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Cutting forces in milling process
In milling, cutting forces are exerted to shear away material in the form of a chip.
Knowledge of the cutting forces is essential for the following reasons:
1. Estimation of cutting power consumption,
2. Structural design of the machine – fixture – tool system
3. Evaluation of role of the various machining parameters (cutting speed, feed,
tool geometry, cutting fluid etc.) on cutting forces
4. Study of behaviour and machinability characterisation of the work materials
Let us consider the cutting forces due to the single tooth engagement of a plain milling cutter
1. Tangential force PT - force will be tangential force PT tangent to the work piece, this
is the most important force.
2. Radial or transverse force PR
Now resultant of these two is R - vector summation of this tangential force and the radial
force PR.So the main forces coming from the cutting process are the tangential force P T and
the radial force PR resultant of which is R
Peripheral milling
The machining is performed by the cutting edges on the periphery of the milling cutter. It is
classified under two headings
1. Up milling
2. Down milling
Up milling
In this method, the work piece mounted on the table is fed against the direction of rotation of
the milling cutter. The cutting force is minimum during the beginning of the cut and
maximum at the end of cut. The thickness of chip is more at the end of the cut. As the cutting
force is directed upwards, it tends to lift the work piece from the fixtures. Application of
coolant on the cutting edge is also difficult. Due to these reasons the quality of the surface
obtained by this method is wavy. This processes being safer is commonly used and
sometimes called conventional milling.
Down milling
The work piece mounted on the table is moved in the same direction as that of the rotation of
the milling cutter. The cutting force is maximum at the beginning and minimum at the end of
cut. The chip thickness is more at the beginning of the cut. The work piece is not disturbed
because of the bite of the cutter on the work. The coolant directly reaches to the cutting point.
So the quality of surface finish obtained is high. Because of the backlash error between the
feed screw of the table and the nut, vibration is setup on the work piece
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Up Milling Down Milling
1. Cutter rotates opposite direction of cutter rotates same direction of feed
feed which is also known as also known as climb milling
conventional milling.
2. chip width size is zero at initial chip size is maximum at start of cut
cut and maximum at the end of and decrease with the feed. It is zero at
feed. the end of feed.
3. In this process, heat is diffuse to In down milling most of heat diffuse
the work piece which causes the to the chip does not change the work
change in metal properties. piece properties.
4. In up milling, tool wear is more In this, tool wear is less compare to the
because the tool runs against the up milling, due to the cutter rotate with
feed. Tool rubs more at the the feed.
beginning of the cut causing faster
tool wear and decreases tool life
6. The cutting chips fall down in The cutting chips fall down behind the
front of the cutting tool which tool and low vibration gives better
again cut the chips and high surface finish.
vibration cause less surface finish.
7. Due to upward force by tool, high In down milling, downward force act
fixture required to hold the work on work piece and low clamping is
piece. required
8. High quality cutting fluid is In this process heat does not diffuse in
required because heat diffuse in the work piece, so simple cutting fluid
the work piece. is required.
9. It required high cutting force It required low cutting force.
compare to down milling.
Climb milling is generally the best way to machine parts today since it reduces the load from
the cutting edge, leaves a better surface finish, and improves tool life. During conventional
milling, the cutter tends to dig into the work piece and may cause the part to be cut out of
tolerance.
Even though climb milling is the preferred way to machine parts, there are times when
conventional milling is the recommended choice. Backlash, which is typically found in older
and manual machines, is a huge concern with climb milling. If the machine does not
counteract backlash, conventional milling should be implemented. Conventional milling is
also suggested for use on casting or forgings or when the part is case hardened since the cut
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Three indexing plates are used. These plates have concentric circles of holes with their
different numbers as described below:
If the pin is moved by one hole on the indexing plate in the circle of 20 holes, the spindle will
𝟏 𝟏 𝟏
revolve by 𝟒𝟎 ∗ 𝟐𝟎 = 𝟔𝟎𝟎 th turn of one rotation
These models are used for high precision angular setting of the work piece with respect to the
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cutter. For reading the angles, an optical system is built into the dividing head.
Universal Dividing Head
In this, the spindle can be rotated at different angles in the vertical plane from horizontal to
vertical. As indicated by its name “universal”, it can be used to do all types of indexing on a
milling machine.
Universal dividing head is using for the following purposes
a) Universal dividing head can set the work piece in vertical, horizontal, or in inclined
position relative to the table surface.
b) To impart indexing movement.
c) For imparting a continuous rotary motion to the work piece for milling helical grooves
Indexing method
a. Direct indexing
b. Simple indexing
c. Compound indexing
d. Differential indexing
Plane/Simple Indexing
It is also named as plain indexing. It over comes the major limitation of direct indexing that is
possibility of dividing circumference of work piece into some fixed number of divisions. In
this case, worm and worm gear is first engaged. Since the gear ratio of worm and worm
wheel is 40:1, it takes 40 turns of the crank to rotate the spindle and hence the work piece
through one complete revolution. One complete turn of the crank will revolve the spindle
only by 1/40th revolution (turn). If the number of divisions on the job circumference (that is
number of indexing) needed is N, then the number of turns (n) that the crank must be rotated
for each indexing can be found from the formula:
40
Number of turns of crank 𝑛 = 𝑡𝑢𝑟𝑛𝑠
𝑁
Indexing Procedure
a) Divide 40 by the number of divisions to be done on the circumference of work piece.
40
Indexing crank movement= 𝑁
N is the number of divisions to be made on the circumference of work piece.
b) If the above number is a whole number, then crank is rotated by that much number of
revolutions after each milling operations, till the completion of the work.
For example, if we want to divide the circumference into 10 number of parts
40
Indexing crank movement 10 = 4 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛
That is the indexing crank is given 4 revolutions after each of milling operation
c) If indexing crank movement calculated by 40/N is not whole number, it is simplified and
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Action
We will select the hole circle of 21 holes. After each milling operation indexing crank will be
rotated by 1 complete circle and 7 holes in 21 holes’ circle. This way milling operation will
be done by total 30 times.
This method can use for indexing upto 50 for any number of divisions after 50 this method is
not capable for some numbers like 96, etc. Compound indexing overcomes the limitations.
Problem
Indexing 48 holes
40
Rotation of crank required = 𝑁
40
ie= 48 which means crank has to be rotated 40 holes in 48 holes circle after every cut for 48
times.
If A is greater than N, resulting fraction is positive and the index plate must move in
same direction as crank (clockwise). This positive rotation uses an idler gear.
If N is greater than A, resulting fraction is negative and index plate must move
counterclockwise. This negative rotation required use of two idler gears.
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Example 1
Obtain the indexing for 87 divisions.
First of all, find out whether the number can be indexed by plain indexing or not
40 40
In plain indexing, crank movement = 𝑁 = 87 , cannot be indexed as 87 number holes are
not available
4. Engage the gears of driver shaft with 24 gears and driven shaft 18 gears ratio (index
plate rotation in the same direction of rotation of crank)
40 8
5. Rotate the crank = 90 = 18 (moving 8 holes in 18 number hole circle)
6. After the every cut, rotate the crank 8 holes in 18 number hole circle for 87 times to
get 87 divisions on the surface
Example 2
Index the given surface to 209 divisions
The required indexing is 40/209 which cannot be obtained with any of the index plate
available. Choose the nearest possible divisions.
CONVENTIONAL MILLING
In conventional milling, also called up milling, the maximum chip thickness is at the end of the cut.
The feed movement is opposite to the tool rotation.
Pros:
1. Tooth engagement is not a function of work piece surface characteristics.
2. Contamination or scale on the surface does not affect tool life.
3. The cutting process is smooth, provided that the cutter teeth are sharp.
4. The width of the chip starts from zero and increases as the cutter finishes slicing.
5. The tooth meets the work piece at the bottom of the cut.
6. Upward forces are created that tend to lift the work piece during face milling.
7. More power is required to conventional mill than climb mill.
8. Surface finish is worse because chips are carried upward by teeth and dropped in front
of cutter. There’s a lot of chip re-cutting. Flood cooling can help!
9. Tools wear faster than with climb milling.
10. Conventional milling is preferred for rough surfaces.
Cons:
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2. The workpiece has the tendency to be pulled up, thus proper clamping is important.
3. Faster wear on tool than climb milling.
4. Chips fall in front of the cutter – chip disposal difficult.
5. Upward force tends to lift up workpiece.
6. More power required due to increased friction caused by the chip beginning at the minimum
width.
7. Surface finish marred due to the chips being carried upward by tooth.
In climb milling, also called down milling, cutting starts with the chip at its thickest location. The
feed movement and the tool rotation have the same direction.
Pros:
1. The downward component of cutting forces holds the work piece in place, particularly for
slender parts.
2. Easier chip disposal - chips removed behind cutter.
3. Less wear - increases tool life up to 50%.
4. Improved surface finish - chips less likely to be carried by the tooth.
5. Less power required - cutter with high rake angle can be used.
6. Climb milling exerts a downward force on work piece - fixtures simple and less costly.
Cons:
1. Because of the resulting high impact forces when the teeth engage the work piece, this
operation must have a rigid setup, and backlash must be eliminated in the table feed
mechanism.
2. Climb milling is not suitable for machining work pieces having surface scale, such as hot-
worked metals, forgings and castings. The scale is hard and abrasive and causes excessive
wear and damage to the cutter teeth, thus reducing tool life
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QUESTIONS
Answer the following questions in one or two words
1. What is the base of a milling machine made of?
2. Name the part which holds the other end of the arbor in a milling machine.
II. Answer the following questions in one or two sentences
1. What is milling?
2. What are the types of milling machines?
3. How is the size of a milling machine specified?
4. Name the fundamental milling processes.
5. What are the types of peripheral milling?
6. Name four work holding devices in a milling machine.
7. What is indexing?
8. What is the use of indexing head?
9. What are the types of indexing head?
10. What are the methods of indexing?
III. Answer the following questions in about a page
1. List out various milling machine attachments.
2. What are the different milling machine operations?
IV. Answer the following questions in detail
1. Draw a neat diagram of a milling machine and explain its construction.
2. Explain – Up milling, Down milling.
3. Explain any four cutter holding devices with diagrams.
4. Draw a neat diagram of a plain milling cutter and explain its nomenculature.
5. What are the differences between a plain milling machine and a universal milling
machine?
6. List out various milling machine attachments.
7. Name the milling cutters.
8. What are the different milling machine operations?
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General
Types of milling cutter in detail
Milling cutters are classified into different categories depending on different criteria as
described below :
According to the Construction of Milling Cutter
(a) Solid milling cutter
(b) Inserted teeth cutter
(c) Tipped solid cutter
Solid cutter consists of teeth integral with the cutter body, in tipped cutter, teeth are made of
cemented carbide or satellite, teeth are brazed to steel cutter body called shank. Inserted teeth
cutter are larger in diameter, teeth of hard material are inserted and secured in the shank.
According to Relief Characteristics of the Cutter Teeth
(a) Profile relieved cutter
(b) Form relieved cutter
In case of profile relieved cutter, a relief to cutting edges is provided by grinding a narrow
land at their back. In case of form relieved cutters a curved relief is provided at the back of
the cutting edges.
According to Method of Mounting the Cutters
(a) Arbor type
(b) Facing cutter
(c) Shank cutter
Arbor type cutters have a central hole and keyways for their mounting on arbor. Milling
Shank type cutters are provided with straight or tapered shanks inserted into the spindle nose
and clamped there. Facing type milling cutter are used to produce flat surfaces. These are
balled or attached to the spindle nose or the face of a short arbor.
According to Direction of Rotation of the Cutter
(a) Right hand rotational cutter
(b) Left hand rotational cutter
A right hand rotational cutter rotates in an anticlockwise direction when viewed from end of
the spindle while left hand rotational cutter rotates in a clockwise direction.
According to the Direction of Helix of the Cutter Teeth
(a) Parallel straight teeth
(b) Right hand helical
(c) Left hand helical
(d) Alternate helical teeth
Parallel or straight teeth cutter consists of teeth parallel to axis of rotation of the cutter with
zero helix angle. In case of right hand and left hand helical teeth cutters, teeth cut at an angle
to the axis of rotation of the cutter. Teeth have opposite inclination in both the cutters.
Alternate helical teeth cutter has alternate teeth of right hand and left hand helical teeth
cutters.
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Direct Indexing
It is also named as rapid indexing. In this case first of all worm and worm wheel is
disengaged. Direct indexing is accomplished by an additional index plate fastened to the
index head spindle. It offers a quick means of milling squares, hexagons, taps, etc. Direct
indexing plate usually contains three sets of hole circles or slots: 24, 30, and 36. The number
of divisions possible to be indexed is limited to numbers that are factors of 24, 30, 36.
By using 24 number index plate, any number of divisions which is a factor of 24 can be
indexed quickly. It is possible to divide the surface of work piece into any number of equal
divisions out of 2, 3, 4, 6, 8, 12, 24 parts.
Example: Problems
If we want to cut a hexagonal bolt by direct indexing, using a 24 number index plate
24
No: of holes to be moved =4
6
After completing one pair of milling whole surface of work piece, we have to move the pin
by 4 holes before next milling operation, that is to be done for 5 number of times for making
hexagonal bolt.
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I.B. Answer the following questions in one or two words
1. What is the base of a milling machine made of ?
2. Name the part which holds the other end of the arbor in a milling machine.
II. Answer the following questions in one or two sentences
1. What is milling?
2. What are the types of milling machines?
3. How is the size of a milling machine specified?
4. Name the fundamental milling processes.
5. What are the types of peripheral milling?
6. Name four work holding devices in a milling machine.
7. What is indexing?
8. What is the use of indexing head?
9. What are the types of indexing head?
10. What are the methods of indexing?
III. Answer the following questions in about a page
1. What are the differences between a plain milling machine and a universal milling
machine?
2. List out various milling machine attachments.
3. Name the milling cutters.
4. What are the different milling machine operations?
IV. Answer the following questions in detail
1. Draw a neat diagram of a milling machine and explain its construction.
2. Explain - Upmilling, Down milling.
3. Explain any four cutter holding devices with diagrams.
4. Draw a neat diagram of a plain milling cutter and explain its nomenculature.
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