MILLING MACHINE

A milling machine is a machine tool

that removes metal as the work is fed
against a rotating multipoint cutter.

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MILLING MACHINE (KNEE TYPE)

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 Types of Milling Machine
The milling machine are classified according to
the general design

1. Column and Knee Type

a) Plain milling machine
b) Ram type milling machine
c) Universal milling machine
d) Omniversal milling machine
e) Vertical milling machine
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 Types of Milling Machine
2. Manufacturing or fixed bed type
a) Simplex milling machine
b) Duplex milling machine
c) Triplex milling machine

3. Planer type

4. Special type
a) Rotary table milling machine
b) Drum milling machine
c) Planetary milling machine
d) Pantograph, tracer controlled milling machine
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HORIZONTAL MILLING MACHINE
(KNEE TYPE)

CH/ONTC/PT
HORIZONTAL MILLING MACHINE
(KNEE TYPE)

CH/ONTC/PT
HORIZONTAL MILLING MACHINE
(KNEE TYPE)

CH/ONTC/PT
HORIZONTAL MILLING MACHINE
(KNEE TYPE)

CH/ONTC/PT
HORIZONTAL MILLING MACHINE
(KNEE TYPE)

CH/ONTC/PT
HORIZONTAL MILLING MACHINE
(KNEE TYPE)

CH/ONTC/PT
HORIZONTAL MILLING MACHINE
(KNEE TYPE)

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VERTICAL MILLING MACHINE
(KNEE TYPE)

CH/ONTC/PT
VERTICAL MILLING MACHINE
(KNEE TYPE)

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VERTICAL MILLING MACHINE
(KNEE TYPE)

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VERTICAL MILLING MACHINE
(KNEE TYPE)

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VERTICAL MILLING HEAD

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 VERTICAL MILLING MACHINE
(KNEE TYPE)

VIDEO
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EDGE FINDER
 VERTICAL MILLING MACHINE
(KNEE TYPE)

VIDEO SETTING CH/ONTC/PT

THE WORKPIECE
UNIVERSAL MILLING MACHINE

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UNIVERSAL MILLING MACHINE

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UNIVERSAL MILLING MACHINE

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UNIVERSAL MILLING MACHINE

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UNIVERSAL MILLING MACHINE

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OMNIVERSAL MILLING MACHINE

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PLANNER TYPE MILLING MACHINE

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PLANNER TYPE MILLING MACHINE

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 SPECIAL PURPOSE MILLING MACHINE

3-PRINCIPLE LINEAR MOVEMENT

2-ANGULAR MOVEMENT

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HEAVY DUTY DOUBLE HOUSING
MILLING MACHNE

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FOUR SPINDLE TRACE
MILLING MACHINE

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TWO OR THREE AXIS TRASING
MACHINE

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TWIN SPINDLE CNC MILLING MACHINE

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CNC MILLING MACHINE

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SPECIAL PURPOSE MACHINE

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 MILLING MACHINE
(FEED MECHANISM)

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MILLING MACHINE ATTACHMENTS
1. Vertical milling attachment
2. Universal milling attachment
3. High speed milling attachment
4. Slotting attachment
5. Universal spiral attachment
6. Rack milling attachment
7. Circular milling attachment
8. Dividing head attachment
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VERTICAL MILLING ATTACHMENT

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VERTICAL MILLING ATTACHMENT

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ROTARY TABLE

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DIVIDING HEAD

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DIVIDING HEAD

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INDEXING PLATE

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INDEXING

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MILLING MACHINE ATTACHMENTS

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BORING HEAD

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BORING HEAD

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TOOL HOLDING DEVICES
1. Collet
2. Spring collet
3. Adapter
4. Arbor

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COLLET

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SPRING COLLET

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ARBOR

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ARBOR

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ARBOR

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TAPER USED IN MILLING MACHINE ARBOR

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WORK HOLDING DEVICES
1. Vice
Plain vice
Swivel vise
Tool makers universal vice
2. Angle plate
3. Step block, T-bolt & strap clamp
4. Vee block
5. Fixtures

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PLAIN VICE

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PLAIN VICE

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SWIVEL VICE

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UNIVERSAL VICE

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UNIVERSAL VICE

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ANGLE PLATE

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V- BLOCK

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SLOT MILLING FIXTURE

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FIXTURES

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MILLING PROCESS
PERIPERAL MILLING
FACE MILLING

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 BASIC MILLING METHOD

1. UP MILLING
2. DOWN MILLING

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MILLING OPERATIONS
1. Plain milling
2. Face milling
3. Side milling
4. Straddle milling
5. Angular milling
6. Gang milling
7. Form milling
8. Profile milling

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MILLING OPERATIONS
9. End milling
10. Saw milling
11. Milling keyways, grooves and slots
12. Gear cutting
13. Helical milling
14. Cam milling
15. Thread milling

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MILLING OPERATION

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PLAIN MILLING

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PLAIN MILLING

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SLAB MILLNG

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FACE MILLING

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FACE MILLING

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END MILLING

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END MILLING

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FORM MILLING (CONVEX)

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FORM MILLING (CONCAVE)

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 FORM MILLING
(CORNER ROUND CUTTER)

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STRADDLE MILLING

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GANG MILLING

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GANG MILLING

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PROFILE MILLING

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KEY WAY MILLING

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T-SLOT CUTTING

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DOVE TAIL CUTTING

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SLITTING

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SLITTING

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ANGULAR FACE MILLING

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ANGULAR FACE MILLING

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HELICAL MILLING

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GEAR CUTTING

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THREAD MILLING

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WALL MILLING

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SPLINE MILLING

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VERTICAL MILLING OPERATIONS

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 MILLING CUTTERS
Standard milling cutters are classified below.

1. Plain milling cutter

a) Light duty plain milling cutter
b) Heavy duty plain milling cutter
c) Helical plain milling cutter
2. Side milling Cutter
a) Plain side milling cutter
b) Staggered teeth side milling cutter
c) Half side milling cutter
d) Inter locking side milling cutter.
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MILLING CUTTERS
3. Metal slitting saw
a) Plain metal slitting saw
b) Staggered teeth metal slitting saw
4. Angle milling cutter
a) Single angle milling cutter
b) Double angle milling cutter
5. End mill
a) Taper shank end mill
b) Straight shank end mill
c) Shell end mill
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MILLING CUTTERS
6. T -slot milling cutter
7. Woodruff key slot milling cutter
8. Fly cutter
9. Formed cutter
a) Convex milling cutter
b) Concave milling cutter
c) Corner rounding milling cutter
d) Gear cutter
e) Thread milling cutter
10. Tap and reamer cutter
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LIGHT DUTY PLAIN MILLING CUTTER

oDiameter of the cutter varies from 16 to 160mm

oWidth of the cutter is less than 20mm
oHelix angle varies from 10 to 25
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HEAVY DUTY PLAIN MILLING
CUTTER (HELICAL)

oDiameter of the cutter varies from 16 to 160mm

oWidth of the cutter is less than 20 to 160mm
oHelix angle varies from 45 to 60
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SIDE MILLING CUTTER
(PLAIN)

oDiameter of the cutter varies from 50 to 200mm

oWidth of the cutter is less than 5 to 32mm

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SIDE CUTTER

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STAGGERED TOOTH SIDE
MILLING CUTTER

oDiameter of the cutter varies from 50 to 200mm

oWidth of the cutter is less than 10 to 45mm

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HALF SIDE MILLING CUTTER

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SLITTING CUTTER

oDiameter of the cutter varies from 50 to 200mm

oWidth of the cutter is less than 0.8 to 5mm

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SINGLE ANGLE MILLING CUTTER

oDiameter of the cutter varies from 40 to 150mm

oAngle of the cutter available in 30,45,60,65,75,80,84

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DOUBLE ANGLE MILLING CUTTER

oDiameter of the cutter varies from 50 to 100mm

oWidth of the cutter available from 12 to 36mm
oAngle of the cutter available in
50,55,60,65,70,75,80,85,90,95
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DOUBLE ANGLE MILLING
CUTTER

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ANGLE MILLING CUTTER

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END MILLING CUTTER

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END MILLING CUTTER

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END MILLING CUTTER

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 T-SLOT MILLING CUTTER

T-SLOT CUTTING

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WOOD ROOF KEYSEAT CUTTER

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FLY CUTTER

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FORM CUTTER (CONVEX)

oDiameter of the cutter varies from 50 to 125mm

oSemicircle varies from 1.6 to 20mm

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FORM CUTTER (CONCAVE)

oDiameter of the cutter varies from 50 to 125mm

oSemicircle varies from 1.6 to 20mm

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 FORM CUTTER
(CORNER ROUND CUTTER)

oDiameter of the cutter varies from 50 to 110mm

oSemicircle varies from 1.5 to 20mm

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KEY WAY MILLING

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INSERTED TYPE MILLING CUTTER

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FACING TYPE MILLING CUTTER

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SHELL MILLING CUTTER

oDiameter of the cutter varies from 40 to 160mm

oWidth of the cutter 32 to 36mm
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SHELL END MILL

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THREAD CUTTER

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TREPANNING CUTTER

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INVOLUTE GEAR TOOTH
CUTTER

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VARIOUS MILLING CUTTERS

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VARIOUS MILLING CUTTERS

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MILLED COMPONENT

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PRECAUTIONS IN USE OF MILLING CUTTER

The milling machine must be stopped before

setting up or removing a workpiece, cutter, or
other accessory.

All the chips should be removed from the cutter.

A wiping cloth should be placed on the cutter to
protect the hands

If cutting teeth are dull, these should be

sharpened on a tool and cutter grinder.
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PRECAUTIONS IN USE OF MILLING CUTTER

Burrs should be removed from the milling cutter

with an abrasive stone.

Hole type milling cutters should be stored on a

rack. It should be ensure that the teeth do not hit
other cutter or metal parts.

The cutter should be rotated in right direction

only

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ELEMENTS OF PLAIN MILLING CUTTER

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ELEMENTS OF PLAIN MILLING CUTTER

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NOMENCLATURE OF
MILLING CUTTER

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RAKE ANGLES OF MILLING CUTTER

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FACE MILLING CUTTER

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INFLUENCE OF RAKE ANGLE

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MACHINING TIME CALCULATION FOR
MILLING MACHINE

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MACHINING TIME CALCULATION

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 MACHINING TIME CALCULATION
In milling machine for machining time calculation the
approach length formula will be changed depends on the
cutter used.

Approach length for plain milling cutter

Approach length for face milling cutter

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MACHINING TIME CALCULATION

L
MACHININGTIME (Tm)
Sz Z n
TOOLLENGTHTRAVEL l la lx
Where,
l = length of the work piece in mm.
la = Approach distance in mm.
lx = over run in mm (Appximately 6mm).

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Approach length for plain milling cutter

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Approach length for plain milling cutter
2 2
D D
A B
2

2 2
or
A B( D B)
Where,
A TheApproachinMM
B TheDepthOf TheCutinMM
D TheDiameterOf TheCutterinMM

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Approach length for face milling cutter
D
A C
2
Where,
A TheApproachLengthinMM
D TheDiameterOfTheCutterinMM
D 2 B 2
C ( ) ( )
2 2
B TheWidthOf TheWorkinMM

CH/ONTC/PT
 MACHINING TIME CALCULATION
FEED :
It is the distance that the work advances in the time
when the cutter turns through one complete revolution.
The feed is expressed in millimeter per revolution.

Sm = N x Srev = (Sz x Z) x N
Where,
Sm = Feed per minute.
Srev = Feed per cutter revolution.
Sz = Feed per tooth
Z = number of teeth in the cutter.
n = the cutter speed in r.p.m
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MACHINING TIME CALCULATION

CUTTING SPEED :
The speed of cutter is its peripheral linear
speed resulting from rotation. It is expressed in
meters per minute.
dn
v m/min
1000
Where,
V = Cutting speed in m/min.
D = Cutter diameter in mm.
N = cutter speed in rpm.

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MACHINING DATA FOR MILLING

HSS CARBIDE
WORK HARDNESS
MTRL. (BHN) SPEED FEED SPEED FEED
(m/min) (mm/rev) (m/min) (mm/rev)

CAST 140 - 240 16 0.15 50 0.18

STEEL

CH/ONTC/PT
THANK YOU

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