Milling
Metal Cutting Processes 2 - Milling
Contents
1. Introduction 6. Typical Milling Operations
2. Types of Milling Machine 6.1 Plain Milling
2.1 Horizontal Milling Machine 6.2 End Milling
2.2 Vertical Milling Machine 6.3 Gang Milling
3. Cutting Tools 6.4 Straddle Milling
3.1 Cutting Tools for Horizontal 7. Milling Set Up
Milling Machine 7.1 Vice Alignment
3.2 Cutting Tools for Vertical 7.2 Work Holding Method
Milling Machine 8. Safety
4. Industrial Applications
5. Milling Processes
5.1 Spindle Speed
5.2 Feed Rate
5.3 Depth of Cut
5.4 Direction of Cutter Rotation
1. Introduction
Milling machine is one of the most versatile conventional machine tools with a wide range of metal
cutting capability. Many complicated operations such as indexing, gang milling, and straddle milling etc.
can be carried out on a milling machine.
This training module is intended to give you a good appreciation on the type of milling machines and the
various types of milling processes. Emphasis is placed on its industrial applications, operations, and the
selection of appropriate cutting tools.
On completion of this
module, you will acquire
some of these
techniques from the
training exercises as
illustrated in figure 1.
However, to gain
maximum benefit, you
are strongly advised to
make yourself familiar
with the following notes
before undertaking the
training activities, and to Figure 1. Milling Products
have a good interaction
between yourself and
the staff in charge of
your training.
Assessment of your
training will be based on
a combination of your
skill and attitude in
getting the work done.
2. Types of Milling Machine
Most of the milling machine are constructed of ¡¥column and knee¡¦ structure and they are classified
into two main types namely Horizontal Milling Machine and Vertical Milling Machine. The name
Horizontal or Vertical is given to the machine by virtue of its spindle axis. Horizontal machines can be
further classified into Plain Horizontal and Universal Milling Machine. The main difference between the
two is that the table of an Universal Milling Machine can be set at an angle for helical milling while the
table of a Plain Horizontal Milling Machine is not.
2.1. Horizontal Milling Machine
Figure 2 shows the main features of a Plain Horizontal Milling Machine.
Their functions are :-
a. 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.
b. 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.
c. 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.
d. 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.
e. Arbor Figure 2. Horizontal Milling Machine
The arbor is an extension of the
spindle for mounting cutters.
Usually, the thread end of an
arbor is of left hand helix.
2.2. Vertical Milling Machine
Figure 3 shows a vertical milling machine which is of
similar construction to a horizontal milling machine
except that the spindle is mounted in the vertical
position.
Its additional features are :-
a. 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.
b. 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.
Figure 3. Vertical Milling Machine
3. Cutting Tools
3.1. Cutting Tools for Horizontal Milling
a. Slab Mills
For heavy cutting of large and flat surfaces.
Figure 4. Slab Mill
b. Side and Face Cutters
This type of cutters has cutting edges on the periphery and
sides of the teeth for cutting shoulders and slots.
Figure 5. Side and Face Cutter
c. Slitting Saws
For cutting deep slots or for parting off.
Figure 6. Slitting Saw
Note: Horizontal milling cutters are specified by the name, the material, the width, the diameter, and the
hub size of the cutter.
Example --- Side and face cutter,
High Speed Steel,
Cutter size : 10 X ø 100
Hub size: ø 25
3.2. Cutting tools for Vertical Milling
a. End Mills
Commonly used for facing, slotting and profile milling.
Figure 7. End Mill
b. Rough Cut End Mills
For rapid metal removal.
Figure 8. Rough Cut End Mill
c. Slot Drills
For producing pockets without drilling a hole before
hand.
Figure 9. Slot Drill
d. Face Milling Cutters
For heavy cutting.
Figure 10. Face Milling Cutter
Note: Most vertical milling cutters are of end mill types and are specified by the material, the diameter,
the length, the helical angle, the types of shank and the shank diameter. For face milling cutter, only the
diameter of the cutter and the types of carbide inserts are required.
4. Industrial Applications
Milling machines are widely used in the tool and
die making industry and are commonly used in
the manufacturing industry for the production of
a wide range of components as shown in figure
11. Typical examples are the milling of flat
surface, indexing, gear cutting, as well as the
cutting of slots and key-ways.
When equipped with digital readout, the Figure 11. Components Made by Milling
machine is capable of producing more precise
work for the manufacturing of plastic moulds,
tool & dies, and jigs & fixtures. Figure 12 shows
a typical plastic mould produced by milling.
Figure 12. Plastic Mould
5. Milling Processes
Milling is a metal removal process by means of using a
rotating cutter having one or more cutting teeth as
illustrated in figure 13.
Cutting action is carried out by feeding the workpiece
against the rotating cutter. Thus, the spindle speed, the
table feed, the depth of cut, and the rotating direction of
the cutter become the main parameters of the process.
Good results can only be achieved with a well balanced
settings of these parameters.
Figure 13. Milling Process
5.1. Spindle Speed
Spindle speed in revolution per minute (R.P.M.) for the cutter can be calculated from the equation :-
where -- N = R.P.M. of the cutter
CS = Linear Cutting Speed of the material in m/min. ( see table 1 )
d = Diameter of cutter in mm
5.2. Feed Rate
Feed rate (F) is defined as the rate of travel of the workpiece in mm/min. But most tool suppliers
recommend it as the movement per tooth of the cutter (f). Thus,
F=f.u.N
where -- F = table feed in mm/min
f = movement per tooth of cutter in mm ( see table 1 )
u = number of teeth of cutter
N = R.P.M. of the cutter
where
C.S. and feed rate for some common material :-
Tool Material High Speed Steel Carbide
Cutting Cutting
Material Feed (f) Feed (f)
Speed Speed
Mild Steel 25 0.08 100 0.15
Aluminium 100 0.15 500 0.3
Hardened Steel --- --- 50 0.1
Table 1
5.3. Depth of Cut
Depth of cut is directly related to the efficiency of the cutting process. The deeper the cut the faster will
be the production rate. Yet, it still depends on the strength of the cutter and the material to be cut.
For a certain type of cutter, a typical range of cut will be recommended by the supplier. Nevertheless, it
should be noted that a finer cut is usually associated with a better surface finish as well as a long tool
life.
5.4. Direction of Cutter
Rotation
a. Up Cut Milling
In up cut milling, the cutter rotates in
a direction opposite to the table feed
as illustrated in figure 14. It is
conventionally used in most milling
operations because the backlash
between the leadscrew and the nut
of the machine table can be
eliminated.
Figure 14. Up Cut Milling
b. Down Cut Milling
In down cut milling, the cutter rotates
in the same direction as the table
feed as illustrated in figure 15. This
method is also known as Climb
Milling and can only be used on
machines equipped with a backlash
eliminator or on a CNC milling
machine. This method, when
properly treated, will require less
power in feeding the table and give a
better surface finish on the
workpiece.
Figure 15. Down Cut Milling
6. Typical Milling Operations
6.1. Plain Milling
Plain milling is the milling of a flat surface with the axis of the cutter parallel to the machining surface. It
can be carried out either on a horizontal machine or a vertical machine as shown in figure 16.
Figure 16. Plain Milling
6.2. End Milling
End Milling is the milling of a flat surface with the axis of the cutter perpendicular to the machining
surface as shown in figure 17.
Figure 17. End Milling
6.3. 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. As illustrated in figure 18,
different type and size of cutters
should be selected for achieving the
desire profile on the workpiece.
Figure 18. Gang Milling
6.4. Straddle Milling
In straddle milling, a group of spacers
is mounted in between two side and
face milling cutters on the spindle
arbor as shown in figure 19. for the
milling of two surfaces parallel to each
other at a given distance.
Figure 19. Straddle Milling
7. Milling Set Up
Correct use of holding device and a
good set up are of crucial importance
in achieving a safe, accurate, and
efficient operation of the machine.
Large workpiece can be mounted
directly onto the machine table by
means of tenons and screws while
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
7.1. 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
7.2. Work Holding Method
In the machining of a complex component, it is usually started off with the milling of a rectangular block.
To ensure that each surface of the rectangular block is perpendicular to its neighbouring surfaces, the
following points should be noted:-
The vice jaws and the workpiece must be free from burrs, chips, and cutting fluid.
Smaller workpiece should be supported by parallel bars to provide the supporting datum.
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. Hide face hammer should be used to assure that the workpiece is in perfect contact
with the supporting base.
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
8. Safety
Safety practices of a machine shop should be
followed. A complete understanding of the Safety
Rules would enable the students to identify potential
hazards that may occur under different working
conditions such that appropriate preventive actions
can be taken to avoid the happening of accidents.
Emphasis should be given that the eyes of the
machine operator must be protected by wearing a
face shield (figure 24) to prevent accident that may
be caused by chips, cutting fluid, and tool breakage.
Machine operators must also take care of their body
Figure 24. Face Shield
such as fingers which keep out of any moving parts,
especially the rotating cutter of the machine, to
prevent any unnecessary accident hurt. The milling
machine must be stopped immediately when any
accidence occurred, so the operator must stand near
by the control panel of the machine and pays more
attention on the operation. Remember the Chinese
phrase 'carefully can be driven the boat in thousand
year' that you will enjoy the benefits provided by
milling.