Milling

Classification of metal machining

 Milling
Milling is a machining process which removing excess material
from the work piece with a rotating multiple teeth cutting tool. The
rotating cutting tool called the “ Milling cutter”

Slab milling with helical Plan milling cutter

Milling machines

Old horizontal type milling machine Modern horizontal type milling machine
Type of milling machines
Milling machines are basically classified as horizontal or vertical to indicate the
axis of the milling machine spindle rotation.
 Vertical milling machines
 Horizontal milling machines

Horizontal type milling machine Vertical type milling machine

Milling machines are also classified as knee-type, ram-type, manufacturing or bed type, or
CNC milling.
Two type of milling machines
Two type of milling machines

Horizontal type milling machine

Vertical type milling machine
 Up milling and Down milling
According to the feed given and direction of cutting, milling operations can be
categorized in to two

Up milling (Conventional Milling): Here the direction of feed of the work

piece is opposite to the direction of rotation of the cutter

Down Milling (Climb Milling): Here the direction of the feed of the work
piece and the rotation of the cutter is in the same direction
Advantages and disadvantages in up milling and
down milling

Down Milling (Climb Milling)

 
1. Less machine power is need because feed is in tool rotation
2. Thin layer can remove easily because tool easily plunge in to the work
surface
3. Cutter tends to push the work piece more firmly to the table
4. When machining surface hard material tool may blunt immediately due to
impact between tool and work surface.
 
Up milling (Conventional Milling)
 
1. High machine power is need because cutter rotation opposite to the
2. Suitable for machine surface hard materials because there is no sudden
impact in between tool and work surface
3. Cutter tends to pull the work piece from the table
4. Tool wear due to initial sliding on the work surface
 Type of milling machining
In general milling operations can be grouped into the
following two types

Peripheral Milling: The work piece surface to be

machined is parallel to the axis of the cutter rotation
and is machined by cutter teeth located on the
periphery of the cutter
Ex: Slab, slotting, side and straddle milling

Face Milling : In face milling, work piece surface to be

machined is at right angle to the cutter axis and it is
obtained by the teeth on the periphery and the flat
end of the cutter
Ex: Conventional, Partial face, end, profile, pocket &
contour
Different type of milling operations
Type of milling cutters
Widely used milling cutters are as follows

PLAIN MILLING CUTTERS.

SIDE AND METAL SLITTING SAW MILLING CUTTERS.
SIDE MILLING CUTTERS.
END MILLING CUTTERS.
T-SLOT MILLING CUTTER.
SINGLE-ANGLE MILLING CUTTERS.
CONCAVE, CONVEX, AND CORNER ROUNDING MILLING CUTTERS.
GEAR HOB.
FLY CUTTER
 Plain milling cutters
Side milling cutters

Side and metal slitting saw milling cutters End milling cutters
 T-Slot milling cutter Gear hob cutter Single-angle milling cutters

Concave, convex, and corner rounding milling cutters. Fly cutter

Different milling machine operations

Plain milling operation Profile milling

Straddle milling operation Slitting operation

Gang milling operation

Keyway milling

Angular face milling Slab milling

Form milling operation
Slot milling

Angular milling Face milling

 Calculations
Maximum chip thickness in slab milling
Cutter diameter = d
Number of cutting edge= n
Rev/min = N
Depth of cut = a
Feed rate = v in/min
Feed per cutting edge = f in 

d
2

f

tm 
a
 

d f
2

tm
a
 Home work
Read the Chapter 23 Machining processes used to produce various shapes
Manufacturing Engineering and Technology
By
Serope Kalpakjian
Steven R. Schmid