MILLING CUTTER

A milling cutter is a special type of cutting tool which has multiple cutting edges.
There are many advantages of milling cutters compared to single point cutting tool.

1) High machining
2) Completes required machining operation in required time.
 SCHEMATIC VIEWS OF CONVENTIONAL UP AND DOWN MILLING

The basic function of milling machines is to produce flat surfaces in any

orientation as well as surfaces of revolution, helical surfaces and contoured
surfaces of various configurations. Such functions are accomplished by
slowly feeding the work piece into the equispaced multiedge circular cutting
tool rotating at moderately high speed as indicated in Fig. Up milling needs
stronger holding of the job and down milling needs backlash free screw-nut
systems for feeding.
 MILLING CUTTER MATERIALS

High-Speed Steel:-
- Iron with additives
- Carbon: hardening agent
- Tungsten and Molybdenum: enable steel to retain hardness
up to red heat
- Chromium: increases toughness and wear resistance
- Vanadium: increases tensile strength
- Used for most solid milling cutters

Cemented-Carbide :-
- Higher rates of production (3-10 times faster)
- Must select proper type of carbide
-Straight tungsten carbide: cast iron, plastics
-- Tungsten-titanium carbide:
high-carbon steel
 PLAIN MILLING CUTTER
- Once widely used
- Cylinder of high-speed steel with teeth
cut on periphery
Axis of shaft is parallel to surface of
workpiece
- Used to produce flat surface
- Several types
- Light-duty
- Light-duty helical
- Heavy-duty
- High-helix
 FACE MILLING CUTTER
Generally over 6 in. in diameter
- Have inserted teeth made of high-speed steel
head in place by wedging device
Most cutting action occurs
at beveled corners and
periphery of cutter
Makes roughing and
finishing cuts in one pass

END MILLING CUTTER

Face milling cutters under 6 inch

Solid, multiple-tooth
cutters with teeth on face and periphery
Held on stub arbor
- May be threaded or use
key in shank to drive cutter
 ANGULAR CUTTERS

-Teeth neither parallel nor perpendicular to cutting axis

- Used for milling angular surfaces
- Grooves, serrations, chamfers and reamer teeth
- Divided into two groups
- Single-angle milling cutters
- Double-angle milling cutters

- Single-angle
- Teeth on angular surface
- May or may not have teeth on flat
- 45 or 60
- Double-angle
- Two intersecting angular surfaces
with cutting teeth on both
- Equal angles on both side of line
at right angle to axis
 FORMED CUTTERS
- Incorporate exact shape of part to be produced
- Useful for production of small parts
- Each tooth identical in shape
- Sharpened by grinding tooth face (may have positive, zero or negative rake)
- Important to maintain original rake
- Difficult to sharpen

TYPES OF FORMED CUTTERS

Concave Convex Gear Tooth

NOMENCLATURE OF MILLING CUTTER
 BODY: The body is the solid portion left in blank after forming
the cutting teeth and the arbor hole.
CUTTING EDGE: The peripheral cutting edge is the intersection
of the face of the tooth with the leading edge of the land. It is
the edge that removes metal from the workpiece.
FLUTE: It is the space between the back of one tooth and the
face of the following tooth.
FILLET: The flute is the curved portion at the bottom of the
flute, provided to allow chip flow and chip curling.
 TOOTH: The tooth is the part of the cutter starting at the body and ending
at the peripheral cutting edge.
FACE: The tooth face is the surface of the tooth between the fillet and the
cutting edge.
LAND: The land is the portion behind the cutting edge on each tooth that
is relieved to avoid interference between itself and the surface being
machined.
OUTSIDE DIAMETER: It is the diameter of the circle passing through the
peripheral cutting edges.
ROOT DIAMETER: It is the diameter of the circle passing tangent to the
bottom of the fillet of the teeth.
HOLE DIAMETER: The hole diameter determines the size of the arbor
necessary to mount the milling cutter.
1. PRIMARY CLEARANCE ANGLE:
It is the angle formed by the back of the tooth with a line drawn
tangent through the periphery cutting edge.

2. SECONDARY CLEARANCE ANGLE:

It is the angle formed by the secondary clearance surface of the
tooth and a line drawn tangent through the periphery cutting edge.

3. RELIEF ANGLE: It is the angle measured between the land and the tangent
drawn to the periphery cutting edge.

4. RAKE ANGLE: It is the angle measured between the tooth face and the center
line of the cutter.