MILLING & SHAPING

Milling Machining
Its the most basic machining operation that allows for removal of large amount of material quickly Its a versatile process that allows for production of 2-D surface work piece finish or complex 3-D interlaced work piece configuration.

Milling Machining
The cutting tool performs a rotational motion, that is the cutting motion. The rotation axis of the tool could be horizontal or vertical, depending on machine tool type.
The feeding motion is achieved either by part or tool, or both, usually on three perpendicular directions.

Milling Machining

The milling is achieved by the tool/cutter having rotational motion while the feeding is by either the tool or the work piece having a translational motion.

Horizontal Milling Machine

Designed for peripheral milling

Vertical Milling Machine

Designed for face milling

Milling types
Up milling Down milling

Or conventional milling: -Wheel rotation opposite of the feed -Length of chip longer - Tool life is relatively shorter - Need more clamping force to hold the work part still.

Also called climb milling: -Wheel rotation parallel to the feed -Length of chip shorter - Tool life is relatively longer - Need less clamping force to hold the work part still.

Horizontal Milling Machine Operations

SLAB milling SLOT milling

The cutter width extends beyond the work piece on both sides

The cutter width is less than the work piece creating a slot.

Horizontal Milling Machine Operations

SIDE milling STRADDLE milling

The cutter machines/mills the side of the work piece.

Two cutters machining two sides of the work piece simultaneously.

Horizontal Milling Machine Operations

FORM Milling FACE milling

The cutter has the form/shape of the desired machined profile.

The cutter as shown removes a layer of material from the upper part of the work piece.

VERTICAL Milling Machine Operations

END Milling PROFILE milling

The cutter diameter is less than that of the work piece.

The tool/cutter cuts a profile/contour on the periphery of a flat work piece.

VERTICAL Milling Machine Operations

POCKET Milling 3-D SURFACE milling

The cutter removes material from a work piece to create a cavity.

The cutter removes material in the work piece in 3-different directions/axes simultaneously.

VERTICAL Milling Machine Operations

SLOT milling T-SLOT milling

The cutter removes material from work piece to create a slot.

The cutter removes material in the work piece creating a T-Slot.

Milling Tools-End Mills

Most common tools used with vertical machine. Has a flattened end. An end mill can cut into a work piece either vertically, like a drill, or horizontally using the side of the end mill to do the cutting

Milling Tools-End Mills

Flat end mills Slots Pockets Facing

Ball end mills

Fillets Rounded Pockets Spherical pockets

Corner rounders

Rounded corners

Conical end mill for chamfers

Work Holding for Milling Operations

Vice- its the most common work piece holding fixture

Indexed Vice- allows for machining of different work piece surface