Detail about the milling technology

1. SAFETY

Safe worker :
Alwayst keep tidy and neat
Alwayst consider the welfare of fellow workers and personnel
Alwayst maintain a responsible attitude when doing any work or
project
Alwayst perform work in a safe and accurate manner

Safety in machine shop :

Machining the work piece
We must understand all mechanisms of machine before
operating it.
Keep hand away from spinning tools
Stop the machine before doing cleaning and measuring
Carrying out machining is prohibited without proper attires ,
well planning and permission
Gloves and cloth must be away from rotating spindle
Dont operate the machines with more than 1 user
Any injuries should be reported and treated immediately

 Personal safety outfit

Avoid wearing loose clothes
Remove any watches, rings and bracelets
Long hair must be protected by hair net
Alwayst keep safety googles wearing on when carrying out
machining
Always wear a proper shoes (Safety boots )

Housekeeping
Stop the machine before clean it
Always keep the machine clean
Do not place the important equipments on machine table
Keep the floor free from oil and grease
Sweep up the floor frequently

 Securing the work piece

Remove all burrs and sharps edges
Do not attempt to lift the heavy object which are difficult to
handle by your own
Be sure the work piece are securely clamped on clamping
attachment
Make sure the cutter are have the safe distance from the work
piece before it rotating

Safety for precision equipment

Do not put measuring equipment on the machine table
Clean the measuring equipment from coolant and chip after
being used
Dont mix-up precision equipments and cutting tool
Keep the safe distance when measuring the work piece to
make sure it not hit with cutting tools


When operating a milling machine
Understanding the operational and mechanism of milling
machine before operating it
Clamp all the work pieces solidly
Use the suitable arbor for selected cutting tool
Ensure all auto-feed levers are in neutral position
Dont perform cutting operation on vice or machine table
Do not clamp the work pieces too high from vice surfaces
Stop the machine immediately if odd noise or vibration
develops while you are operating it
Plan your work thoroughly before starting work
Return all the tools / equipments to proper storage after
being use
Do not attempt to remove chips with your fingers
Do not talk or fooling around ( horseplay ) during machining

2. Types of milling machines and its components function

Milling machines are a very versatile machine tool. Milling machines are
capable of machining one or two pieces as well as large volume production
runs. The milling machine can produce a variety of surfaces by using a
circular cutter with multiple teeth that progressively produce chips as the
cutter rotates.
The advantage of having a circular milling cutter with multiple teeth has led
to the design of a large variety of milling machine types. These different
milling machine types can be classified as Knee and Column, Fixed Bed,
Bridge Type, and Special. All of these classifications can have either a
vertical or horizontal spindle configuration. Further classifications of milling
machines are made on the basis of the type of computer numerical control the
machine uses.
Types of milling machines

Knee and column type milling machines

Work table, on which the work piece is clamped using the T-slots. The table moves
longitudinally with respect to the saddle.
Saddle, which supports the table and can move transversely.
Knee, which supports the saddle and gives the table vertical movements for adjusting
the depth of cut.
Overarm in horizontal machines, which is adjustable to accommodate different arbor
lengths.
Head, which contains the spindle and cutter holders. In vertical machines the head
may be fixed or vertically adjustable.
Differences of knee and column type milling machines

1. Vertical knee and column type milling

machines
A vertical type knee and column milling machine has the
spindle located vertically, parallel to the face of the
column, and perpendicular to the top of the table.
The ram style knee and column type milling machine
light duty milling machine. This type of
machine is well suited for a variety of tool
room work as well as other light duty operations.
head is mounted on a ram that can be swivelled or
brought forward. This allows the head to be brought
an operating position over most of the table.

2. Universal knee and column type milling machines

The universal knee and column milling is
very similar to the plain knee and column
milling machine. The largest difference
being the swivelling table housing. The
swivelling table housing allows the table to
be swivelled at an angle to the axis of the
spindle.

3. Horizontal knee and column type milling machines

is a

The
into

The most distinguishing characteristic of this type of machine is the knee and
column configuration This type of milling machine is unique in that the table can
be moved in all three directions. The table can be moved longitudinally in the Xaxis as well as in and out on the Y-axis. Since the table rides on top of the knee,
the table can be moved up and down on the Z-axis. There are several different
types of knee and column type milling machines, but they all have the same
characteristic. The knee slides up and down on the column face.

Fixed bed type milling machines

The most distinguishing aspect of the fixed bed
type milling machine is the absence of the knee.
The fixed bed construction of this style of milling
machine minimizes deflection and allows very
heavy cuts to be taken. Fixed bed style milling
machines can be used for general purpose work
although many people look upon them as high
production machines. The table can move in a
longitudinal and a transverse direction. The
vertical position of the spindle, with respect to the
work table, is obtained by moving the head up
down along the column of the machine.

and

Bridge type milling machines

The construction of the Bridge Type milling machine
resembles that of a bridge
The table is mounted on the bed. On either side of the
bed are two vertical columns connected at the top by
a brace. A cross rail is mounted on the brace. The
cross rail houses the spindle head. Bridge type
milling machines are typically used to machine large
pieces such as castings, machine tables and housings.

Planer machines
Planer machines are similar to bed type machines but
equipped with several cutters and heads to mill various
surfaces.

are

Rotary table machines

Rotary table machines are similar to vertical milling
machines and are equipped with one or more heads to do
face milling operations.

Tracer controlled machines

Tracer controlled machines reproduce parts from a
master model. They are used in automotive and
aerospace industries from machining complex parts
and dies.

Computer numerical control ( CNC ) Machines

Various milling machine components are being replaced rapidly with computer
numerical control (CNC) machines. These machine tools are versatile and capable of
milling, drilling, boring and tapping with repetitive accuracy.

3. Processes perform by milling machines

The time required to produce a given quantity of parts includes the initial setup time
and the cycle time for each part. The setup time is composed of the time to setup the
milling machine, plan the tool movements (whether performed manually or by
machine), and install the fixture device into the milling machine. The cycle time can
be divided into the following four times:
Load/Unload time - The time required to load the workpiece into the milling
machine and secure it to the fixture, as well as the time to unload the finished
part. The load time can depend on the size, weight, and complexity of
the workpiece, as well as the type of fixture.
Cut time - The time required for the cutter to make all the necessary cuts in
the workpiece for each operation. The cut time for any given operation is
calculated by dividing the total cut length for that operation by the feed rate,
which is the speed of the cutter relative to the workpiece.
Idle time - Also referred to as non-productive time, this is the time required
for any tasks that occur during the process cycle that do not engage the
workpiece and therefore remove material. This idle time includes the tool
approaching and retracting from the workpiece, tool movements between
features, adjusting machine settings, and changing tools.
Tool replacement time - The time required to replace a tool that has exceeded
its lifetime and therefore become to worn to cut effectively. This time is
typically not performed in every cycle, but rather only after the lifetime of the
tool has been reached. In determining the cycle time, the tool replacement
time is adjusted for the production of a single part by multiplying by the
frequency of a tool replacement, which is the cut time divided by the tool
lifetime.
Following the milling process cycle, there is no post processing that is required.
However, secondary processes may be used to improve the surface finish of the part
if it is required. The scrap material, in the form of small material chips cut from the
workpiece, is propelled away from the workpiece by the motion of the cutter and the
spraying of lubricant. Therefore, no process cycle step is required to remove the scrap
material, which can be collected and discarded after the production.

4. Cutting tools for milling operation

Angles on milling cutting

(a)
(b)
(c)
(d)
(e)

Cutter = Multi-edge cutting tool

The teeth remove chips one after another
= clearance angle
= wedge angle
= rake angle

Milling cutter
Milling cutters come in several shapes and many sizes. There is also a choice
of coatings, as well as rake angle and number of cutting surfaces.
(a) Shape: Several standard shapes of milling cutter are used in industry
today, which are explained in more detail below.
(b) Flutes / teeth: The flutes of the milling bit are the deep helical grooves
running up the cutter, while the sharp blade along the edge of the flute is
known as the tooth. The tooth cuts the material, and chips of this material
are pulled up the flute by the rotation of the cutter. There is almost always
one tooth per flute, but some cutters have two teeth per flute. Often, the
words flute and tooth are used interchangeably. Milling cutters may have
from one to many teeth, with 2, 3 and 4 being most common. Typically,
the more teeth a cutter has, the more rapidly it can remove material. So, a
4-tooth cutter can remove material at twice the rate of a 2-tooth cutter.
(c) Helix angle: The flutes of a milling cutter are almost always helical. If
the flutes were straight, the whole tooth would impact the material at
once, causing vibration and reducing accuracy and surface quality.
Setting the flutes at an angle allows the tooth to enter the material
gradually, reducing vibration. Typically, finishing cutters have a higher
rake angle (tighter helix) to give a better finish.
(d) Centre cutting: Some milling cutters can drill straight down (plunge)
through the material, while others cannot. This is because the teeth of
some cutters do not go all the way to the centre of the end face. However,
these cutters can cut downwards at an angle of 45 degrees or so.
(e) Roughing or Finishing: Different types of cutter are available for
cutting away large amounts of material, leaving a poor surface finish
(roughing), or removing a smaller amount of material, but leaving a good
surface finish (finishing). A roughing cutter may have serrated teeth for
breaking the chips of material into smaller pieces. These teeth leave a
rough surface behind. A finishing cutter may have a large number (4 or
more) tooth for removing material carefully. However, the large number
of flutes leaves little room for efficient sward removal, so they are less
appropriate for removing large amounts of material.

(f) Coatings: The right tool coatings can have a great influence on the
cutting process by increasing cutting speed and tool life, and improving
the surface finish. Polycrystalline (PCD) is an exceptionally hard coating
used on cutters which must withstand high abrasive wear. A PCD coated
tool may last up to 100 times longer than an uncoated tool. However the
coating cannot be used at temperatures above 600 degrees C, or on
ferrous metals. Tools for machining aluminium are sometimes given a
coating of TiAlN. Aluminium is a relatively sticky metal, and can weld
itself to the teeth of tools, causing them to appear blunt. However it tends
not to stick to TiAlN, allowing the tool to be used for much longer in
aluminium.
(g) Shank: The shank is the cylindrical (non-fluted) part of the tool which is
used to hold and locate it in the tool holder. A shank may be perfectly
round, and held by friction, or it may have a Weldon Flat, where a set
screw, also known as a grub screw, makes contact for increased torque
without the tool slipping. The diameter may be different from the
diameter of the cutting part of the tool, so that it can be held by a
standard tool holder.

Type of milling cutter

(i) End mill cutter
End mills (middle row in image) are those tools which have
cutting teeth at one end, as well as on the sides. The
words end mill are generally used to refer to flat bottomed
cutters, but also include rounded cutters (referred to as ball
nosed) and radiuses cutters (referred to as bull nose,
or torus). They are usually made from high speed
steel or cemented carbide, and have one or more flutes. They
are the most common tool used in a vertical mill.
(ii) Slot mill cutter
Slot drills (top row in image) are center-cutting end mills, generally two(sometimes three- or four-) fluted cutters that are
capable of drilling (plunge-cutting) straight down into
the material and then moving laterally to cut a slot.
The plunge-cutting action is possible because at least
one (diametrically opposite) pair of teeth extend all the
way to the centre of the end face. Such a feature of end
mills is called "center-cutting". Slot drills are so
named for their use in cutting keyway slots. The
term slot drill is usually assumed to mean a twofluted, flat-bottomed end mill if no other information
is given.

(iii) Roughing end mill

Roughing end mills quickly remove large amounts of

material. This kind of end mill utilizes a wavy tooth form
cut on the periphery. These wavy teeth form many
successive cutting edges producing many small chips,
resulting in a relatively rough surface finish. During cutting,
multiple teeth are in contact with the workpiece reducing
chatter and vibration. Rapid stock removal with heavy
milling cuts is sometimes called hogging. Roughing end
mills are also sometimes known as ripping cutters.
(iv) Ball nose cutter
Ball nose cutters (lower row in image) are similar to slot drills, but the
end of the cutters is hemispherical. They are ideal for
machining 3-dimensional contoured shapes in machining
centres, for example in moulds and dies. They are
sometimes called ball mills in shop-floor slang, despite the
fact that that term also has another meaning. They are also
used to add a radius between perpendicular faces to
reduce concentrations. There is also a term bull
nose cutter, which refers to a cutter having a corner radius
that is fairly large, although less than the spherical radius
(half the cutter diameter) of a ball mill; for example, a 20mm diameter cutter with a 2-mm radius corner. This usage
is analogous to the term bull nose center referring to lathe
centers with truncated cones; in both cases, the silhouette
is essentially a rectangle with its corners truncated (by
either a chamfer or radius).
(v) Slab mill cutter
Slab mills are used either by themselves or in gang
milling operations on manual horizontal or universal milling
machines to machine large broad surfaces quickly. They have
been superseded by the use of cemented carbide-tipped face
mills which are then used in vertical mills or machining
centres.

(vi) Side-and-face cutter

The side-and-face cutter is designed with cutting teeth on its

side as well as its circumference. They are made in varying
diameters and widths depending on the application. The teeth
on the side allow the cutter to make unbalanced cuts (cutting
on one side only) without deflecting the cutter as would
happen with a slitting saw or slot cutter (no side teeth).Cutters
of this form factor were the earliest milling cutters developed.
From the 1810s to at least the 1880s, they were the most
common form of milling cutter, whereas today that distinction probably
goes to end mills.
(vii)
Involute gear cutter
There are 8 cutters (excluding the rare half sizes) that will cut
gears from 12 teeth through to a rack (infinite diameter).

(viii)

Face mill cutter

A face mill is a cutter designed for facing as opposed to i.e.,

creating a pocket (end mills). The cutting edges of face
mills are always located along its sides. As such it must
always cut in a horizontal direction at a given depth coming
from outside the stock. Multiple teeth distribute the chip
load, and since the teeth are normally disposable carbide,
this combination allows for very large and efficient face
milling.
(ix) Formed cutter
Formed cutter is a n incorporate the exact of the shape of the part it is
suitable for production small parts. There are some type of formed cutter
such as concave, convex and profiling.
(x) Angle cutter
Single angle milling cutter (dovetail cutter) {mill guide ways, angle
available- 45o, 50o, 60o }
Double angle milling cutter { mill guide ways, angle available- 45o, 50o,
60o }

(xi) Relieved cutter

Relieved cutter id used for cutting profiling
shape. Example involutes gear cutter, twist
drill groove cutter, sprocket cutter & radius
cutter.

5. Clamping technique ( work pierce and tool )

Clamping technique in tool

When started work, we must check that the cutter runs true. Direction of spindle
must be same with cutting direction. After finish using, must clean the internal
taper of milling spindle. Always keep the arbor and collars clean. Last, mount the
cutter short as possible.
(i) Cutter mounting
Direct mounting
The taper of cutting tool fitted directly into the work spindle. I may have
morse taper or steep taper shape.

Steep taper shape

morse taper shape

Indirect mounting
Cutter not inserted directly into the taper of the work spindle. Mounted to
the correct attachment.

Collet chuck

collet

end-mill

(ii) Mounting attachments

(a) Arbor mounting for vertical milling
Shell end arbor = mainly use to mount shell end mill and cutter
head.
Adapter self-locking chuck = use to reduce the internal taper
in the work spindle so that its fits on the required arbor or
cutter.
Collect chuck = design to take small cylindrical cutter to
various cutter. Widely use at industries' ER40, ER32, ER16
used with BT40 and R8 arbor.
Drill chuck = It use when there is a drilling process ,center
drill, deep drilling ,reaming ,counter bore.

(b) Mounting of cutter on vertical milling

Cutter should be clamped as near to the collet as possible.
This is to minimize overhanging of cutter that lead to cutter
deflection.
To reduce the vibration during cutting operation that lead to
chattering at work piece
(c) Mounting of cutter on horizontal milling
Maximum rigidity is an essential of efficient machining.
Arbor support permits considerable metal removal.
Cutter should be places near to headstock to maintain the maximum
rigidity of clamping and to reduce the cutter deflection.

Clamping technique in work pierce

i. Direct clamping
Holding pressure is provided by clamp bolt which should be as
close as possible so it can maintain the force applied. Work piece
with a surface can be directly clamp on the work table, using
variety of clamp and t-bolt.
From clamp and t-bolt
(a) Clamping kit
(c)
(b)
Ordinary clamp

(d) U clamp

(e) Gooseneck clamp

(f) Edge clamping

(g) Rules of clamping

is the hold
pressure that
provide by the
clamp which
should be close as

possible to
workplace
(h)
(i)
(j)
(k)
(l)
(m)
(n)
(o)
(p)
(q)

(r)

ii. Vise clamping

(a) Angular vise

(b) Machine vise with swivel base

(s)
(c) Vise alignment technique
(t) In setting up the vise onto machine table the fix jaw must be parallel
to the machine table.

(u)
(v)
(w)
iii. Other clamping attachment
(a) Chuck clamping for round wok piece

(x)
(y)
(z)
(aa)

6. Type and method of cutting fluid used in milling process

(ab)

The major advantage of using a coolant or cutting oil is that it dissipates heat,
giving longer life to the cutting edges of the teeth. The oil also lubricates the cutter
face and flushes away the chips, consequently reducing the possibility of marring the
finish.
Types
(ac)Cutting oils are basically water-based soluble oils, petroleum oils, and
synthetic oils. Water-based coolants have excellent heat transfer qualities; other
oils result in good surface finishes. The cutting oil compounds for various metals
are given in Table 4-3 in Appendix A. In general, a simple coolant is all that is
required for roughing. Finishing requires cutting oil with good lubricating
properties to help produce a good finish on the work piece. Plastics and cast iron
are almost always machined dry.
Method of Use

(ad)
The cutting oil or coolant should be directed by means of coolant
drip can, pump system, or coolant mist mix to the point where the cutter contacts
the work piece. Regardless of method used, the cutting oil should be allowed to
flow freely over the work piece and cutter.
(ae)
(af)
(ag)

7. Relation of the cutting parameters

Cutting speed
a. Important factor that affected milling operation efficiency
b. In order to work efficiently and economically
c. Its symbol is V. It is expressed in meter/min (m/min)
d. Formula: Cutting speed = diameter of cutter x x spindle speed
(ah)
V=dxxn
(ai)
(aj)
e. Selection of proper cutting speed
Type of material to be machined
Type of tool material
Rigidity and condition of the machine
Types of cutting operations
(ak)
(al)
(am)
Spindle speed
i. Defined as the speed at which the spindle of a milling machine rotates
per minute
ii. Its symbol is n. It is expressed in revolution/min (rpm)
iii. Formula :
(an)
Spindle speed =
Cutting speed
(ao)
Diameter of cutter x
(ap)
n=
v
(aq)
dx
(ar)
(as)
(at)
(au)
(av)
(aw)
(ax)
(ay)
iv. Selection of proper cutting speeds
For longer cutter life, use the lower cutting speeds in the
recommended range.
Know the hardness of the material to be machined.
When starting a new job, use the lower range of the cutting speed and
gradually increase to the higher range if conditions permit.
If a fine finish is required, reduce the feed rather than increase the
cutter speed.

 The use of coolant, properly applied, will generally produce a better

finish and lengthen the life of the cutter since it absorbs heat, acts as
a lubricant and washes chips away.
(az)
Feed rate
i. Defined as the distance in millimeters per minute that the work moves into
the cutter.
ii. Its symbol is f. It is expressed in (mm/min).
iii. Formula:
(ba)
Feed = no of teeth x rec. feed/tooth x spindle speed
(bb) f
= N x f/t x n
iv. Factors on which feed rate depends on
The depth and width of the cut.
The design or type of the cutter.
The sharpness of the cutter.
The work piece material.
The strength and uniformity of the work piece.
The type of finish and accuracy required.
The power and rigidity of the machine
(bc)
(bd)