Milling Operations

Module 04
Material Removal Processes
MPA 8th Semester IQTM
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- Turning and
related operations
Conventional Drilling and

- machining related operations
- Milling
I
Other machining
- operations
Material removal Abrasive Grinding

processes processes operations
- Other abrasive
processes
Mechanical energy
- processes
Nontraditional Electrochemical
- machining machining
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Thermal energy
processes
Chemical
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04-03
Milling Operations
Milling Machine
• Milling is the process of cutting away material by feeding a
workpiece past a rotating multiple tooth cutter
• Milling machine is the most versatile and widely used

machine tool after lathe
• Milling machines exist in two basic forms: horizontal and

vertical, which terms refer to the orientation of the cutting
tool spindle
The milling machine is in

a way the opposite of a
lathe?
ram-type milling machine
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Schematic view of a milling machine

Column-and-knee Type Milling Machines
Schematic illustration of
(a) a horizontal-spindle column-and-knee type milling machine and
(b) vertical-spindle column-a
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Vertical and Horizontal Milling Machines
Parts of the Milling Machine
• The base gives support and rigidity to the machine
• The column is a precision-machined section used to

support and guide the knee when it is moved vertically
• The knee is attached to the column face and may be

moved vertically on the column face either manually or
automatically. It houses the feed mechanism
• The saddle is fitted on the top of the knee and may be
moved in or out either manually by means of the
crossfeed handwheel or automaticaly by the means of
crossfeed engaging lever
Parts of the Milling Machine…
• The swivel table housing, fastened to the table on a
universal milling machine, enable the table to be
swiveled 45° to either side
• The table rests on the guideways in the saddle and
travels longitudinally in a horizontal plane. It supports
the vise and the work
• The crossfeed handwheel is used to move the table
toward or away from column
• The table handwheel is used to move the table

horizontally left and right in front of the column
Parts of the Milling Machine…
• The spindle provides the drive for arbor and cutters
• The overarm provides correct alignment and support for

the arbor. It can be adjusted and locked in various
positions
• The arbor support is fitted to the overarm and can be

clamped at any location on the overarm
• The elevating screw gives an upward or downward

movement to the knee and the table
Overarm
Arbor support
Arbor
Cutter
Spacers
Table
handwheel
vise column
Slides or Table
Ways saddle
Vertical Crossfeed Knee

hand-feed handwheel Base
crank
. .f
TABLE
COLUMN
SWIVEL HOUSING
ELEVATING SCREW
SADDLE
KNEE
Rotation of spindle
Z-axis or Vertical
axis
Direction of Feed
End Mills
Operations performed on a vertical milling machine using end mills
Plain Milling Cutters
• Most widely used
• Teeth cut on the periphery
• Used to produce flat surface
Plain milling cutters (a) light-duty (b) light-duty helical (c) heavy-duty (d)
high-helix
Side Milling Cutters
•Have teeth on each side as well as on the periphery
•Staggered-tooth cutters have each tooth set alternatively to the right and left
Side milling cutters (a) plain (b) staggered tooth (c) half-side
Formed Cutters
•Incorporate the exact shape of the part to be produced
Formed cutters (a) concave (b) convex

Metal-Slitting Saws
•Thin plain milling cutters with sides relieved
•Used to mill narrow slots or to cut off work
Metal-slitting saws
Other Milling Cutters
(a) A T-slot cutter (b) a dovetail cutter
Milling Operations
The two basic types of milling are:
Plain milling:
• The surface cut is parallel to the periphery of the cutter
• Also called peripheral milling
Face milling:
• The surface cut is at right angle to the axis of the cotter
Milling Operations…
Side milling:
• Side milling is used to machine a vertical surface on
the sides or the ends of a workpiece
Straddle milling:
• It involves the use of two side milling cutters to
machine the opposite sides of a workpiece in one cut
Milling Operations…
Gang milling:
• It is performed by using two or more cutters on the
arbor to produce the desired shape
Sawing and Slitting:
• Metal-slitting saws may be used for milling narrow
slots and for cutting off work
Form milling:
• The exact shape of the part to be produced is
incorporated on the cutter
(e) peripheral milling (f) face milling (g) end milling
Milling operations: (a) straddle milling, (b) form milling, (c) slotting,
(d) slitting, (e) peripheral milling, (f) face milling, (g) end milling.
Conventional Milling, HMCs, VMCs
Cutting Speed and Feed
• Surface speed is how fast the metal comes into contact with the
tool at the cutting point
• On a lathe, it is the rate at which the surface of the stock passes the
cutting tool
• This takes into account the diameter of the stock
• On a milling machine, it is the rate at which the milling cutter

moves past the stock
• This takes into account the diameter of the cutter
• Surface speed is usually measured in Surface Feet per Minute (SFM)
• SFPM: It is the number of feet per minute that a given point on the
circumference of a cutter travels per minute
Cutting Speed and Feed…
r/min = 12 x CS / πD ≈ 4 x CS / D
Where D is the diameter of the cutter
Example: At what speed should a 2-in. diameter

carbide cutter revolve to mill a piece of cast iron (CS
150 ft/min.)?
Metric Calculations:
r/min = CS (m) x 1000/π x D (mm)
≈ CS (m) x 320/D (mm)
• Milling machine feed may be defined as the distance in
inches (or millimeters) per minute that the work moves
into the cutter
• Measured in in./min or mm/min
• Feed = no. of cutter teeth x chip/tooth x cutter r/min
• Feed (in./min) = N x CPT x r/min

– N = number of teeth in the milling cutter
– CPT = chip per tooth for a particular cutter and metal, as given
in table
– r/min = Revolutions per minute of the milling cutter
Example: Find the feed in inches per minute using a
3.5-in. diameter, 12-tooth helical cutter to cut
machine steel (CS 80).
Solution: r/min = 4 x CS / D = 4x80/3.5 = 91
Feed (in./min) = N x CPT x r/min
= 91 x 0.010 x91
≈ 11 in/min
• The formula used to find work feed in millimeters per

minute is the same as the formula for in./min, except
that mm/min is substituted for in./min
Milling Machine Accessories
Parallels:
• Parallels are used to support a workpiece when
clamping it in a milling vise
Milling Machine Accessories…
Vises:
• It is the most convenient way to hold workpiece by
using vise for many operations
Plain vise
Vises:
Swivel Base Vise

Vises:
Universal Vise
End Mill Adaptors
Fixtures:
• It is a custom-designed work-holding device fastened too the
table
• Used when large quantities are to be machined
An Overview on Milling
Milling Machine Operations Video
Mill Cutting Tools Video
Mill Workholding Video
Milling Controls Video
Milling Machine Specifications
• Type: ordinary or swiveling bed type
• Size of the work table
• Range of travels of the table along X-X-Z
• Arbor size (diameter)
• Power of the main drive
• Range of spindle speed
• Range of table feeds in X-Y-Z directions
• Floor space occupied
Questions??
References
• Technology of Machine Tools by J. F. Krar
• Fundamentals of Modern Manufacturing ; Materials,

Processes, And Systems, 3rd Ed. By Mikell P. Groover;
John Wiley And Sons
• Degarmo’s Materials And Processes In Manufacturing,

10th Ed. By J.T Black, R.A. Kohser; John Wiley And Sons

Milling Operations

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Module 04

Material Removal Processes

MPA 8th Semester IQTM

Conventional Drilling and

Material removal Abrasive Grinding

• Milling machine is the most versatile and widely used

• Milling machines exist in two basic forms: horizontal and

The milling machine is in

Schematic view of a milling machine

• The base gives support and rigidity to the machine

• The column is a precision-machined section used to

• The knee is attached to the column face and may be

• The table handwheel is used to move the table

• The overarm provides correct alignment and support for

• The arbor support is fitted to the overarm and can be

• The elevating screw gives an upward or downward

Vertical Crossfeed Knee

Formed cutters (a) concave (b) convex

(a) A T-slot cutter (b) a dovetail cutter

• On a milling machine, it is the rate at which the milling cutter

• Surface speed is usually measured in Surface Feet per Minute (SFM)

Example: At what speed should a 2-in. diameter

• Feed = no. of cutter teeth x chip/tooth x cutter r/min

• Feed (in./min) = N x CPT x r/min

• The formula used to find work feed in millimeters per

Swivel Base Vise

End Mill Adaptors

Mill Cutting Tools Video

Mill Workholding Video

Milling Controls Video

• Fundamentals of Modern Manufacturing ; Materials,

• Degarmo’s Materials And Processes In Manufacturing,

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