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METAL MACHINING
Chapter 21
 Material Removal Processes
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 Milling
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 Machining operation in which work is fed past a

rotating tool with multiple cutting edges
 Axis of tool rotation is perpendicular to feed
direction

Milling (Video)
• Vertical Machining Centers
• Horizontal Machining Centers
• Machining center workholding
• Milling cutters and operations
 Milling
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 Creates a planar surface; other geometries possible either

by cutter path or shape

 Milling is an interrupted cutting operation

 Cutting tool called a milling cutter
 Cutting edges called "teeth"
 Machine tool called a milling machine
 Milling types
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 Peripheral milling
 Cutter axis is parallel to surface being machined
 Cutting edges on outside periphery of cutter
 Face milling
 Cutter axis is perpendicular to surface being milled
 Cutting edges on both the end and outside periphery of the
cutter
 Slab milling
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 The basic form of peripheral milling in which the

cutter width extends beyond the workpiece on both
sides
 Slotting/Slot milling
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 Width of cutter is less than workpiece width, creating

a slot in the work

 Thickness too small, like sheet

 Saw milling
 Side milling
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 Cutter cuts the side of the workpiece

 Straddle milling
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 Same as side milling but the cutter cuts both sides

of the workpiece
 Form milling
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 Milling tooth defines the cut profile

 P. Milling acc. to rotation direction
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 Up milling
 Conventional milling
 Direction of motion of teeth is opposite
to the feed
 Milling against the feed
 Down milling
 Climb milling
 Milling with the feed
 More tool life
 Tends to hold the work
 Conventional face mill
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Cutter overhangs work on both sides

 Partial face mill
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Cutter overhangs work on one sides

 End mill
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 Cutter diameter is less than work width, so a slot is

cut into part
 Profile millig
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 Form of end milling in which the outside periphery

of a flat part is cut
 Pocket milling
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 Another form of end milling used to mill shallow

pockets into flat parts
 Surface contouring
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 Ball‑nose cutter is fed back and forth across the

work along a curvilinear path at close intervals to
create a three dimensional surface form
 Type w.r.t Spindle direction
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 Horizontal milling
 Spindle is horizontal
 Designed to perform peripheral mill
 Vertical milling
 Spindle is vertical
 Appropriate for
 Profile mill, end mill, face mill, surface mill etc.
 Other classifications
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 Knee and column type milling machine

 Bed type milling machine
 Planner type milling machine
 Tracer mills
 CNC Milling machines
 Knee and column type milling machine
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 Basic machine tool for milling

 Knee
 Supports the worktable
 Column
 Supports the spindle
 Horizontal
 Arbor support and overarm supports arbor
 Vertical
 No need for arbor
 Knee and column type milling machine
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 Movement
 X: worktable
 Y: Saddle
 Z: Knee
 Knee and column type milling machine
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 Universal milling machine

 Table rotates: Cutting angular shapes and helix of parts
 Ram mill
 Adjustable ram and rotating toolhead
 Bed type milling machine
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 More rigid
 Heavy DOF and FEED:
 High production
 Spindle head
 can be adjusted vertically
 Simplex
 One spindle head
 Duplex
 Two spindle heads
 Triplex
 Third spindle is added vertically
 Planer type milling machine
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 Multi point cutting tool

 Relative motion
 Planer
 Bed is V. heavy and close to
ground
 Machine v large parts
 Tracer/profiling mills
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 Trace the profiles created on

a template
 Manual or automatic
 X-Y tracing
 X-Y-Z- tracing
 Products:
 Dies and molds
 Now this operation can be
performed on CNC
 CNC Milling machines
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 Cutter path is controlled by numeral data rather than template

 Operations in which two axis should be simultaneously controlled for
complex parts
 Machining Centers
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 Highly automated machine tool capable of

performing multiple machining operations under
CNC control in one setup with minimal human
attention
 Typical operations are milling and drilling
 Three, four, or five axes
 Other features: Video
 Automatic tool changing Milling and machining centers
1. Vertical machining centers
 Pallet shuttles 2. HMC
 Automatic workpart positioning 3. Machining center
workholding
 Mill-Turn Centers
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 Highly automated machine tool that can perform turning,

milling, and drilling operations on a workpart
 General configuration of a turning center
 Can position a cylindrical workpart at a specified angle so a
rotating cutting tool (e.g., milling cutter) can machine features
into outside surface of part
 A conventional turning center cannot stop workpart at a defined
angular position and does not possess rotating tool spindles
 Mill-Turn Center
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turn second diameter

(1)

mill flat with part in programmed angular position

(2)

drill hole with part in same programmed position

(3)

cutoff
(4)
 Shaping and Planing
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 Similar operations Video

1. Gear functions
 Both use a single point 2. Gear machining
cutting tool moved linearly
relative to the workpart
 Shaping and Planing
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 A straight, flat surface is created in both operations

 Interrupted cutting
 Subjects tool to impact loading when entering work
 Low cutting speeds due to start‑and‑stop motion
 Usual tooling:
 single point high speed steel tools
 Shaping
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 Tool: cutting motion

 Table: Feed motion
 Forward stroke: Cut
 Return stroke: Tool is lifted
 Feed after each stroke
 High speed on return
 Planing
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 Tool: Feed motion

 Table: cutting motion
 Parts: Larger than shapper
 Open side planer
 Single column planer
 Double-column planer
 Limits the width of work
 Broaching
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 Moves a multiple teeth cutting tool linearly relative

to work in direction of tool axis
 Cutting tool: Broach
 M/C Tool: Broaching machine
 Broaching
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 Vertical/ horizontal broach

 Broaching machines pull the broach past the work
 Exceptions
 broaching press:
 Pushes the broach (internal)
 Continuous broaching machine
 Continuous belt and stationary broach
 Only surface broaching
 Broaching Advantages
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 Good surface finish

 Close tolerances
 Variety of work shapes possible
 Owing to complicated and often custom‑shaped
geometry, tooling is expensive
 External Broaching
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 Performed on external surface of a hole

 Creates certain cross sectional shapes
 Internal Broaching
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 Performed on internal surface of a hole

 A starting hole must be present in the part to insert
broach at beginning of stroke
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 Sawing
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 Cuts narrow slit in work by a tool consisting of a

series of narrowly spaced teeth
 Tool called a saw blade
 Types according to blade types
 Hacksawing
 Bandsawing
 Circular Sawing
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42 End