CHAPTER 5 MILLING MACHINES

PURPOSE OF MILLING MACHINES

Milling is

basic machining process by which surface is

generated progressively by the removal of chips from a work piece

as it is fed against a multitooth rotating cutter.
Milling

machine is used for machining flat surfaces, angled

surfaces, contoured surfaces, key slots, external and internal threads, helical surfaces of various cross-sections etc.

TYPES OF MILLING MACHINES

The milling machine supplies an accurate rotating spindle for the cutter and a table (vise) to fix and position the work part.

1. Column and knee type milling machines (a) Hand milling machine (b) Horizontal milling machine (c) Universal milling machine (d) Vertical milling machine 2. Planer milling machine 3. Fixed-bed type milling machine (a) Simplex milling machine. (b) Duplex milling machine. (c) Triplex milling machine. 4. Machining centre machines 5. Special types of milling machines (a) Rotary table milling machine. (b) Planetary milling machine. (c) Profiling machine. (d) Duplicating machine. (e) Pantograph milling machine. (f) Continuous milling machine. (g) Drum milling machine (h) Profiling and tracer controlled milling machine
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COLUMN & KNEE MILLING MACHINE

Column, spindle, cutter, table, knee, base are the common parts of the vertical and horizontal milling machines 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

HAND MILLING MACHINE

HORIZONTAL MILLING MACHINE

In horizontal, arbor supports the cutter and an over arm supports arbor The vertical column houses the electrical, main drive, spindles etc mounted on a heavy base

UNIVERSAL MILLING MACHINE

Has a table that can be rotated in a horizontal plane to any specified angle

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UNIVERSAL MILLING MACHINE

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VERTICAL MILLING MACHINE

In vertical, milling cutters can be mounted directly in the spindle Housing (Head) can be fixed or Swiveling type Fixed Type - Head is always vertical and can be adjusted up and down Swiveling Type Head can be swiveled to any desired angle

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 KEY SLOT MAKING IN VERTICAL MILLING MACHINE

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PLANNER TYPE MILLING MACHINE

Consists of a fixed bed carrying a table having longitudinal movements It is a heavy duty milling machine. Consists of 2 vertical columns on each side of the bed Cross rail fitter across columns can be raised or lowered Each column carries a milling head(side/horizontal) moving upwards or downwards All cutters can be operated simultaneously to machine 4 surfaces at a time

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BED TYPE MILLING MACHINE

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Bed Type Milling Machines

Designed for mass production

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

Three types are available w.r.t. the count of spindles available

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FIXED BED TYPE MILLING MACHINE

SIMPLEX
Fixed bed replaces saddle and knee.
The table has longitudinal travel only Spindle head carries spindle to which arbor is fitted to carry cutter that moves up and down along column ways

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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
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CNC Milling Machines

Cutter path controlled by numerical data Suited to profile, pocket, surface contouring.

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DIFFERENT MILLING OPERATIONS

Milling operations can be classified into two broad categories

1. Peripheral Milling

2. Face Milling

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PERIPHERAL MILLING

Operation performed by milling cutter to produce a machined surface parallel to axis of rotation of cutter Cutting force is not uniform throughout the length of the cut by each tooth Quality of surface generated and shape of the chip formed depends upon the rotation of cutter relative to direction of feed movement It can be either UP milling or DOWN milling
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UP MILLING

Also called conventional milling, - Wheel rotation opposite of the feed - The chip formed by each cutter tooth starts out very thin & 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.
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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.
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1. PLAIN MILLING(SLAB MILLING)

Operation of production

of

plain

flat
to

surface
axis of

parallel cutter

rotation of plain milling

Cutter

width extends

beyond the work piece on both sides

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2. FACE MILLING

The generated surface is at right angles to the cutter axis is axis work

The

face

milling about to

cutter an the

rotated

perpendicular

surface.

It 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 provides the surface finish.
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More Examples on Face Milling

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3. END MILLING

Combination of peripheral and face milling Cutter has teeth both on end face and periphery Vertical milling machine is most suitable for end milling operation

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4. SIDE MILLING

Operation of production of flat vertical surface on side of work piece by using side milling cutter
Depth of cut adjusted by rotating vertical feed screw of

the table
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5. STRADDLE MILLING

Operation of production of flat vertical surfaces on both side of the workpiece by using two side milling cutters mounted on the same arbor
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6. ANGULAR MILLING

Operation of production of angular surface on a workpiece other than at right angles to the axis of milling machine spindle
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7. GANG MILLING

Operation of milling several surfaces of the workpiece simultaneously by feeding the table against a number of cutters having same or different diameters
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8. FORM MILLING

It is the operation of production of irregular contours using form cutters The contours maybe convex, concave or any other shape

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9. PROFILE MILLING

It is the operation of reproduction of an outline of a template or complex shape of a master die on a workpiece
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10.MILLING KEYWAYS, GROOVES & SLOTS

Operation of production of keys, grooves and slots of varying shapes and size by using a plane milling cutter, a metal slitting saw, an end mill or by side milling cutter

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11. THREAD MILLING

Operation of production of threads by using a single or multiple thread milling cutter. It is performed in special thread milling machine to produce accurate threads

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BIBLIOGRAPHY

Reading Material Wikipedia www.howstuffworks.com www.custompart.net Workshop Tech - Hajra Choudhury Vol 2 Images/Videos Google Image Search Efunda.com Youtube.com

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