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Milling
Milling
Machine
consists
basically of a motor driven
spindle, which mounts and
revolves the milling cutter,
and
a
reciprocating
adjustable
worktable,
which mounts and feeds
the work piece.
Working Principle
Work is rigidly clamped on table of machine, or held b/n
centres & revolving multi teeth cutters are mounted either
on spindle/ arbor.
cutter revolves at high speeds
& work fed slowly past the cutter.
Work can be fed in vertical,
longitudinal/ cross direction.
As work advances cutter teeth
remove metal from w/p surface to
produce desired shape.
Classification of Milling
1. Peripheral Milling :
In peripheral (or slab) milling, the milled surface is
generated by teeth located on the periphery of the cutter
body. The axis of cutter rotation is generally in a plane
parallel to the work piece surface to be machined.
2. Face Milling:
In face milling, the cutter is mounted on a spindle
having an axis of rotation perpendicular to the work
piece surface.
The milled surface results from the action of cutting
edges located on the periphery and face of the cutter.
3. End Milling :
The cutter in end milling generally rotates on an axis
vertical to the work piece.
It can be tilted to machine tapered surfaces.
Cutting teeth are located on both the end face of the cutter
and the periphery of the cutter body.
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b)
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d)
e)
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d)
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b)
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f)
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Used for general purpose milling operations, column and knee type
milling machines are the most common milling machines.
The spindle to which the milling cutter is may be horizontal (slab milling)
or vertical (face and end milling).
The basic components are:
Work table, on which the work piece is clamped using the T-slots. The
table moves longitudinally with respect to the saddle.
Saddle, which supports the table and can move transversely.
Knee, which supports the saddle and gives the table vertical movements
for adjusting the depth of cut.
Over arm in horizontal machines, which is adjustable to accommodate
different arbor lengths.
e) Head, which contains the spindle and cutter holders. In vertical machines
the head may be fixed or vertically adjustable.
1. a. Hand Milling:
a. Column:
Vertical 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.
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.
c. Saddle
The saddle consists of two slide ways, 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.
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 work piece or clamping
fixtures.
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.
f. Over Arm:
It supports yoke which in turn supports the free end of
Arbor.
Not only possess both horizontal milling arbour and the vertical
axis spindle, the latter spindle can be further tilted about one (X) or
both the horizontal axes (X and Y) as shown in diagram enabling
machining jobs of complex shape.
Milling Methods
Conventional / Up milling:
In up cut milling, the cutter rotates
in a direction opposite to the table
feed as illustrated in figure.
In this thickness of chip is
minimum at beginning of cut & it
reaches to max.
In other words we can say chip
thick ness is min(zero) at start of
cut & max at end of cut.
Cutting force is directed up wards
& this tend to lift work from
fixtures.
(b) Form relieved cutters where the job profile becomes the replica
of the tool-form.
i. Form cutters
ii. gear (teeth) milling cutters
iii. spline shaft cutters
iv. tool form cutters
v. T-slot cutters
vi. Thread milling cutter
Slitting Saws:
These milling cutters are very
similar to the slotting cutters
having only one peripheral
cutting edge on each tooth.
However, the slitting saws
are larger in diameter and
much thin
possess large number of
cutting teeth but of small
size
used only for slitting or
parting
Form cutters
Such disc type HSS cutters are generally used
for making grooves or slots of various profiles as
indicated in Fig.
Form cutters may be also end mill type like T-slot cutter as
shown in Fig.
Applications
Straddle Milling:
For faster and accurate machining 2 parallel vertical
surfaces at definite distance, two separate side milling
cutters are mounted at appropriate distance on the horizontal
milling arbor as shown in Fig.
Gang Milling:
In Gang milling, being employed, where feasible, for quick
production of complex contours comprising a number of parallel
flat or curved surfaces a proper combination of several cutters are
mounted tightly on the same horizontal milling arbor as indicated
in Fig.