
35

CUTTING CONDITIONS IN MILLING(cont..1)

The rotational speed in milling is related to the

desired cutting speed at the surface of the work
piece by equation.
f r= N.n t . f
f r = feed rate, in/min (mm/min)
f = chip load, in/tooth (mm/ tooth)
n t = number of teeth on cutter
MRR= w. d. f r
d = depth of cut, in (mm)
w = width of cut, in (mm)

36

SLAB MILLING:
L+A
T m = -------------------fr
A : Approach distance to reach full cutter depth
A = d.(D-d)
T m: Machining time, min

37

FACE MILLING:
L+2.A
T m = -------------------fr
A : Approach distance to reach full cutter depth
A = w.(D-w): For partial Face milling
A = D/2 : For conventional Face milling

38