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Milling
Milling
Milling
FEED
WORK PIECE
Movable jaws
Swivel base
Elevating screw
The table is mounted on a fixed bed instead of the saddle and knee
and travel in longitudinal direction only It can neither move up and down nor crosswise . A rigid vertical column carries parallel vertical ways on which the adjustable spindle head or spindle carrier is mounted. This spindle head carries the spindle to which the arbor can be fitted to carry the cutter. Table is provided with longitudinal motion.
Each spindle head carry a horizontal spindle on which cutters can be mounted
The spindle head can be adjusted vertically up and down The table has longitudinally movement only This machine enables machining of two surfaces simultaneously.
machine time.
Used in mass production
Cam milling machine : Used for making profiles of cam on disc. The movement of table is
Base:
Made of grey cast iron capable to withstand entire weight of the machine. Supports the column at one end. Accommodates coolants.
Column:
A casting mounted vertically on the base. The front portion provides guide ways to support knee. Over hanging arm is held on its top. It houses driving mechanism for the spindle and table feed.
Saddle:
Provides cross feed for the work by moving away or towards the face of the column.
Knee:
A grey cast iron structure, attached to the face of the column
,moves on slides. Table can be moved up and down . Supports the saddle on its top.
Work table:
T-slots are provided on its top for direct mounting of the work. Provides longitudinal feed .
Over arm:
Located on top of the knee. Supports the cutter holding and driving mechanism.
Provides more rigidity to the machine. Movable jaws and arbor are supported.
Arbor: Fixed in a spindle nose . Locates the cutters in position. Transmits power to cutters from spindle.
Yoke: Clamped to the guide ways provided on the over hanging arm. Supports the arbor at number of sections and ensures vibration-free machining. It houses bearings on which arbor is mounted. Elevating screw:
Spacing collars
Multiple cutters at different sections on an arbor can be placed with
spaces. Available in different lengths.
Driving mechanism
It supplies the driving torque to the spindle in particular and other
mechanisms of the machine. Transmission done through gears and belts are housed. Coolant supply, lubricating-oil circulation and auto-feed needs power.
Feed Cranks
Hand driven cranks are used to effect all feed movements Viz., longitudinal, cross and vertical.
S5 C3 S6
Nut
B1 B2
S4 S2
S1
S3 C2
C1
Telescopic shaft
Milling cutter
Multi cutting-edged rotating tool. Most of them are made with high speed steel or special alloy steels.
Milling cutter
Each milling cutter is identified by the
outer diameter,
thickness, no. of teeth and
Form cutters
gear (teeth) milling cutters
Face width more than 20mm, helical teeth with 25 degree helix angle.
used only for slitting or parting Standard saws are made thinner at the center than at the outer edge to provide clearance Used to mill thin deep slots and cut-off
Parting by slitting saw
operations.
A - mill size or cutting diameter B - shank diameter C - length of cut or flute length D - overall length
very versatile and widely used in vertical spindle type milling machines
contours.
a) Convex milling cutter: Teeth curved outwards on the
circumference.
Used to produce concave grooves. Diameter ranges from 50mm to 125mm. Width varies from 3.2mm to 40mm.
Generates
convex
1.5mm- 20mm.
Straddle milling
For faster and accurate machining two parallel vertical surface at a definite distance, two separate side milling cutters are mounted at appropriate distance on the horizontal milling arbour 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 arbour as indicated in Fig.
form V shape).
Cutting edges are included at 45, 60 and 90 degree.
Slot drill
Used for machining a sunk key way in a shaft. Similar in action to twist drill. Has two cutting edges .
Cutting edges
Smaller sizes up to 50 mm diameter. Used for cutting key-seats to fit woodruff keys.
Fly cutter
Single point cutting tool attached to stub arbor or held in bar. Exactly same way as a boring tool in boring bar.
Cutting edge of the tool can be ground to any desired shape. Thus be considered as form tool.
Generally used for experimental purpose. Used to reproduce contoured surface.
Milling operations
Process of removing metal with a rotating cutter. Usually flat or form surfaces are produced.
Milling operations
The direction of rotation of the cutter is important. Some of the commonly performed operations are as follows 1. Plain milling 3. Straddle milling 5. Angular milling 7. Profile milling 2. Face milling 4. Gang milling 6. Form milling 8. End milling
Plain milling
Machining a flat surface parallel to the axis of the cutter. They are also referred as slab milling or peripheral milling.
Plain milling
Plain milling
Plain milling operation can be carried out in two methods. 1. Up milling or conventional milling 2. Down milling or climb milling
Face milling
Cutting of a flat surface at right
Straddle milling
Used for cutting two or more horizontal and
Straddle milling
Gang milling
Operation of machining several surfaces simultaneously by different types of cutters. All cutters are mounted on the same horizontal arbor. No spacing collars are used. Generally Side and plain milling cutter are used
Gang milling
Angular milling
Cutting a flat surface at an inclination to the axis of the cutter. Achieved by angular milling cutter( either by a single and double angle cutter). Swiveling the work or the spindle can also provide angular milling.
Form milling
Cutting the surface having a regular or irregular outline. The contours are convex ,concave or a gear tooth
cutting.
Profile milling
Operation of machining complex shapes with the help of template on a tracer
machine.
Movement of the cutter is guided by contact finger .This finger runs in contact with the outline to be duplicated and the tracer mechanism guides the tool
movement accordingly. The end mill is mostly used for profile milling.
End milling
Operation of machining horizontal or vertical surfaces by end mill. Generally performed on a vertical
milling machine.
Saw milling
Machining narrow slots or grooves using metal slitting saw. Also used for parting off operations.
Key-way milling
Cutting key-ways , groove and slots using a special cutter, key-cutter. T slots can be cut with the help of T- slot cutter.
Rough machined rectangular slot
Rough machined Dovetail slot
Dovetail cutter
Gear cutting
Spur gears and helical gears are cut on milling machine with help of gear cutters. Profile is identical with tooth space of gear to be cut. It involves indexing operation.
Gear milling cutter
Gear cutting
Cam milling
Milling a cam profile on milling machine using dividing head. End milling cutter is held in vertical attachment such
Cam milling
This attachment extends the processing capabilities and application range of the milling machine.
Slotting attachment
Used for converting a milling machine into a slotter (rotational motion of the horizontal spindle machine in to up and down vertical reciprocating motion) The slotting head is fitted to the spindle and used for cutting slots. The tool slide (reciprocating movement like the ram of a slotter ) driven from the main spindle of the milling machine by an eccentric.
Slotting attachment