Lecture # 14

Dr. N. VENKAIAH
Assistant Professor
Mechanical Engineering Department
NIT Warangal 506 004
Disclaimer
The content presented here is not entirely my own. Some portions are taken from
different sources with great regard. This content is solely for class room teaching and
not for any commercial use.

"Money is only an idea. If you want more money, simply

change your thinking."

~ Robert T. Kiyosaki

Flat surfaces in vertical, horizontal and inclined planes

Slots or ribs of various sections
Slitting or parting
Surfaces of revolution
Grooves, flutes and profiles in various cutting tools, e.g., taps,
reamers, drills, hobs, gear shaping cutters etc.
Long thread milling on large lead screws, power screws, worms etc
and short thread milling for small size fastening screws, bolts etc.
2-D contouring like cam profiles, clutches etc and 3-D contouring
like die or mould cavities
Spur gears, straight toothed bevel gears, worm wheels, sprockets,
clutches etc.

Horizontal & Knee Type Milling Machine

Base: Gives support and rigidity to
machine
Acts as reservoir for cutting fluids
Column face: Precision-machined
and scraped section used to
support and guide knee when
moved vertically
Knee: Houses feed mechanism
Attached to column face and moves
vertically
Saddle: On top of knee
Moves towards or away from column
Table: Rests on guideways in saddle
and travels left and right
Supports vise and work
Arbor: Used for mounting milling
cutter
Inserted and held in main spindle by
draw bolt
Over-arm: Provides correct
alignment and support for arbor
Various attachments can be adjusted
and locked in various positions

Vertical & Knee Type Milling Machine

Works using end mill type
and face milling cutters

Bed Type Milling Machine

The vertical feed is given to the milling head
instead of the knee.
These machines have high stiffness and are
used for larger size jobs and high production
work.

These are heavy duty large

machines
Look like planing machines
Equipped with a number of
milling heads to mill a number
of longitudinal flat surfaces
simultaneously, viz., lathe
beds,
tables and
beds of planning machine etc.

Planer Type Milling Machine

Rotary Table Type Milling Machine

Possesses one large rotary work-table and
one or two vertical spindles
The positions of the job(s) and the milling
head are adjusted according to the size
and shape of the job.

Tracer Control Copy Milling Machine

Mechanically or hydraulically operated
semi-automatic milling machine
Used for mass production of cams, dies
etc by copying the master piece.

CNC Milling Machine

Replacement of hard or rigid automation by Flexible
automation by developing and using CNC has made
a great break through since mid seventies in the
field of machine tools control.
The advantageous characteristics of CNC machine
tools over conventional ones are:
flexibility in automation
change-over (product) time, effort and cost are
much less
less or no jigs and fixtures are needed
complex geometry can be easily machined
high product quality and its consistency
optimum working condition is possible
lesser breakdown and maintenance requirement
The versatility of CNC milling machine has been
further enhanced by developing what is called
Machining Centre.
Single Purpose & Automatic Milling Machines: Used for short thread milling like in mass production
of small bolts and screws.

Cutting and feed motions opposite direction

Chip is thin at beginning.
Cutter tends to lift work upward

Cutting and feed motions same direction

Max. chip thickness at beginning
Assists work holding

1 Workpiece; 2 Work Table; 3 Feed Screw Nut; 4 Feed Screw

Up Milling

Down Milling

Up Milling

Down Milling

The depth of the cut starts at zero

thickness, and increases up to the
maximum

The depth of the cut starts at the

maximum thickness and decreases to
zero.

Used to machine scaly surfaces.

Used to machine non-scaly surfaces.

Tool life is shorter because of initial

rubbing.

Better tool life when workpiece

doesnt have any scaly surface.

The cutting forces are directed

upwards, which tends to lift the
workpiece from machine table.

The cutting forces are directed

towards the table and hence small
wok holding forces are enough.

Surface finish is poor.

Surface finish is good.

Difficulty in applying the coolant.

Easy to apply the coolant.

The chips accumulate at the cutting The chips are also disposed off easily
zone and interfere with machining. and doesnt interfere with machining.
Can be employed on older
machines as the process eliminates
backlash.

Even with so many advantages, it cant

be used on older machines due to
backlash error

Slab/Plain/Peripheral milling cutters

Hollow straight HSS cylinder of 40 to 80 mm
outer diameter having 4 to 16 straight or helical
equi-spaced flutes or cutting edges
Teeth are located on the periphery of the cutter
body.
Used on horizontal arbour to machine flat
surface

Operation: Slab/Plain/Peripheral milling

The axis of cutter rotation is in a plane parallel to
the workpiece surface to be machined.

Slab Milling

Side/slot milling cutters

Disc type cutters
Large number of cutting teeth on the periphery.
Each tooth has a peripheral cutting edge and another
cutting edge on one face of single sided cutter
Single sided cutters are used to produce one flat
surface or steps comprising two flat surfaces at right
angle.
Two cutting edges on both the faces in case of
double sided cutter.
Double sided cutters are used for making
rectangular slots bounded by three flat surfaces.

Gang Milling
Two separate side milling cutters are
mounted at appropriate distance on
the horizontal milling arbour.

A proper combination of several cutters are

mounted tightly on the same horizontal milling
arbour.

Used for faster and accurate

machining of two parallel vertical
surfaces at a definite distance,

Used for quick production of complex contours

comprising a number of parallel flat or curved
surfaces.

Slit milling cutter or parting tool

Very similar to the slotting cutters having only one
peripheral cutting edge on each tooth.
However, the slitting saws
are larger in diameter and thinner

possess large number of cutting teeth but

of small size
used only for slitting or parting

End Milling Cutters

(End Mills)
Mostly made of HSS

4 to 12 straight or helical teeth

on the periphery and face
Diameter range: 1 - 40 mm

Pocket Milling

Very versatile and widely used

in vertical spindle type milling
machines
It can be tilted to machine
tapered surfaces.

Peripheral Milling

Angular Milling

Face Milling Cutters

Usually large in diameter (80
to 800 mm) and heavy
Cutting edges are located on
the periphery and face of the
cutter
Used only for machining flat
surfaces in different
orientations
Axis of rotation is
perpendicular to w/p surface
Coated or uncoated carbide
inserts are clamped at the
outer edge of the carbon steel
body as shown
Generally used for high
production machining of large
jobs.

Photographic view

Schematic view

Form Milling Cutters

Fig. Short thread milling

Fig. Long thread milling

T-Slot Milling Cutter

TC =

LC
(for job width < cutter length)
fm

Where, LC = total length of travel of the job

= Lw + A + O + Dc 2
Lw = length of the workpiece
A, O = approach and over run (5 to 10 mm)
DC = diameter of the cutter, mm
f m = table feed, mm/min
= fZN
where, f = feed per tooth, mm/tooth
Z = number of teeth of the cutter
N = cutter speed, rpm.
N has to be determined from VC as
VC =

DC N
= m/min
1000

fm

Determine machining time for plain milling a rectangular surface of length 100 mm
and width 50 mm by a helical fluted plain HSS milling cutter of diameter 60 mm,
length 75 mm and 6 teeth. Assume A = O = 5 mm, cutting velocity = 40 m/min and
feed = 0.1 mm/tooth
Ans. 1.1 min.