Milling Operation

 A milling machine is a machine tool that removes

material from a work piece by rotating a cutter and
moving it into the material.
 A milling machine produces:
 Plane surfaces that may be parallel or perpendicular or at angle to
the work table.
 Unlike the lathe or the shaping machine, the milling machine uses
a muti-tooth cutter
Types of milling machines
Types of Milling Machines
There are two major types of milling machines,
 the vertical milling machine and
 the horizontal milling machine.
 A vertical milling machine has
 its spindle axis vertical,
 its machine table moves perpendicular to the spindle axis of
rotation and whilst
 A horizontal milling machine
 spindle axis is horizontal, here
 the work table that moves parallel to the spindle axis of rotation
Basic movements
 Of a vertical milling machine:
 The movements and alignment are such that the axis of rotation
of the cutter by a spindle is perpendicular to the work table, or a
desired and controlled angle to the work table.
 The work table provides datum surface from which the wor is set
as well as supporting the workpiece.
 The working surface of the work table, therefore, must lie
horizontally beneath the cutter and perpendicular to the cutter
axis.
 The work table must move in a direction at right angles to the
longitudinal traverse.
 It is necessary to raise or lower the work table in order to feed
the work into the cutter and to compensate for different
thicknesses of work.
 Table movements are controlled by lead screws fitted with
Basic movements
 Of a vertical milling machine:
 Table movements are controlled by lead screws fitted with
micrometer dials for accurate positioning of the table and
workpiece under the cutter.
Basic movements
 Of a horizontal milling machine:
 The movements and alignment required are the location and
movement of workpiece by the worktable in a plane beneath the
cutter, parallel to the spindle axis.
 The spindle must have a horizontal axis.
 The work table must move in a direction at right angles to the
longitudinal traverse.
 The work table should be able to able to be raised or lowered in
order to feed the work into the cutter and to compensate for
different thicknesses of work.
 Table movements are controlled by lead screws fitted with
micrometer dials for accurate positioning of the table and
workpiece under the cutter.
Milling cutters
 A milling cutter is a cutting tool that is used on a milling
machine.
 Milling cutters are available in many standard and special
types, forms, diameters, and widths.
 The teeth maybe straight (parallel to the axis of rotation)
or at a helix angle.
 The helix angle helps a
slow engagement of the
tool distributing the forces .
Milling cutters
 The cutter may be right-hand (to turn clockwise) or left-
hand (to turn counterclockwise).The figure shows a
typical end milling cutter.
Milling cutters

 Milling cutters have a secondary clearance angle to

prevent the heel of the tooth interfering with the
machined surface of the workpiece.
 The tooth can be made up of a series of straight lines, or
it can be a curved profile.
Milling cutters
Cutting Action
 Up-cut milling
 Traditional method – great
advantage of not tending to drag the
work into the cutter – can be used
on worn and cheap machines.
 Disadvantages:
1. Tends to rub before biting into the
metal, resulting in cutter wear and
poor finish
2. Cutting forces at maximum as the
chip leaves the workpiece –
resulting in transmission bounce
(ramble).
Cutting Action
 Up-cut milling
3. Cutting forces tend to lift the
component off the work table.
4. The feed mechanism drives the
workpiece against the full thrust of
the cutter.
Cutting Action
Down-cut milling
 This process has a number of
advantages:
1. The cutter bites into the workpiece
immediately and the load is eased off the
tooth gradually – thus smoother
operating conditions; longer cutter and
machine life, and good surface finish.
2. Cutting forces press the workpiece down
on to the table – maximum rigidity
3. Feed mechanism controls the feed rate
only, as the cutter tends to draw the
work through.
Cutting Action
Down-cut milling
 The major disadvantage is, it can only be
used on modern machine in good
condition and fitted with a backlash
eliminator.
Standard milling vs. climb milling
Plain milling and End milling