BMM3643

Manufacturing Processes

Lecturer: Dr. Mas Ayu Bt Hassan

Email: masszee@ump.edu.my
Phone: 09-4246316 1
 8.0 MATERIALS REMOVAL
PROCESSES: Machining (continue)

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Lesson Objectives:

After today’s lecture, students are expected to:

• Analyze the mechanics of milling operation

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Machining Processes Used to Produce
Various Shapes: Milling
 Introduction

• Milling is a basic machining process by which a

surface is generated by progressive chip removal.
• The workpiece is fed into a rotating cutting tool.
• The workpiece may remain stationary, and the
cutter is fed to the work.
• Generally, a multiple-tooth cutter is used so that the
material removal rate is high.

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 Introduction
• It is widely used especially in mass
production due to:
– high material removal rate (hence faster
machining)
– good surface finish
• The cutting tool used in milling is known as
a milling cutter.

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 Principle of Operation (cont.)
1. End Milling
• It is used to produced various profiles
of flat surfaces.
• Cutter generally rotates on an axis
vertical to the work-piece
• 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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 Milling Cutters and Milling Operations

Some basic types of milling cutters and milling operations. (a) Peripheral milling. (b)
Face milling. (c) End milling. (d) Ball-end mill with indexable coated-carbide inserts
machining a cavity in a die block. (e) Milling a sculptured surface with an end mill, using a
five-axis numerical control machine. Source: (d) Courtesy of Iscar. (e) Courtesy of The
Ingersoll
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 Milling Cutter (End Mill)

End mills and ball nose end mills. These

cutters are able to produce elaborate
contours and are often used in the machining
of dies and molds.

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 Principle of Operation (cont.)

• 2. Peripheral (Slab) Milling

• Milled surface generated by teeth located on
the periphery of the cutter body
• Cutters for slab milling may have straight or
helical teeth.

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 Principle of Operation (cont.)

• The helical teeth on the cutter are preferred

over straight teeth because the load on the
tooth is lower, resulting in a smoother operation
and reducing tool forces and chatter.

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 Principle of Operation (cont.)

• In peripheral milling, there are two possible ways of

milling operation:
i) Up Milling (also known as conventional milling)
– Cutter rotation opposes the feed motion
– WP tends to be pulled up
– Advantage: the tool life is longer since only small
amount of material is removed.
– Disadvantage: The workpiece has a tendency to be
pulled upward (chattering), then it needs a proper
clamping.

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 Conventional and Climb Milling

(a) Schematic
illustration of
conventional milling
and climb milling.

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 Principle of Operation (cont.)
ii) Down Milling (also known as climb milling)
– Direction of cutter rotation is same as the feed
motion.
– Cutter tooth begins to mill the full chip thickness.
– Advantage: the downward component of the cutting
forces holds the workpiece in place (reduce chatter).
– Disadvantage: not suitable for machining hard
materials due to excessive wear and damage to the
cutter teeth, shortening tool life.

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 MILLING PARAMETERS

(b) Slab milling operation, showing depth of cut, d, feed per tooth, f,
chip depth of cut, tc, and workpiece speed, v. (c) Schematic
illustration of cutter travel distance lc to reach full depth of cut.
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 Summary of Milling Parameters and
TABLE 23.1 Formulas
N = Rotational speed of the milling cutter, rpm
f = Feed, mm/tooth or in./tooth
D = Cutter diameter, mm or in.
n = Number of teeth on cutter
v = Linear speed of the workpiece or feed rate, mm/min or in./min
V = Surface speed of cutter, m/min or ft/min
=πDN
f = Feed per tooth, mm/tooth or in/tooth
=v /N n
l = Length of cut, mm or in.
t = Cutting time, s or min
=( l+lc ) / v , where lc =extent of the cutter’s first contact with workpiece
MRR = mm3/min or in.3/min
=w d v , where w is the width of cut
Torque = N-m or lb-ft
( Fc ) (D/2)
Power = kW or hp
= (Torque) ( ) = specific energy x MRR, where  = 2 N radians/min
Note: The units given are those that are commonly used; however, appropriate units must be
used in the formulas.
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 Example 1

• A slab milling is being carried out on a 30 cm long,

10 cm wide annealed mild steel block at a feed f =
0.025 cm/ tooth and a depth of cut d = 0.3 cm.
The cutter is D = 5 cm in diameter, has 20 straight
teeth, rotates at N = 100 rpm, and by definition is
wider than the block to be machined. Calculate
the material removal rate, estimate the power
and torque required for this operation. (specific
energy of annealed mild steel is 3.0 W.s/mm3)

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 Principle of Operation (cont.)

• 3. Face Milling
• Cutter is mounted on a spindle having an axis
of rotation perpendicular to the WP

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 Face-Milling Operation

Face-milling operation showing (a) action of an insert in face milling;

(b) climb milling; (c) conventional milling; (d) dimensions in face milling.
The width of cut, w, is not necessarily the same as the cutter radius.
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 Principle of Operation (cont.)

• Milled surface results from the action of

cutting edges on the face of the cutter.
• When the cutter rotates in the same direction
with the workpiece movement, it is called
climb milling.
• When it rotates in the opposite direction, the
operation is called conventional milling (similar
manner in slab milling)

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 Example 2

• In a face milling operation, assume that D = 150 mm,

w = 60 mm, l = 500 mm, d = 3 mm, v = 0.6 m/min,
and N = 100 rpm. The cutter has 10 inserts, and the
workpiece material is a high-strength aluminium
alloy. If the specific energy of the material is 1.1
W.s/mm3, calculate the material removal rate,
cutting time, and feed per tooth, and estimate the
power required.

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 Other milling operations and Cutters

Cutters for (a) straddle milling, (b) form

milling, (c) slotting, and (d) slitting with a
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 T-Slot Cutting and Shell Mill

(a) T-slot cutting with a milling cutter. (b) A shell mill.

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 Problems and solutions With Milling Operations
TABLE 23.5
Problem Probable causes
Tool breakage Tool material lacks toughness; improper tool angles;
cutting parameters too high.
Tool wear Cutting parameters too high; improper tool material;
excessive improper tool angles; improper cutting fluid.
Rough surface Feed too high; spindle speed too low; too few teeth on
finish cutter; tool chipped or worn; built-up edge; vibration
and chatter.
Tolerances too Lack of spindle stiffness; excessive temperature rise;
broad dull tool; chips clogging cutter.
Workpiece surface Dull tool; depth of cut too low; radial relief angle too
burnished small.
Back striking Dull cutting tools; cutter spindle tilt; negative tool
angles.
Chatter marks Insufficient stiffness of system; external vibrations;
feed, depth, and width of cut too large.
Burr formation Dull cutting edges or too much honing; incorrect angle
of entry or exit; feed and depth of cut too high;
incorrect insert geometry.
Breakout Lead angle too low; incorrect cutting edge geometry;
incorrect angle of entry or exit; feed and depth of cut
too high.
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Any questions??
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