MATERIAL ENGINEERING

& METAL PROCESSING

Rachmada Wishnu Putra Adinova
04211841000046
INTRODUCTION
Milling is the cutting operation that removes metal by feeding the work
against a rotating, cutter having single or multiple cutting edges. Flat or
curved surfaces of many shapes can be machined by milling with good
finish and accuracy. A milling machine may also be used for drilling,
slotting, making a circular profile and gear cutting by having suitable
attachments.
MILLING MACHINE FUNCTION
Milling machine is used in
■ Shaping solid materials, specifically metals.
■ Shaping flat and irregular surfaces.
■ Drilling.
■ Routing.
■ Planning.
■ Cutting gears.
■ Boring.
■ Producing slots among others.
WORKING PRINCIPLE
■ The power that used in this machine is electrical energy, that transform into kinetic
energy by engine.
■ The kinetic energy will be forwarded through transmission to produce a rotary
motion on the spindel engine.
■ The workpiece is holding on the worktable of the machine.
■ The table movement controls the feed of workpiece against the rotating cutter.
■ The cutter is mounted on a spindle or arbor and revolves at high speed.
■ As the workpiece advances, the cutter teeth remove the metal from the surface of
workpiece and the desired shape is produced.
TYPE OF MILLING MACHINE
TYPE OF MILLING MACHINE :
Knee Type
Knee-Type milling machines employ
a vertical workspace supported by a
knee, which is an adjustable vertical
casting. The knee supports a saddle
and can be adjusted to allow for a
customizable workspace.
TYPE OF MILLING MACHINE :
Plain Vertical and Horizontal

Milling machines with a standard

work surface can either be oriented
vertically or horizontally. The tooling
assembly is generally affixed on a
turret and swivel, typically positioned
parallel to the workspace. The turret
and swivel allow the tool to move
freely around the workpiece to
enforce tight tolerances.
TYPE OF MILLING MACHINE :
Universal Horizontal Milling
Machine
The differs from the plain horizontal
type because it has a table swivel
housing, which allows the table to
move out 45 degrees from the
standard horizontal position.
TYPE OF MILLING MACHINE :
Ram-Type and Universal
Ram-Type Milling Machines
A ram-type machine is used to allow the
tooling to position itself on a greater
range of space with regards to the
workpiece. The ram-type machine has a
spindle on a movable housing, which
can move within a set horizontal plane.
TYPE OF MILLING MACHINE :
Swivel Cutter Head Ram-
Type Milling Machine
Milling machine can rotate from a
completely vertical to a completely
horizontal position. The worktable also
moves, providing the user with a very
liberal degree of motion and
orientation.
PART OF MILLING
MACHINE
 PART OF MILLING MACHINE :
HORIZONTAL
• Column : The 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

• 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.

• Saddle The saddle consists of two slideways, one on

the top and one at the bottom located at 90º to each
other, for providing motions in the X or Y axes by means
of lead screws.

• 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 workpiece or clamping
fixtures.
 PART OF MILLING MACHINE :
HORIZONTAL
• Arbor : The arbor is an extension of the spindle for
mounting cutters. Usually, the thread end of an arbor is
of left hand helix.

• Base : The base of the milling machine, along with the

column, are the major structural components. They
hold, align, and support the rest of the machine.

• Spindle : The spindle holds the tool and provides the

actual tool rotation.

• Spindle Reverse Lever : The position of this lever

determines the spindle direction. The three positions of
the handle are; In, Middle, and Out. The middle position
is the neutral position. Never move the spindle reverse
lever when the spindle is turning.
 PART OF MILLING MACHINE :
HORIZONTAL
• Spindle Clutch Lever : The spindle clutch lever engages
the spindle clutch to the motor. By manipulating the
spindle clutch lever the operator can start and stop the
spindle

• Feed Rate Selection Lever : The feed rate selection

lever is used to change the feed rate setting. The feed
rate settings are expressed in inches per minute.

• Motor Start and Stop Buttons : The motor start and

stop buttons control the power to the main motor for the
machine ı
 PART OF MILLING MACHINE :
VERTICAL
Horizontal milling machine except that the spindle is
mounted in the vertical position.

• Milling head The milling head consisting the spindle, the

motor, and the feed control unit is mounted on a swivel
base such that it can be set at any angle to the table.

• Ram The ram on which the milling head is attached can

be positioned forward and backward along the slideway
on the top of the column.
 MILLING PROCESSES, TYPICAL
MILLING OPERATION, AND SAFETY
RULES
MILLING PROCESSES
■ Spindel Speed ■ Feed Rate
Spindle speed in revolution per minute (R.P.M.) for Feed rate (F) is defined as the rate of travel of the
the cutter can be calculated from the equation workpiece in mm/min. But most tool suppliers
recommend it as the movement per tooth of the cutter
(f).
F=f.u.N
F : table feed in mm/min
N : R.P.M. of the cutter f : movement per tooth of cutter in mm
CS : Linear Cutting Speed of the material in m/min u : number of teeth of cutter
D : Diameter of cutter in mm N : R.P.M. of the cutter

■ Depth of Cut ■ Diraction Of Cutter Rottating

Depth of cut is directly related to the efficiency of Up cut milling and down cut milling.
the cutting process. The deeper the cut the faster
will be the production rate.
Typical Milling Operations
■ Plain Milling
Plain milling is the milling of a flat surface with the axis of the cutter parallel to the
machining surface.
■ End Milling
End Milling is the milling of a flat surface with the axis of the cutter perpendicular to the
machining surface.
■ Gang Milling
Gang milling is a horizontal milling operation that utilises three or more milling cutters
grouped together for the milling of a complex surface in one pass.
■ Straddle Milling
In straddle milling, a group of spacers is mounted in between two side and face milling
cutters on the spindle arbor.
SAFETY RULES FOR MILLING MACHINES
Milling machines require special safety precautions while being used. These are in addition to
those safety precautions
■ Do not make contact with the revolving cutter.
■ Place a wooden pad or suitable cover over the table surface to protect it from possible
damage.
■ Use the buddy system when moving heavy attachments.
■ Do not attempt to tighten arbor nuts using machine power.
■ When installing or removing milling cutters, always hold them with a rag to prevent cutting
your hands.
■ While setting up work, install the cutter last to avoid being cut.
■ Never adjust the workpiece or work mounting devices when the machine is operating.
■ Chips should be removed from the workpiece with an appropriate rake and a brush.
Reference

■ https://www.unidue.de/~kte010/modularte/html/main_modules/thoughtData/99/
mill%20%20SON.pdf
■ https://en.wikipedia.org/wiki/Milling_machine
■ http://uhv.cheme.cmu.edu/procedures/machining/ch8.pdf
■ http://www.engineeringarticles.org/milling-machine-definition-process-types/