Milling process 02

Milling Machines

The milling machine supplies an accurate rotating spindle

for the cutter and a table (vise) to fix and position the work
part. There are two types of machines
Horizontal milling machines:
- Horizontal spindle
- Designed for peripheral milling operations
- (In our Lab.s we have this type of machines)
Vertical milling machines:
- Vertical spindle
- Designed for face milling operations
(In our Lab.s we do not have this type of machines)

IE 262 Class Notes by Figen Eren 2

 DIFFERENCES BETWEEN HORIZONTAL &
VERTICAL MILLING MACHINES
SL. NO. HORIZONTAL MILLING MACHINE VERTICAL MILLING MACHINE

Spindle is horizontal & Spindle is vertical &

01
parallel to the worktable. perpendicular to the worktable.

Cutter cannot be moved up Cutter can be moved up &

02
& down. down.

Cutter is mounted on the Cutter is directly mounted on

03
arbor. the spindle.

Spindle can be tilted for

04 Spindle cannot be tilted.
angular cutting.

Operations such as slot

Operations such as plain
milling, T-slot milling, angular
milling, gear cutting, form
milling, flat milling etc., can be
05 milling, straddle milling,
performed and also drilling,
gang milling etc., can be
boring and reaming can be
performed.
carried out.
 PRINCIPLE OF MILLING
MACHINE
Milling operates on the principle of rotary
motion. A milling cutter is spun about an axis
while a workpiece is advanced through it in
such a way that the blades of the cutter are
able to shave chips of material with each
pass.
 Two Forms of Milling

Two forms of milling: (a) peripheral milling, and (b) face milling.
 Peripheral milling
Cutter axis parallel to surface being machined
Cutting edges on outside periphery of cutter
Face milling
Cutter axis perpendicular to surface being milled
Cutting edges on both the end and outside
periphery of the cutter
 MILLING OPERATIONS
Plain or slab milling
Face milling
End milling
Slot milling
Angular milling
Form milling
Straddle milling
Gang milling
Slitting or saw milling
Gear cutting
Face milling Profile milling

Pocket milling End milling

IE 262 Class Notes by Figen Eren 8

More Examples on Face Milling

IE 262 Class Notes by Figen Eren 9

 T-Slot Cutting and Shell Mill

Figure 24.12 (a) T-slot cutting with a milling cutter. (b) A shell mill.

Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
 SLOT MILLING

SLOT Milling:
Operation of producing slots
like T-slots, plain slots, dovetail
slots etc.,
FIG. T-SLOT MILLING
Cutter: End milling cutter, T-
slot cutter, dovetail cutter or
side milling cutter

Machine: Vertical Milling

Machine

FIG. DOVE TAIL SLOT MILLING

 SLOT MILLING

SLOT Milling:
Operation of
producing slots like T-
slots, plain slots,
dovetail slots etc.,

Cutter: End milling

cutter, T-slot cutter,
dovetail cutter or side
FIG. T-SLOT MILLING
milling cutter

Machine: Vertical
Milling Machine
 Slotting
Width of cutter is less than workpiece
width, creating a slot in the work
Slab Milling
Basic form of peripheral milling in
which the cutter width extends beyond
the workpiece on both sides
Conventional Face Milling
Cutter overhangs
work on both sides
 End Milling
Cutter diameter
is less than
work width, so
a slot is cut into
part
 PLAIN/SURFACE/ SLAB MILLING

Plain Milling:
Process to get the flat
surface on the work
piece in which the cutter
axis and work piece axis
are parallel.

Cutter: Plain/ Slab

milling cutter.

Machine: Horizontal
Milling m/c.

FIG. PLAIN MILLING

 FACE MILLING

Face Milling:
Operation carried out for
producing a flat surface, which
is perpendicular to the axis of
rotating cutter.

Cutter: Face milling cutter.

Machine: Vertical Milling

Machine
FIG. FACE MILLING
 END MILLING

End Milling:
Operation performed for
producing flat surfaces, slots,
grooves or finishing the edges of
the work piece.

Cutter: End milling cutter.

Machine: Vertical Milling

Machine

FIG. END MILLING

 ANGULAR MILLING

Angular Milling:
Operation of producing all types
of angular cuts like V-notches
and grooves, serrations and
angular surfaces.

Cutter: Double angle cutter.

Machine: Horizontal Milling

Machine

FIG. ANGULAR MILLING

 FORM MILLING

End Milling:
Operation of producing all types
of angular cuts like V-notches
and grooves, serrations and
angular surfaces.

Cutter: Double angle cutter.

Machine: Horizontal Milling

Machine
FIG. FORM MILLING
FIG. FORM MILLING
 STRADDLE MILLING

Straddle Milling:
Operation of machining two
parallel surfaces
simultaneously on a work piece.

Cutter: 2 or more side & face

milling cutters

Machine: Horizontal Milling

Machine

FIG. STRADDLE MILLING

 GANG MILLING

Gang Milling:
Process to get different profiles
on the work piece
simultaneously with two or
more cutters at one stretch.

Cutter: Different cutters as

required.

Machine: Horizontal Milling

Machine

FIG. GANG MILLING

Profile Milling
Form of end
milling in which
the outside
periphery of a
flat part is cut
Pocket Milling

Another
form of end
milling used
to mill
shallow
pockets into
flat parts
Surface Contouring
Ball-nose cutter
fed back and forth
across work along
a curvilinear path
at close intervals
to create a three
dimensional
surface form
 Milling Cutter
Depth of cut

Milling processes, a)- main motion, b)- feed motion,

c)- working travel of a cutting tooth.
 Feature of workpiece Manufactured By milling
Workpieces of all materials, e.g. of steel , cast
iron, non-ferrous metals and synthetic
plastics can be provided with plain and
curved surfaces, bolts, grooves , teeth Shown
in Figure by the process of milling .

Examples of parts manufactured by milling

 a
a

a a

a) Plain milling, b)rack milling,, c)gear cutting, f) contours, side milling

 Milling methods
a)- cylindrical milling: Peripheral milling
During cylindrical milling the cutter axis situated parallel to the machined
surface of the workpiece. In the cylindrical milling the material removal
by the circumferential of cutter .
b- Face Milling
In face milling the cutter is mounted on a spindle having an axis of
rotation is perpendicular to the workpiece surface
In the face milling the material removal by the face of cutter
c)- End milling
During end milling the cutter axis is situated Perpendicular to the
machined surface . While the metal removal by both face and periphery
of the cutter
 Comparison of cylindrical milling with end milling:

During cylindrical milling, the milling machine is

irregularly stressed by the wedge shaped chips. It is
difficult to prevent a slight beat of the cutter, a milling
mark is produced. During face- milling, each tooth
cuts off an evenly thick chip. Therefore, the milling,
machine is every stressed.

In case of end milling, the cutting capacity is 15- 20%

higher than that of cylindrical milling. A slight beat of
the face mill is of no consequence to the plainness of
the surface. The machined surfaces have, therefore, a
better grade of plainness, plane surfaces should be
machined by end mill.
During cylindrical milling, the feed movement
is usually directed against the sense of
rotation, but can also run parallel to the rotary
direction. Accordingly, a distinction is made
between conventional (up) and climb (down) -
milling.
COMPARISON BETWEEN UP MILLING & DOWN MILLING

SL. UP MILLING DOWN MILLING

NO. (CONVENTIONAL MILLING) (CLIMB MILLING)

01 Work piece fed in the Work piece fed in the same

opposite direction that of the
cutter.
02 Chips are progressively
thicker.
03 Strong clamping is required
since the cutting force is
directed upwards & tends to
lift the work piece.
direction that of the cutter.
Chips are progressively thinner.
Strong clamping is not required
since the cutting force is directed
downwards & keep the work piece
pressed to the table.

04 Gives poor surface finish, Gives good surface finish, since

since chips gets accumulated the chips are thrown away during
at the cutting zone. cutting.
05 Used for hard materials. Used for soft materials and
finishing operations.
 Up milling
Also called conventional milling,
- Wheel rotation opposite of the feed
- The chip formed by each cutter tooth starts out very thin and 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.

IE 262 Class Notes by Figen Eren 37

 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.

IE 262 Class Notes by Figen Eren 38

The conventional (up) milling: is the usual
method of cylindrical milling. Hence the chip is
first cut off at the thinnest place. Before the
cutting teeth enter the material, they slide on
the machining surface. Thereby, a strong
fiction is caused. The cutting force attempts to
lift the workpiece.
During climb (down) milling, the cutter points
attack the chip at the thickest place sense the
workpiece is pressed tightly against the
machine table. The process is suitable for thin
workpieces, for deep cuts it is also suitable.
However, the machine must be built specially
for climb milling. The spindle and the table
must have, above all, no play otherwise the
workpiece is drawn into the cutter
 (Up and dawn milling)
Conventional (up) milling
The minimum chip thickness at the beginning while, the
maximum chip thickness is at the end of the cut as the tooth
leaves the workpiece surface.
Advantage: cutting process is smooth.
Disadvantages: the workpiece has a tendency to be pulled
upward, a strong fiction is caused
Climb (Down ) milling
Cutting starts at the surface of the workpiece, where the chip is
thick.
The advantages: downward component of cutting forces hold
workpiece in place, is suitable for thin workpieces and deep cuts
Disadvantages: The spindle and the table must have above all, no
play otherwise the workpiece is drawn into the cutter.
 1
1

2 2 3

Up milling Dawn milling

1-main motion 2- feed motion

3-working travel of a cutting tooth
 Cutting conditions in milling process
Cutting speed
Cutting speed V = DN
V = cutting speed in peripheral milling is the
surface speed of the cutter
D = cutter diameter, mm
N = rotational speed of the
cutter,rev/min
 Feeds in milling operation

Basics of a peripheral (slab) milling operation.

 Three types of feed in milling can be
identified
:
1- feed per tooth fz:
2- feed per revolution fr:
fr = fzn
n being the number of the cutters teeth;
3- feed per minute fm:
fm = fznN = frN mm/min
 Feed per tooth
is given by:
fz = fmlNn

Fm = linear speed (feed rate) of workpiece,

mm/min
n = Number of teeth on the periphery of
cutter
N = Rotational speed of the milling cutter,
rpm
Milling Cutting time is given by:
t =(l + lc)/Fm lc<<<<l hence t =l /Fm
(assume the width of cutter is equal to the width of W.P)
l = length of workpiece
lc = extent of the cutters 1st contact with workpiece
Fm = linear speed (feed rate) of workpiece,
mm/min
Material Removal Rate

w = width of cut
MRR = lwd/t= wdFm
d=depth of cut
 Rough and finish milling:
During rough milling the excessive material has
to be removed in the shortest time possible.
Therefore, a big rate of feed has to be selected.
For the subsequent finish milling operations
0.5-1 mm should remain. With regard a life of
the milling cutter a small cutting speed has to
be selected.

In finish milling, the workpiece must be accurate

in size and must get the required surface quality.
For this purpose, a higher cutting speed and a
small rate of feed is necessary.
Distribution of cutting force in face milling
operation

Distribution of cutting force in face milling operation

 Types of milling machine
1- Horizontal milling machine.
2- vertical milling machine
3-universal milling machine
 Milled tooth cutters
Cutting capacity of the cutter and
surface quality of the workpiece depend
mainly on the cutting edges of milling
cutters. The tooth angles depend on the
material to be machined. The tooth
pitch is also depending on the material.
Milling soft materials, results in large
amount of chips accumulate, which are
collected between the large gaps of the
course pitch cutter and are driven away.
Angle and tooth pitch for machining various materials
a)-small tooth pitch for hard steel Small rack angle
b)-medium tooth pitch for soft steel
c)-big tooth pitch for soft. metals High rack angle
Types of milling Operation
and milling Cutters
 Cylindrical milling cutters

a) straight cutting edges (low cutting capacity ),

b) helical cutting edges (high capacity)
Face milling cutters
form-relieved cutter
Gang milling cutter consisting of one staggered
tooth milling cutter, one plain cutter and one
form relieved cutter
T-slot cutting with a milling cutter.
 Material of Milling cutters:
Milling cutters are made of high-speed steel, because this
permits the application of higher cutting speeds than plain
tool steel. Frequently the cutting edges are made of
cemented carbide. Since high speed steel is expensive, the
cutter body of bigger ending cutters is made of structural
steel in which cutting edges of high speed steel are inserted.
Milling cutters with carbide tips are suitable for machining of
such materials which exert a heavy abrasive effect on the
cutting edges
Mounting of milling cutters:
Rules for mounting of cutters:
1- The proper cutter and corresponding milling arbor must
be selected, feather key must not be forgotten.
2- Tapers on milling arbor and milling spindle head must be
protected against damage
3- Before the assembly, all fitting surfaces have to be
cleaned, e.g. arbor, taper on spindle head, spacers and
milling cutter.
4- The rotary direction of the milling machine and cutting
direction of the milling cutter must correspond with each
other.
 Clamping of workpieces:
The workpieces must be clamped firmly. If
they become loose during machining,
rejections of jobs and breakage of the cutter
may result.
vice
 T-Slotte Clamping
1 machine table
2 workpiece
3 clamping bolt
4 clamp with bore hole
5 base
6 vertical clamping force

Workpiece clamping on machine table

 Selection of the rpm
The number of revolutions depends on the
permissible cutting speed and the diameter
of the cutter. Cutting speed of the cutter
means the travel of one cutting tooth in
meter/min. the permissible cutting speed will
be taken from the cutting speed table (1)
according to the milling width. depth of cut,
type of milling and type of finish . Table (2)
illustrate the numbers of revolutions of
milling cutters per min according to the
diameter of milling cutters
 Some milling operations
,

Face milling partial milling Slot milling

contour milling Curved milling

 Cooling during the milling operation
Cooling with suitable media contributes
to the improvement of surface quality
and to increase the life of the milling
cutter.
 Rules for milling:

1-The proper machine and milling tools have to be selected.

2-The milling cutter must run true.
3-The workpiece has to be clamped tightly and safely
4-The correct number of revolutions and feed has to be
selected.
5-Before setting the feed, check that the workpiece or milling
table do not knock against anything
6-Coolant has to be given in time.
 Example:
A stripe of steel 42 with a length of 250 mm has to be rough
milled by plain milling. Calculate the machining time

Given:
Ia = 30 mm , Ib = 5 mm, rate of feed = 100 mm/min
Ic= Ia + Ib
L = I + Ic= 250 mm + 30 mm + 5 mm = 285 mm
tm = L/Fm = 285 mm/ 100 (mm/ min) = 2.85 min
 Dividing with indexing attachments
Milling of hexagons:
Workpieces which have equally distributed
surfaces or milled areas on the circumference
are used in all varieties of shapes, shown in
figure. During milling attention has to be paid
to an equal distribution of the faces. Milling
with the V-block for clamping is only a
substitute. A more accurate distribution of
faces is obtained with the dividing head.
 Dividing with indexing attachments
In order to distribute faces and milled areas
accurately on the circumference of a
workpiece, dividing heads are used. In this
method, marking is not necessary. The plain
indexing attachment, shown in figure suffices
when a small number of divisions have to be
produced. The workpiece is clamped
between the centers of the indexing head
(chuck) and the tail-stock. This method of
indexing is called direct indexing
Examples of parts with equally distributed faces and milled
surfaces a) bolt, b)Multiple splined shaft, c)gear, d) ring nut
The dividing head, can be used for any number of divisions. In the
housing, a worm gear with a ratio of 40:1 is installed. The worm wheel is
fitted tightly on the index spindle
Indexing with the dividing head:
To be able to divide with the dividing head, the number
of revolutions of the handle must be ascertained. The
numbers of revolutions of the handle result when the
number of teeth of the worm gear is divided through
the index number.

Terms used:
Nk = numbers of revolutions of the handle
z = number of teeth of the worm gear (usually 40)
t = indexing number (e.g.4,6,8,10,12 divisions)
 Indixing head
I 15 16 17 18 19 20

II 21 23 27 29 31 33

III 37 39 41 43 47 49

Dividing Head
 Detail of indexing head

Main parts of dividing head, a) index spindle, b) worm gear,

c)worm d) index-plate, e) spring bolt, f) handle, g) index pin ,h)
sector arm , i) index-plate for direct indexing.
Example:
A hexagon has to be milled. How many revolutions
have to be made so that the workpiece turns 1/6
after each milling of a face?

Result :
Numbers of revolutions of the handle nk=z/t; nk =
40/6=(6)(4/6) revolutions, i.e. the handle must be
turned around 6 4/6=6/2/3 times.
Performance:
A hole circle which can be divided by 3 is selected,
e.g. a hole circle with 15 holes.
a) On the hole circle 2/3 x 15 = 10 holes are counted
and width of brace is set.
b) After milling the first face of the hexagon the
handle is turned 6 times around and 10 holes in
addition.
c) Sector arms are immediately set to the new
position