B

Facemilling (1) involves the combined cutting action of the cutting edges mainly the edges on the periphery and to some extent, the edges on the face of the tool. The milling cutter rotates at a right angle to the direction of radial feed against the workpiece. Peripheral (slotting) milling (2) uses the cutting edges on the periphery of the tool. The milling cutter rotates around an axis parallel to the tangential feed. The two methods may also be distinguished by the depth of cut taken: Facemilling has a depth of cut in an axial direction determined by how deep the peripheral edges cut. The edges on the face of the tool generate the finished surface. Peripheral milling has a depth of cut in a radial direction determined by how deep the diameter of the cutter penetrates the workpiece. Some milling cutters can also work along a third feed direction - axially. Axial milling is actually a drilling operation performed by the cutting edges on the face of the cutter. This method (3) is used for closed pockets or slots where the tool drills down to a certain depth and then changes to a

C
Directions in milling

and the capability of the machine are matched, factors such as stability, accuracy and finish should be assessed. Instability is the greatest threat in metal cutting not only to quality but also to tool-life and total performance, despite the suitability of the machine or tool.

BASIC MILLING
Any type of milling cutter will basically employ one or a combination of the following machining methods. With the variations in methods of milling, it is important to distinguish between the different feed directions in relation to the axis of tool rotation. (A) is the axial direction, (B) is the radial direction and (C) is designated as the tangential direction.

Facemilling, peripheral milling and axial-feed milling

X-4

MODERN METAL CUTTING

radial feed direction, letting the peripheral cutting edges open up the hole. A combination of feed directions is also possible where angled planes or curved surfaces are generated. The axially-fed milling cutter must have edges across the center of the tool to allow a cutting action across its face. To set up a milling operation, a number of factors must be considered. These elements define the dynamics of a rotating milling tool with a diameter (D), moving against the workpiece. Spindle speed (n - in rpm) is the number of revolutions the milling tool on the spindle makes per minute. This is a machine oriented value and does not say much about what is happening on the periphery, where the cutting edge is machining.

Cutting speed (vc - in ft/min) on the other hand indicates the surface speed at which the cutting edge machines the workpiece. This is an important tool oriented value and part of the cutting data which ensures that the operation is carried out as efficiently as possible by the tool being used. The spindle speed, tool diameter and cutting speed are obviously related, and can be simply expressed by the following formulas. Feed per minute or feed speed (v - in in/min) is the feed of the tool against the workpiece in distance per timeunit. It is also called the table-feed or machine feed.

n V Vc , z D n Vc V , z D

Vc =

xDxn (ft/min) 12

n=

Vc x 12

xD

(rpm)

MODERN METAL CUTTING

X-5

Feed per revolution (f - in in/rev) is a value used especially for feed calculations and determining the finishing capability of a facemill. It is an auxiliary value indicating how far the tool moves during the rotation.

z
v

z
v

z = n x z

(in)

= n

(in/rev)

Feed per tooth (fz - in in/tooth) is an important key value in milling. As the milling cutter is a multi-edge tool, a value is needed to ensure that each edge machines under satisfactory conditions. The capability of each tooth sets the limits for the tool. It is the linear distance moved by the tool while one particular tooth is engaged in cut.

ae ap ap ae

Cutting depth in face and peripheral milling

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MODERN METAL CUTTING