CLD 20502 Basic Engineering Workshop

Topic 3:
Machining Process
3.3: Milling Machine
OBJECTIVES
Identify the milling machine.
Identify the various types and uses of milling machine.
Identify the uses, functions of various parts and units of
milling machine.
MILLING
Process
cutting away material by feeding a workpiece past a
rotating multiple tooth cutter

Workpiece
flat, angular, curved or combinations

Product
external and internal round profiles and cutting
operations of complex shapes
 Milling Machine

Horizontal milling machine Vertical milling machine

Vertical milling machine which is of similar construction to a

horizontal milling machine except that the spindle is mounted in the
vertical position.
Horizontal Milling Machine
a. Column
The column houses the
spindle, the bearings,
the gear box, the
clutches, the shafts, the
pumps, and the shifting
mechanisms for
transmitting power
from the electric motor
to the spindle at a
selected speed.
 Horizontal Milling Machine

b. Knee
The knee mounted
in front of the
column is for
supporting the table
and to provide an up
or down motion
along the Z axis.
 Horizontal Milling Machine

c. Saddle
The saddle consists
of two slideways,
one on the top and
one at the bottom
located at 90 to
each other, for
providing motions
in the X or Y axes
by means of lead
screws.
 Horizontal Milling Machine

d. Table
The table is
mounted on top of
the saddle and can
be moved along the
X axis. On top of the
table are some T-
slots for the
mounting of
workpiece or
clamping fixtures.
 Horizontal Milling Machine

e. Arbor
The arbor is an
extension of the
spindle for
mounting
cutters. Usually,
the thread end of
an arbor is of left
hand helix.
 Vertical Milling Machine
Its additional features are:

a. Milling head
The milling head
consisting the spindle,
the motor, and the feed
control unit is mounted
on a swivel base such
that it can be set at any
angle to the table.
Vertical Milling Machine
b. Ram
The ram on which
the milling head
is attached can be
positioned
forward and
backward along
the slideway on
the top of the
column.
Types Of Milling Machine

Knee and column milling machine

universal and ram
Bed type milling machine.
CNC milling machine
Knee and Column Milling Machine
Knee and Column Milling Machine

Most common milling machine

Very versatile machine.
Found primarily in job shops and tool and die
shops.
Used for general purpose milling operation
The most distinguishing characteristic of this type
of machine is the knee and column configuration
Unique in that the table can be moved in all three
directions, x-y-z axes.
The worktable can moved in the x-direction, the
saddle can moved in the y-direction and the knee
can be moved vertically to achieve the z-direction.
Knee and Column Milling Machine
Knee and Column Milling Machine

Universal Knee and Column Milling Machine

It has a table that can be swiveled in a horizontal plane (about the vertical
axis) to any specified angle.
This facilitates the cutting of angular shapes and helixes on workpart.
Knee and Column Milling Machine

Ram Knee and Column Milling Machine

The toolhead containing the spindle is located on the end of a
horizontal ram.
The ram can be adjusted in and out over the worktable to locate the
cutter relative to the workpart.
The toolhead also can be swiveled to achieve an angular
orientation.
Knee and Column Milling Machine
 Fix Bed type Milling Machine

Work table is mounted on bed.

Move only longitudinally.
Not versatile.
Have great stiffness.
Used for high production work.
The most distinguishing aspect of the
fixed bed type milling machine is the
absence of the knee.
CNC Milling Machine

The cutter path is controlled by

alphanumerical data than a physical
template (G code, M code).
Suited for profile milling, pocket milling,
surface countouring and die sinking, in
which two or three axes of the worktable
must be simultaneously controlled to
achieve the required cutter part.
 Milling Operation

Peripheral
milling
Milling
Operation
Face
milling
 Slab milling

Peripheral Slotting
milling

Side milling

Straddle
milling
Peripheral Milling

Also known as plain milling or slab milling.

Surface is generated by the teeth located on the
periphery of the cutter body.
Surface is parallel with the axis of rotation of the
cutter.
Axis of tool is parallel to the surface being
machined.
Operation is by cutting the edges on the outside
periphery of the cutter.
Usually performed on horizontal-spindle milling
machines.
Peripheral Milling

Slab Milling
Cutter width extends beyond the work piece on

both sides.
Peripheral Milling

Slot Milling
Cutter width is less than the work piece width, creating
a slot.
If the cutter is very thin, it can be used to cut a work
part into two, called saw milling.
Peripheral Milling

Side Milling
Cutter, machines the side of the work piece.
Peripheral Milling

Straddle Milling
Similar to side milling, but cutting takes on both
sides of the work part simultaneously.
 Conventional face
milling

Partial face
milling

End milling

Face milling Profile milling

Pocket
milling

Surface
countouring
Face Milling

Surface generated is at right angles to the

cutter axis.
Axis of the cutter is perpendicular to the
surface being machined.
Operation is by cutting the edges on both
end and outside periphery of the cutter.
Face Milling

Conventional Face milling

Diameter of tool is larger than work parts width.
Face Milling

Partial Face Milling

Cutter width extends beyond the work piece on both
sides.
Face Milling

End Milling
Cutters diameter is less than the work parts
width.
Face Milling

Profile Milling
Outside periphery of flat part is cut.
Face Milling

Pocket Milling
Similar to end milling, but the shape created is a
shallow pockets in flat surfaces.
Face Milling

Surface countouring
A ball-nose cutter is fed back and forth across the
work part to create a contoured surface perpendicular
to the cutter.
Horizontal Milling Cutter

Slab Mills

To machine flat surfaces.

The cutter are basically
cylindrical with the cutting
teeth on the periphery.
For heavy cutting of large
and flat surfaces.
Horizontal Milling Cutter

Side and Face cutters

The cutter is mounted on a

spindle which have an axis of
rotation perpendicular to the
work piece surface
Horizontal Milling Cutter

Slitting saw
Used for cutting off operations
or for deep slots.
Arbor mounted.

Teeth around the

circumference while some
have side teeth as well.
For cutting deep slots or for
parting off.
Vertical Milling Cutter

End mill
Used for milling slots, key
ways and pockets.
The cutter usually rotates on
the axis which is
perpendicular to the work
piece.
Commonly used for facing,
slotting and profile milling.
Vertical Milling Cutter

Rough cut end mill

For rapid metal removal.
Vertical Milling Cutter

Slot drills
For producing pockets
without drilling a hole.
Vertical Milling Cutter

Face mill
For heavy cutting.
Milling Movement (Peripheral milling)

Up Milling Down Milling

Milling Movement

Up Milling (Conventional milling)

Wheel rotation opposite of the feed.
The chip formed by each cutter tooth starts out very thin and
increases its thickness.
The length of the chip is relatively longer
Tool life is relatively shorter.
Need more clamping force to hold the work part still.
Cutting tool rotates in the opposite direction to the table
movement.
The maximum chip thickness is at the end of the cut.
Milling Movement

Down Milling
Wheel rotation is parallel to the feed.
The chip formed by each cutter tooth starts out thick and leaves
out thin.
The length of the chip is relatively short
Tool life is relatively longer.
Need less clamping force to hold the work part still.
Cutting tool rotates in the same direction to the table
movement.
The maximum chip thickness is at the beginning of the cut.
Cutting Condition

These three factors; cutting speed (N), feed

rate(f) and depth of cut (d) are known as cutting
conditions.
Cutting conditions are determined by the
machinability rating.
Machinability is the comparing of materials on
their ability to be machined.
Cutting Condition

Cutting speeds depend primarily on the kind of

material you are cutting and the kind of cutting
tool you are using.
The hardness of the work material has a great
deal to do with the recommended cutting speed.
The harder the work material, the slower the
cutting speed. The softer the work material the
faster the recommended cutting speed.
Cutting Condition

Effect of work material

Steel Iron Aluminum Lead
Increasing Cutting Speed

Effect of cutting tool material

Carbon Steel High Speed Steel Carbide

Increasing Cutting Speed

Cutting Condition

Cutting speed or surface speed is the speed at

the outside edge of the milling cutter as it is
rotating.
Surface speed, surface footage, and surface area
are all directly related.
The size of cutting tool give an effect on surface
speed. If two cutters of different sizes are
turning at the same revolutions per minute
(RPM), the larger cutter has a greater surface
speed.
Cutting Condition

Surface speed is measured in surface feet per

minute (SFPM).
The cutting speed is calculated by

N = 12 x (surface speed)
D
D = cutter diameter
Cutting Condition

Feed rate, f
Rate at which the work advances past the cutter.

Unit is inch per min @ mm per min(in/min @

mm/min)
Feed rate is calculated as

f = feed per tooth x number of teeth x N

Feed per tooth is a chip load. Unit is inch/tooth

or mm/tooth
Factors Affecting Surface Finish

Feed rate
Nose radius of tool
Cutting speed
Rigidity of machining operation
Temperature generated during machining
process
Factors Affecting Surface Finish

Direct relationship between temperature of

workpiece and quality of surface finish
High temperature yields rough surface finish
Metal particles tend to adhere to cutting tool and
form built-up edge
Cooling work material reduces temperature of
cutting-tool edge
Result in better surface finish
REVIEW QUESTIONS.
1. Give the classification of milling machine.
2. What is the different between horizontal
and vertical cutting tool?
3. Give an example of peripheral and face
milling operation.
4. What are the advantages of down milling
compare to up milling?
5. Explain about 3 cutting conditions.