Milling and

grinding
machine

Milling

Milling is a metal cutting

operation in which the work is
progressively moved towards a
rotating cutter for material
removal process.

Milling cutter is a multipoint

cutting tool.

Milling machine

A milling machine is a power operated

machine tool in which the work piece
is mounted on moving table is
machined to various shapes when
moved under a slow revolving cutter.

Work piece is fed against a milling

cutter.

Metal is removed in the form of

chips by using a rotating multiple
teeth milling cutter.

Milling process is used for

producing flat, contoured or
helical surfaces for toothed gears,
slots, etc.

Principle of milling

The workpiece is mounted on the table can be

fed either in the direction opposite to that of
rotating cutter or in the same direction of the
cutter.
Classification

Conventional or up milling.
Climb or down milling.

Up milling

Work piece
advances
against the
rotating cutter.
Chips are
progressively
thicker.

Down milling

Work piece is fed

in the same
direction as that of
the cutter tooth.
Cutter enters top
of the work piece
and removes the
chip that gets
progressively
thinner.

comparison
Up milling

Work piece is fed in

opposite direction of that
of cutter.
Chips are progressively
thicker.
Strong clamping is
required since the cutting
force is directed upwards
and tends to lift the work
piece.
Poor surface finish and
used for hard materials.

Down milling

Work piece is fed in same

direction of that of cutter.
Chips are progressively
thinner.
Strong clamping is not
required since the cutting
force is directed
downwards and keeps
work piece pressed to
table.
Good surface finish and
used for soft materials.

classification
Milling machine can be broadly classified into :
1.

Plain or horizontal type of milling machine

2.

Vertical milling machine

3.

Universal milling machine

4.

Planer type milling machine

5.

Profile cutting milling machine

Horizontal milling
machine

Base
Column
Arbor
Knee
Saddle
Table
Over arm

YOKE

Base it is a hollow cast iron structure

which forms the foundation of machine on
which other parts are mounted.
Column houses main drive, transmission
system, spindle. It is provided with vertical
guide square or dovetail to accommodate
knee.
Knee mounted on vertical guide of
column moved up or down by an elevating
screw.

YOKE

Saddle mounted on knee which slides

on it by operating cross feed handle.
Table mounted on top of saddle with a
dovetail fit. Table slides perpendicular
to the axis of saddle movement.
Arbor shaft which carries the cutter
with its other end supported by yoke.

YOKE

Over arm mounted on top of column.

Supports the free end of arbor through
yoke.

Working
Work

piece is mounted directly on

table using machine vice.
Cutter of required shape and size
are mounted over the arbor which is
driven by spindle.

Feed in all 3 axis can be given by

using knee elevating handle, cross
slide handle, table movement
handle.

YOKE

Vertical milling machine

Base
and
column

Spindle
head

Base and column base is the

foundation for the machine and
column is the vertical part houses
motor, transmission system.

Spindle head mounted on front face

of the column at the top. It has a
vertical spindle run by motor to which
milling tool is fitted to end.

Working
Work

piece is mounted on
table and cutter is mounted on
vertical spindle.
Feed is given by movement of
saddle and table and also
vertical movement of tool.

Milling process

Plain milling
End milling
Slot milling
Angular milling
Form milling
Straddle milling
Gang milling

Plain milling

Process used to
mill flat surfaces of
the work piece.
Milling cutter axis
is parallel to the
surface that is
being milled.

End milling

Process of milling
that is used to mill
slots, pockets and
keyways.
Axis of milling
cutter is
perpendicular to
the surface of the
work piece.

Slot milling

Cutter tool slot

drill
Axis of spindle is
horizontal or
parallel to surface
of work.
To produce
rectangular slots,
T-slots, dovetail
slots.

Angular milling

To produce angular
surfaces like
dovetail, grooves
and chamfers.
Surface of slot is
neither parallel
nor perpendicular
to the milling
cutter axis.

Form milling

This is a process
used to machine
special forms /
contours consisting
of curves.
form milling
cutter is the cutting
tool which is shaped
exactly to the
contour to be milled.

Straddle milling

Used to machine two

parallel vertical
surfaces at a single
time.
It has two cutters
mounted parallel on
the arbor separated
by a calculated
spacing.
Also used to mill
sides of hexagon.

Gang milling

Gang milling is
the term applied to
an operation in
which two or more
milling cutters are
used together on
one arbor when
cutting horizontal
surfaces.

Specification of milling
machine

Clamping area area

of the work table
where the jobs are to
be clamped.
Longitudinal
movement (mm)
this is the distance
along the X axis by
which the table along
with the job moves
longitudinally.

Transverse movement
(mm) distance
along Y-axis by which
the table travels in
traverse direction.
Speed speed of the
spindle rotation
( rpm)
Power of milling
spindle motor power
capacity of motor of
spindle. (kW)