WORKSHOP TECHNOLOGY

CHAPTER 4 : MILLING MACHINE

WHAT IS MILLING MACHINE??

• Milling is the process of removing the

metal from a work piece by feeding it past
a rotating cutting tool called a milling
cutter.

• The cutters used here are provided with

multiple tooth and produce a number of
chips in one revolution
TYPES OF MILLING MACHINE
 CHARACTERISTIC OF MILLING
MACHINES
• The milling cutter rotates at high speed and it removes
metal at a very fast rate with the help of multiple cutting
edges/cutting tools (pemotong pinggir).
• One or more number of cutters can be mounted
simultaneously on the arbor of milling machine. This is the
reason that a milling machine finds wide application in
production work.
• Milling machine is used for machining flat surfaces,
contoured surfaces, surfaces of revolution, external and
internal threads, and helical surfaces of various cross-
sections.
 PARTS OF MILLING MACHINE

HORIZONTAL MILLING MACHINE VERTICAL MILLING MACHINE

SIDE VIEW
BASE:
• is a foundation for the milling machine for support all the
parts.
• serves as a reservoir for cutting fluid.

COLUMN:
• main supporting member mounted vertically on the base.
• houses all the driving mechanism for the spindle and
table feed.
KNEE:
• slides up and down on the vertical ways of the column
face.
• An elevating screw mounted on the base is used to
adjust the height of the knee and it also supports the
knee.

Saddle
• The saddle is placed on the top of the knee and it slides
on guideways set exactly at 90° to the column face.
• The top of the saddle provides guide-ways for the table.
TABLE:
• The table rests on the saddle and a lead screw under the
table engages a nut on the saddle to move the table
horizontally by hand or power.
• In universal machines, the table may also be swiveled
horizontally.
• Table also used for clamp the workpiece.

Overhanging arm
• It is mounted on the top of the column, which extends beyond
the column face and serves as a bearing support end of the
arbor.(vertical milling machine)
SPINDLE:
• used to hold the milling cutter

ARBOR:
• Only in horizontal milling machine.
• Used to hold the milling cutters
• The draw bolt is used for managing for locking the arbor
with the spindle and the whole assembly
Principle of milling
operation
 In general, all milling operations
can be grouped in the following
two types:
 Peripheral milling
 Face milling
 Peripheral milling
The finished surface is parallel to the
axis of the cutter
Is machine by the cutter teeth located
on the periphery of the cutter
 Face milling
The finished surface is at right angles to the axis of the
cutter
Is obtained by the teeth on the periphery and on the
flat end of the cutter.
The face milling process is done on Vertical Milling
Machine.
Have two methods of milling flat surfaces with plain
milling cutter-up milling and down milling
 Conventional (up) Milling
The direction of the feed of the work-piece, is opposite
to the direction of rotation of the cutter.
In up milling, the thickness of the chip removed,
gradually increases during the cut.
 Climb(Down) Milling
The work-piece is fed in the same direction as that of
the rotation of the cutter.
In down milling, the thickness of the chip is of
maximum thickness at the beginning of the cut and
goes on decreasing further.
Difference Between Up Milling
and Down milling
No Factors Up milling Down milling

1 Direction of feed of work-piece Opposite Same

and rotation of the cutter
2 Thickness of the chip at the start Less More

3 Thickness of the chip at the end More Less

4 Cutting force Less at the start More at the start

and gradually. and reduces
(zero to gradually.
maximum) (maximum to
zero)
5 Effect of cutting force It tries to lift the It tries to push the
job out of the job into the fixture
fixture
No Factors Up milling Down milling

6 Clamping force Greater clamping force Lower clamping

force

7 Chip disposal Difficult Easy

8 Surface finish Chances of wavy surface Under controlled

conditions,improved
surface finish
9 Effect of backflash No effect There is effect of
backflash

10 Effect of the scale on It does not affect tool life It effect tool life
the tool life
Milling Cutter
Various types of milling cutter

Plain milling cutter

Side milling cutter
Face milling cutter
Angular cutter
Single corner rounding
 Plain milling cutter
Cylinder made of high-speed steel with teeth cut on the periphery.
Used to produce a flat surface
Cylindrical cutter are made in a variety of diameter and length up to 160mm long.

Light duty light duty helical heavy duty high helix

Side milling cutter
Narrow cylindrical milling cutter with teethon each side.
Used for cutting slot and for and straddle milling operation.
This cutter have have free cutting action at high speeds and feeds.
A staggered tooth side cutter have teeth on the periphhery and on both side,is
designed for deep-slotting operations.
Half side miling cutter are used when only one side of the cutter is required as in
end facing.

Straight teeth straggered-tooth half side cutter both side cutter

  Face milling cutter
The teeth may be of high-speed steel or cast tool steel.
The face of the the tooth removes a small amount of stock left by the cutter
This types of cutter is used as combination cutter.
They are usually held on stub arbor which may be threaded or may use a key in
the shank to drive the cutter.

Face milling cutter shell end mill and adapter

Angular
Angular cutter have teeth are neither parallel or perpendicular to the cutting

cutter
axis.
Used for milling angular surface
Divide into two groups
Single angle cutter are available with the angle of 60 to 80 and the double
angle cutter with 45,60 and 90 included angle.
1.single angle cutter 2.double angle cutter

have teeth on the flat side have two intersecting angular

surface with cutting teeth on
both.
 Single corner rounding
cutter
This cutter has a concave quater circle on one side is
used to produce a corner radius on the edge of the
workpiece.
The cutter are available with a variety of radius from
1.5mm to 20mm.
 MILLING CUTTER
• MILLING IS A PROCECESS OF GENERATING
MACHINED SURFACES BY PROGRESSIVELY
REMOVING A PREDETERMINED AMOUNT OF
MATERIAL FROM THE WORKPIECE.
 END
• END MILL CAN BE USED ON VERTICAL AND HORIZONTAL
MILLING MACHINES FOR A VARIETY OF FACING,SLOTTING
AND PROFILING OPERATIONS.
• THERE ARE TWO TYPE WHICH ARE SOLID END MILL AND
SHELL END MILL.
 FLY
• IS A SINGLE-POINTED CUTTING TOOL WITH THE CUTTING
END GROUND TO THE DESIRED SHAPE.
• USED IN EXPERIMENTAL WORK AND THE HIGH COST OF A
SPECIALLY SHAPED CUTTER WHOULD NOT BE
WARRANTED.
 T-SLOT
• USED TO CUT THE WIDE HORIZONTAL GROOVE AT THE
BOTTOM OF A T-SLOT AFTER THE NARROW VERTICAL
GROOVE HAS BEEN MACHINED WITH AN END MILL OR SIDE
MILLING CUTTER.
 FORMED
Formed cutter are particularly useful for the
production of small parts. Each tooth of
formed cutter is identical in shape.
 METAL-SLITTING SAWS
 Metal-slitting saws basically thin plain milling
cutter with sides relieved or ‘’dished” to
prevent rubbing or binding when in use.
 Milling Set Up
Correct use of holding device and a good set up
are important in achieving a safe, accurate, and
efficient operation of the machine. Small
workpieces are usually held by machine vice as
shown in figure 20. In either case, a dial
indicator is used for alignment checking.

Figure 20. Machine Vice

Vice Alignment
In the setting up of the vice onto the machine table,
the fix jaw of the vice must be set parallel to the
machine table using a Parallel Bar and a Dial Indicator
as illustrated in figure 21. Adjustments can only be
made by using a hide face hammer to correct its
position such that a near zero indicator movement is
achieved at all positions along the parallel bar.

Figure 21. Machine Vice Set-up

Work Holding Method
• The vice jaws and the workpiece must be free from burrs, chips, and cutting
fluid.
• Round bar must be placed between the workpiece and the movable jaw to
ensure that the workpiece is in perfect contact with the fix jaw.
• The vice handle should be tightened by hand to avoid over clamping of the
workpiece as well as the vice.
• On completion of the milling of the first face, the workpiece should be
unloaded, deburred, and cleaned before the next operation.
• To machine the second and the third faces, the workpiece should be
clamped with its preceding machined surface facing against the fix jaw of
the vice.
• Similar clamping method can be applied in the machining of the fourth face.
• Yet it can also be clamped on the vice without the round bar.
• Both ends of the workpiece can be machined with the periphery flutes of
the cutter using up cut milling as shown in figure 23.
Figure 22. Holding Method by Using a Machine Vice

Figure 23. End Surface Milling

 Tool Holding
A Milling Machine without the tooling would
be a fairly useless machine tool. It is the vast
amount of tool holders and accessories that go
along with the milling machine that expands the
uses for this machine. This section is entitled
Tool Holding . In tool holding we try to include
the most common types of tool holding
methods.
Collects
Two type of collects used on milling machines :
 Solid collect
• The solid collet is the most rigid type of tool
holding collet
• The solid type of collet has a precision ground
shank which fits precisely into the spindle of the
machine.
• The collet is held in the machine using a draw-in
bolt which runs through the center of the spindle
• The solid collet also has a precision ground hole in it
to accept the shank of the cutter .
•  The set screw is tightened down on top of the flat
which is ground or cast into the shank of the tool.
• Solid collets are used were the cutting forces might
cause the tool to slip in a less rigid type of tool holder.
• Solid collects size is precision ground to accept
different size cutters and tool holder shanks.
 Split collects
• Split collets are very popular on vertical milling
machines.
• The pulling in of the collet causes the split collet to
squeeze down onto the tool shank. 
• Split collets are a very effective tool holding method,
although under heavy cutting pressures split collets
may have a tendency to slip. Another type of split
collet system where the tool slippage may be
minimized is the collet chuck system
• The collet chuck system uses a split type collet
commonly referred to as a spring collet.
• The collet chuck adapter is machined to accept the
spring collet. As the nosepiece for the collet chuck is
tightened the collet clamps down onto the tool shank.
• Some collet chuck systems utilize a non-pull out
button which aligns with the flat on the tool shank to
prevent slippage
• It is important to note that when using the collet
chuck system, snap the collet into the nosepiece
first before placing the tool and the collet into the
body of the collect chuck .
• Failure to assemble the collet chuck in the proper
order can cause serious damage to the collet and
the chuck.
 SHELL END MILL ADAPTER
• Face milling cutters under six inches are known as
shell end mills .
• Shell end mills come in different cutting tool
materials such as carbide and high speed steel
• To use the shell end mill, it has to be attached to an
adapter before it can be mounted in the machine
spindle.
•  The adapter holds the milling cutter in place
through the use of a clamp screw.
CALCULATE THE
RPM FEED RATE
AND CUTTING
TIME
FEED RATE

FEED RATE=RPM × CHIP LOAD × TEETH

METRIX CALCULATION

 Example
 Calculate The feed in milimiters per minute for a 75mm
diameter,six tooth helical carbide milling cutter when
machining a cast iron workpieces(cs60)

feed(mm/min)=N×CPT×rpm

=6×0.25×256
=384mm/min
RPM
CALCULATION FOR RPM FORMULA
METRIX CALCULATION

 Find the feed in inches per minute using a 3.5in diameter 12tooth
helical cutter to cut machine steel (cs80)
 rpm=
 =91

N×CPT×RPM
feed(in/minute)=12×.010×91
=10.9
 THE SAFETY PROCEDURE
USING THE MILLING MACHINE

Always follow the training provided by your employer.

Ensure guard in position to avoid contact with cutter, swarf and coolant

Always wear eye protection while using the milling machine.

Take great care before engaging automatic feeds and ensure table traversing
handle is disenggaged.

Do not allow large quantities of chips to accumulate around the work piece or
machine table. After stopping the machine, use a brush or rag to remove all
excess chips from the mill bed and stock.
Make sure workpiece and workholding equipment are securely clamped.
make sure safety limit stop are present and in the correct position.

Always isolate the machine when changing the chuck , arbor or cutter.

Handle the milling cutter carefully as the cutting edge are sharp.

Ensure the cutter is rotating in the correct position

Never use damage cutter.

Always ensure machine is fully stoped before taking measurement.

Do not attempt to adjust the coolant supply or remove swarf when the
machine is running.

Do not wear jewellery or loose clothing.