Milling

Machine .
RAVINDER SINGH
LOVELY PROFFESIONAL UNIVERSITY
 What is Milling

Milling is the process of machining flat, curved,

or irregular surfaces by feeding the workpiece
against a rotating cutter containing a number
of cutting edges..
 Milling Operations
• Milling operations may be classified under four
general headings as follows:
• Face milling. Machining flat surfaces which are at
right angles to the axis of the cutter.
• Plain or slab milling. Machining flat surfaces which
are parallel to the axis of the cutter.
• Angular milling. Machining flat surfaces which are at
an inclination to the axis of the cutter.
• Form milling. Machining surfaces having an irregular
outline.
 Milling
The usual Mill consists basically of a
• motor driven spindle - which mounts and
revolves the milling cutter, and a
• Reciprocating adjustable worktable- which
mounts and feeds the workpiece
 Types of Milling Machines
• Knee and Column type
• Horizontal
• Vertical
• Universal
• Turret type
• Production (Bed) type
• Simplex
• Duplex
• Triplex
 Types of Milling
Machines
Plano millers
Special type
• Rotary table
• Drum type
• Copy milling (Die sinking
machines)
• Key way milling machines
• Spline shaft milling machines
Methods Of Cutting
A workpiece can be cut in different ways in a
Milling machine. Depending upon the direction
of the rotation of tool and workpiece we have
two types of cuttings
• Up Milling
• Down Milling
 Up Milling

In up milling the cutting tool rotates in the

opposite direction to the table movement.
In the conventional or up milling, the chip
starts as zero thickness and gradually
increases to the maximum size.
There is a possibility that the cutting tool
will rub the work piece before starting the
removal.
 Down Milling (Climb Milling)

In down milling the cutting tool

rotates in the same direction as
that of the table movement.
In the climb or down milling, the
chip starts as maximum thickness
and goes to zero thickness
 Down Milling (Climb Milling)
• The cutting force will act downwards
and as such would keep the workpiece
firmly in the work holding device.
This is good for thin and frail
workpieces.
It may be used where breakout at the
edge of the workpiece could not be
tolerated.
It requires upto20% less power to cut
by this method.
MILLING CUTTERS
Classification of Milling Cutters
 Milling Cutters Classification
Based on construction
• Solid
• Inserted tooth type
Based on mounting
• Arbour mounted
• Shank mounted
• Nose mounted
Base on rotation
• Right hand rotation (Counter clockwise)
• Left hand rotation (Clockwise)
Based on helix
• Right hand helix
• Left hand helix
 Size of Milling Cutter
In selecting a milling cutter for a particular job, choose
one large enough to span the entire work surface so the
job can be done with a single pass. If this cannot be
done, remember that a small diameter cutter will pass
over a surface in a shorter time than a large diameter
cutter which is fed at the same speed.
 Types of Teeth

The teeth of milling cutters may be made for right-hand or

left-hand rotation, and with either right-hand or left-hand
helix. A right-hand cutter must rotate counter clockwise; a
left-hand cutter must rotate clockwise. The right-hand helix
is shown by the flutes leading to the right; a left-hand helix
is shown by the flutes leading to the left.
 Saw Teeth

Saw teeth are either straight or helical in the

smaller sizes of plain milling cutters, metal
slitting saw milling cutters, and end milling
cutters.
 Helical Milling Cutters

The steep helix produces a shearing action that results in

smooth, vibration-free cuts. They are available for arbour
mounting, or with an integral shank with or without a
pilot. This type of helical cutter is particularly useful for
milling elongated slots and for light cuts on soft metal
Side Milling Cutters
• Side milling cutters are essentially plain milling
cutters with the addition of teeth on one or both
sides. Side milling cutters are generally used for
slotting and straddle milling.
• Interlocking tooth side milling cutters and
staggered tooth side milling cutters are used for
cutting relatively wide slots with accuracy.
Interlocking tooth side milling cutters can be
repeatedly sharpened without changing the width
of the slot they will machine.
End Milling Cutters

• These are shank mounted and generally used in vertical axis

milling machine.
• They are used for milling slots, key ways and pockets where other
type of milling cutter cannot be used.
• There are a large variety of end mills.
• High cutting speed are recommended for this type of milling
cutter.
 T-Slot Milling Cutter

The T-slot milling cutter is used to machine T-slot grooves

in worktables, fixtures, and other holding devices. The
cutter has a plain or side milling cutter mounted to the
end of a narrow shank. The throat of the T-slot is first
milled with a side or end milling cutter and the
headspace is then milled with the T-slot milling cutter.
 Angle Milling Cutters

The angle milling cutter has peripheral teeth which

are neither parallel nor perpendicular to the cutter
axis. Common operations performed with angle
cutters are cutting V-notches and serration's. Angle
cutters may be single-angle milling cutters or double-
angle milling cutters. The single-angle cutter contains
side-cutting teeth on the flat side of the cutter. The
angle of the cutter edge is usually 30°, 45°, or 60°,
both right and left. Double-angle cutters have
included angles of 45, 60, and 90 degrees.
 FORM MILLING

Form milling is the process of machining special

contours composed of curves and straight lines, or
entirely of curves, at a single cut. This is done with
formed milling cutters, shaped to the contour to be
cut. The more common form milling operations
involve milling half-round recesses and beads and
quarter-round radii on workpieces. This operation is
accomplished by using convex, concave, and corner
rounding milling cutters ground to the desired circle
diameter.
 Rotary or Circular Milling

A number of fixtures depending are

located on a rotary table such that a
number of workpieces can be loaded
simultaneously on the machine table.
This will save the setting time of the
workpieces and keeps the machine
cutting all the time except during the
indexing of the rotary table.
Gang Milling

In gang milling a number of milling

cutters are fastened to the arbour to
suit the profile of the workpiece to be
machined.
The advantage of gang milling is
that several surfaces are machined at
the same time.
 String Milling
• A number of the workpieces will be
kept on the machine table in a line and
hence called as 'string milling' or 'line
milling'.
• By having a number of workpieces kept
in line the approach distance will be
only at the beginning and end of the
line, thus considerably saving the
machine time.
ARBORS
 INDEXING FIXTURE
The index fixture consists of an index head, also
called a dividing head, and footstock which is similar
to the tailstock of a lathe. The index head and
footstock attach to the worktable of the milling
machine by T-slot bolts.
An index plate containing graduations is used to
control the rotation of the index head spindle. The
plate is fixed to the index head, and an index crank,
connected to the index head spindle by a worm gear
and shaft.