Milling machine

Prepared by : J.M.PATEL

Milling Processes
Milling is one of the basic machining processes. Milling is a very versatile process capable of producing simple two dimensional flat shapes to complex three dimensional interlaced surface configurations.

The Process
The milling process:
Typically uses a multi-tooth cutter Work is fed into the rotating cutter Capable of high MRR Well suited for mass production applications Cutting tools for this process are called milling cutters

MILLING METHODS
Conventional or up milling methods

Climb or down milling methods

Milling Method
End Milling

Straddle milling

Gang Milling

Operating Parameters
Rpm
CS converted into Rpm based on cutter diameter

Feed rate
Feed per tooth Table feed rate

Classification Milling machines

According to nature of purpose:
1. General purpose- for small production 2. Single purpose: - thread milling, cam milling 3. special purpose: used for mass production

1. 2. 3.

According to configuration of work holding table/bed Knee type: horizontal & vertical knee milling machine. Planer type Rotary type

Milling Machine Parts

Feed dial Used to regulate table feeds Spindle Provides drive for attachments, arbors, cutters Overarm Provides for correct alignment and support of arbor and various attachments Can be adjusted and locked in various positions
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1. Feed dial Used to regulate table feeds Spindle Provides drive for attachments, arbors, cutters Over arm Provides for correct alignment and support of arbor and various attachments Can be adjusted and locked in various positions Arbor support Fitted to over arm and can be clamped Aligns and supports various attachments Elevating screw Gives upward or downward movement to knee and table (manually or automatically) Spindle speed dial Set by crank used to regulate spindle speed

 Base
Gives support and rigidity to machine and Acts as reservoir for cutting fluids

Column face
Precision-machined and scraped section used to support and guide knee when moved vertically

Knee
Houses feed mechanism attached to column face and moved vertically. Saddle On top of knee moved in or out by means of cross feed hand wheel (manually or automatically) Swivel table housings Enables table to be swiveled 45 either side of centerline

Milling Machines
Bed
Used extensively in production milling operations Rigid construction capable of heavy cuts Table is mounted directly to the bed Spindle head moves vertically to set depth of cut Head locks into position for cut Base of machine functions as a coolant reservoir

Knee & Column Milling Machines

Vertical Knee & Column

Horizontal Knee & Column

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Horizontal type: non automatic

Work table can be linearly fed along three axis. Widely used for batch production of job Vertical type: only spindle is vertical End mill cutter and face mill cutter using Table may or may not swivelling feature

Bed Type Milling Machines

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Variation of Machines
Variations include:
Profilers and duplicators

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Process Accuracy
Accuracy of milling machines
Factors to consider
Fixture Rigidity of machine tool Accuracy of the spindle Cutter condition Coolant Type Delivery method Material condition

Milling Cutter Classifications

Arbor Shank Face

Milling Cutters

Workholding Devices
Vise Chucks Rotating tables Angle plates Special fixtures Universal dividing head Modular fixturing systems Clamp work to table

Workholding Devices