Milling Operations

Examples of Parts Produced

Using Milling Operations

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 Objective
To understand the machining processes
required to obtain complex and flat
surfaces, i.e., milling operations
Types of machines, operation and
operating conditions including machining
time and MRR

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 Introduction
 Milling process is one of the most versatile
machining process.
 It is used for producing flat as well as
curved shapes.
 Intricate shapes , which can not be
produced in other machine tool are
produced in milling machine.
 It can be used for machining operations
like gear cutting, drilling, reaming, boring,
slotting, and tapping etc.
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Milling

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 A Milling Cutter

Cutter

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 Types of Milling Machine Tools
 A milling machine is a machine tool that removes
metal as the work is fed against a rotating multipoint
cutter.
 The cutter rotates at a high speed and because of
multiple cutting edges it removes metal at a very fast
rate.
 Knee and Column Type
– Horizontal
– Vertical

 Bed Type
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Horizontal Column-and-Knee Type
Milling Machines

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Parts of a Horizontal Column-and-
Knee Type Milling Machines

• Work table: Workpiece is clamped on it

using T-slots. The table moves
longitudinally relative to the saddle.

• Saddle: Supports the table and moves in

transverse direction.

• Knee: Supports the saddle and gives the

table vertical movement for depth of cut.
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Vertical Column-and-Knee Type
Milling Machines

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 Bed-Type Milling Machine
• Table is
mounted
directly on the
bed which
replaces the
knee
• Not versatile
as compared
to the column
and knee type
machines
• Stiff
• Simultaneous
machining

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 Overhanging arm
Arbor

Front brace

Cutter Column

Spindle
Table

Saddle

Knee

Elevating screw

Base

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 Milling Operation
 Workpiece is fed into rotating cutting tool
known as milling cutter.
 Multi-point cutting tool is used.
 It is an intermittent cutting operation.

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Milling Operations

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 Conventional vis-à-vis Climb Milling
Conventional
• Also known as up milling
• Cutting and feed motion
are in opposite direction
• Higher clamping forces
• Depth of cut zero (chip
thickness) at the start of cut
and maximum at the end of
the cut
• Tooth engagement is not a
function of workpiece
surface characteristics
• Safer and commonly used
Climb
• Also known as down milling
• Cutting and feed motion
are in same direction
• Lower clamping forces
• Depth of cut (chip
thickness) maximum at the
start of cut and zero at the
end of the cut
• Not suitable for workpieces
having surface skill such as
hot-worked, forged and
castings
• Better surface finish and
longer tool life
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Operating Conditions

Cutting speed (v)

DN
Cutting speed (v)  m/min
1000
where,
D = Diameter of cutter in mm
N = rotational speed of cutter in rpm

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 Operating Conditions

Feed (f)
• It is the distance moved by the work
piece w.r.t. the cutter axis
• It is the rate at which the work piece is
fed
• Feed is expressed in three ways:
mm/tooth or mm/revolution or mm/minute

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 Operating Conditions

Feed/tooth (F1)
f
F1  mm/tooth
Nz
where,
f = feed rate in mm/min
N = rpm of cutter
z = number of teeth on cutter

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 Operating Conditions
Feed/cutter revolution (F2)
• F2 = F1  z mm/rev

Feed/minute (f)
• f = F2 N = F1  z  N mm/minute

f  F2 N  F1 zN
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 Operating Conditions

Depth of cut (d)

Depth of cut is defined as the thickness of the

layer of material removed in one pass of the
workpiece under the cutter

•Roughing cut: 3 to 8 mm
•Finishing cut: < 1.5 mm

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 Operating Conditions
Width of cut (w)
 If cutter width is less than width of
workpiece then more than one pass will
needed.

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MATERIAL REMOVAL RATE (MRR)

MRR = w  d  f
MRR = w  d  F2  N
MRR = w  d  F1  z  N
where,
w = width of cut in mm,
d = depth of cut in mm,
f = feed rate in mm/min,
F1 = feed in mm/tooth,
F2 = feed in mm/rev,
z = number of cutter teeth,
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N = rpm of the cutter.
 Machining Time

length of cut L L L
t    min
feed rate f F2 N F1 z N

mm mm
t 
mm/min (mm/rev)(r ev/min)
mm
  min
(mm/tooth) (tooth)(re v/min)
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 Length of Cut (L)
Cutter position at start of cut Cutter position at end of cut
A B B

A
D

F
E
Feed

Depth of cut (d)

Workpiece

L1 Length of workpiece L2
to be machined (L j )
Approach Overtravel

L = L1 + Lj + L2 L1  d ( D  d )
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L = L1 + Lj + L2 + length of approach + length of overtravel
Length of Cut (L)

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TYPES OF MILLING OPERATIONS
•It is used for
removing material
from upper Plain/Slab Milling
surface of the
work piece (flat
Surface)
•For Plain milling
Up milling or
Down milling
process is used
•Axis of rotation of
cutter is parallel
to the workpiece
surface 26
 TYPES OF MILLING OPERATIONS

•Cutter is
Face Milling
mounted on
the spindle
having an
axis of
rotation
perpendicular
to the
workpiece
surface

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 TYPES OF MILLING OPERATIONS
•In this
operation both
horizontal
Side and Face Milling
surface and Side and face cutter
vertical
surfaces are
machined.
•It removes
material from
side and face
of the work
piece
•Cutter used is
side and face Workpiece 28

cutter
 TYPES OF MILLING OPERATIONS

End Milling
Shank
End mill

Workpiece

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 End Mill Cutter
•Milling cutter used is
called endmill
•End mill resembles a
drill bit in shape but
having no pointed
edge
•Used for removing
material from sides
of work piece and for
cutting complicated
profiles

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 TYPES OF MILLING OPERATIONS

•Two or more
cutters are
Straddle Milling
mounted on
an arbor and
are used to
machine two
parallel
surfaces on
the
workpiece

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TYPES OF MILLING OPERATIONS

Form Milling
•Cutters
have
specially
shaped
teeth to
produce
curves
profiles
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TYPES OF MILLING OPERATIONS

Slotting

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TYPES OF MILLING OPERATIONS

Slitting

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TYPES OF MILLING OPERATIONS

T Slot Cutting

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