Dr.

Ikbal Bahar Laskar

Workshop Theory and Practice-I

Department of Mechanical Engineering Prepared By:

Jorhat Engineering College (JEC), Jorhat, Assam, India Ikbal Bahar Laskar
 Dr. Ikbal Bahar Laskar
Syllabus Drilling Machine Module 4

MODULE 4: MILLING:

Introduction – Classification – Specifications - Principal parts of a milling

machine. Elements of a milling cutter, milling processes – Up-milling – Down

milling – Face milling – End milling. Cutting Speed, Feed and Depth of Cut –

Machining Time. Indexing and Dividing Head

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 Dr. Ikbal Bahar Laskar
Milling machines
A milling machine is a machine tool that removes metal as the work is fed
against a rotating multipoint cutter. The milling cutter rotates at high speed
and it removes metal at a very fast rate with the help of multiple cutting
edges. 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
Fig. Job surfaces generated by milling machine
surfaces, surfaces of revolution, external and internal threads, and helical
surfaces of various cross-sections. Typical components produced by a milling
are given in Figure. In many applications, due to its higher production rate
and accuracy, milling machine has even replaced shapers and slotters.

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Principle of Milling
In milling machine, the metal is cut by means of a rotating cutter having multiple cutting edges. For cutting

operation, the workpiece is fed against the rotary cutter. As the workpiece moves against the cutting edges of

milling cutter, metal is removed in form chips of trochoid shape. Machined surface is formed in one or more

passes of the work. The work to be machined is held in a vice, a rotary table, a three jaw chuck, an index head,

between centers, in a special fixture or bolted to machine table.

The rotatory speed of the cutting tool and the feed rate of the workpiece depend upon the type of material being

machined.

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 Dr. Ikbal Bahar Laskar
Methods of milling

There are two distinct methods of milling classified as

follows:
1. Up-milling or conventional milling
2. Down milling or climb milling

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 Dr. Ikbal Bahar Laskar
Methods of milling
UP-Milling or Conventional Milling Procedure
In the up-milling or conventional milling, as shown in Figure

Principle of up milling
The metal is removed in form of small chips by a cutter rotating against the direction of travel of the workpiece. In this type of

milling, the chip thickness is minimum at the start of the cut and maximum at the end of cut. As a result the cutting force also

varies from zero to the maximum value per tooth movement of the milling cutter. The major disadvantages of up-milling

process are the tendency of cutting force to lift the work from the fixtures and poor surface finish obtained. But being a safer

process, it is commonly used method of milling.

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 Dr. Ikbal Bahar Laskar
Methods of milling
Down-Milling or Climb Milling
Down milling is shown in Figure

Principle of down milling

It is also known as climb milling. In this method, the metal is removed by a cutter rotating in the same direction of
feed of the workpiece. The effect of this is that the teeth cut downward instead of upwards. Chip thickness is
maximum at the start of the cut and minimum in the end. In this method, it is claimed that there is less friction
involved and consequently less heat is generated on the contact surface of the cutter and workpiece. Climb milling
can be used advantageously on many kinds of work to increase the number of pieces per sharpening and to produce
a better finish. With climb milling, saws cut long thin slots more satisfactorily than with standard milling. Another
advantage is that slightly lower power consumption is obtainable by climb milling, since there is no need to drive
the table against the cutter.
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TYPES OF MILLING CUTTERS
Figures illustrates some types of milling cutters along with workpieces. Milling cutters are made in various forms to
perform certain classes of work, and they may be classified as:
(1) Plain milling cutters
(2) Side milling cutters,
(3) Face milling cutter,
(4) Angle milling cutters,
(5) End milling cutter,
(6) Fly cutter,
(7) T-slot milling cutter,
(8) Formed cutters,
(9) Metal slitting saw

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 Dr. Ikbal Bahar Laskar
Plain milling cutters
Plain Milling Cutter is the most commonly used
tool in a horizontal milling machine. Plain Milling
Cutter's shape is like disc or cylindrical, which has
blades on the outer circumference of
the cutter for milling the plane which parallel to
the cutter axis. The blade shapes include straight and Straight blade Helical
helical blade-shaped.

Profile milling is a type of milling process, usually used to semi-finish

or finish the vertical or slanted surfaces, including multi-axis milling of
convex and concave shapes in two or three dimensions.

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Profile milling work

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Side milling cutters

The side milling cutters have teeth on its periphery and also on one or both of its. The side milling

cutters are intended for removing metals from side of the work

Side millingcutters

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Slide Milling Cutter

Plain Slide milling Cutter Staggered teeth Slide milling Cutter

Half Slide milling Cutter

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End milling Cutter
The end mills have cutter teeth on the end as well as on the periphery of the cutter. The peripheral teeth may be straight or helical
and the helix may be right hand or left hand. These are solid circular cutters which are manufactured in two different verities
those having the shank and the other which do not have shank.
The end mills are used for light milling operation like cutting slots, machining accurate holes, producing narrow flat surfaces and
for profile milling operation.
Shank type end mill may have either taper shank or straight shank and are available in wide range of diameter from 3 mm to 50
mm

End Milling Cutter

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End Milling Cutter

End Milling Cutter nomenclature

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Type of end Milling Cutter

Common Type end milling Cutter Two lipped Taper shank Cutter

Shell end milling cutters are larger and Heavier than most of other type of mill. They have
teeth on the periphery and the end both. Generally they are made over 50 mm diameter.
Face milling operation usually performed using these cutters. An end mill is a type of
milling cutter, a cutting tool used in industrial milling applications. It is distinguished from
the drill bit in its application, geometry, and manufacture. While a drill bit can only cut in
the axial direction, most milling bits can cut in the radial direction. Not all mills can cut
Shell End Milling Cutter
axially; those designed to cut axially are known as end mills.

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 Dr. Ikbal Bahar Laskar
Shell end milling cutter

Shell end milling cutter

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Face Milling Cutter
These are made in two common form. The smaller type almost resembles a Shell end milling cutter and is known as Shell type
face milling cutter. Maximum cutting is done by the teeth on the periphery and those on the end perform a type of finishing
operation.
The larger type of face cutter called the built up face milling cutter, consist of steel body, along the periphery of which are
inserted the cutting teeth.
The former is used for small work whereas the latter is used for larger work. the shell type cutter is usually held in a stud arbor
and the larger type can be mounted on spindle nose.

Built up type face milling cutter

Shell milling cutter

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 Dr. Ikbal Bahar Laskar
Metal Slitting Cutters
Plain Slitting Cutters: The cutter are also frequently called Metal Slitting saws. They are used for cutting thin slot or
parting off.
Plain Slitting saws: they are plain milling cutter which are very thin as compare to other types of milling cutter. Their teeth are
provided some side relief in order to prevent rubbing. They are made in different widths, ranging between 1 mm and 5 mm.
Staggered Teeth milling Cutter (saw): these saws are used for comparatively heavier wprk. They have the teeth staggered alternatively and have
side teeth also, similar to the staggered teeth side milling cutter. These saws are generally made in different widths, ranging between 4 mm and 10 m

Staggered Teeth milling Cutter (saw)

Plain Slitting Cutters

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Angle Milling Cutter
The cutter carry sharp angular teeth which are neither parallel no normal to their axis. Their specific use in milling V-grooves,
notches, reamer teeth and other angular surfaces

1. Single Angle Cutter

2. Double angle Cutter

Single Angle Cutter

Single Angle Cutter Double angle Cutter

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 Dr. Ikbal Bahar Laskar
Form Milling Cutter
They are also known as form relieved milling cutter. This category includes fairly large variety of milling cutters used for
producing different shape contours.
Their teeth are provided with a certain angle of relief so that their form and and size are retained even after re-sharpening .
1. Counter rounding cutter

R.H corner rounding L.H corner rounding Double rounding

cutter cutter cutter

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Form Milling Cutter
Concave and Convex Cutters

A concave cutter A convex cutter

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Form Milling Cutter
Gear Cutters: they are used for milling gear teeth on milling machine

A form relieved gear cutter A form relieved gear cutter

(roughing) (finishing)

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Form Milling Cutter
Tap and Reamer flutting Cutters : These formed cutter are used for milling flutes on reamer and Taps. In appearance they look
like Double angle Cutter such that their two inclined faces meet to form a rounded corner

Tap and reamer Fluting Cutter

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Form Milling Cutter
Gear Hobs:

A gear hob

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Form Milling Cutter
Woodruff Key milling Cutter: It is a small type of end milling cutter which resembles with plain and side mills.
Smaller size up to 50 mm diameter, are made to have solid shank to be fitted in the machine spindle, whereas the larger size are
provided with a hole for mounting the same on arbor..

Smaller size- straight teeth, little clearance

Larger size- staggetred teeth both on periphery as well as the sides

Woodruff Key milling Cutter

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Form Milling Cutter
T- Slot milling Cutter:

A T- slot milling cutter

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Type of Milling Machines
Milling machine rotates the cutter mounted on the arbor of the machine and at the same time automatically feed the work in the
required direction.
The milling machine may be classified in several forms, but the choice of any particular machine is determined primarily by
the size of the workpiece to be undertaken and operations to be performed.
With the above function or requirement in mind, milling machines are made in a variety of types and sizes. According to
general design, the distinctive types of milling machines are

1. Column and knee type milling machines

(a) Hand milling machine
(b) Horizontal milling machine
(c) Universal milling machine
(d) Vertical milling machine

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 Dr. Ikbal Bahar Laskar
Type of Milling Machines
2. Planer milling machine
3. Fixed-bed type milling machine
(a) Simplex milling machine.
(b) Duplex milling machine.
(c) Triplex milling machine.
4. Machining center machines
5. Special types of milling machines
(a) Rotary table milling machine.
(b) Planetary milling machine.
(c) Profiling machine.
(d) Duplicating machine.
(e) Pantograph milling machine.
(f) Continuous milling machine.
(g) Drum milling machine
(h) Profiling and tracer controlled milling machine

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Type of Milling Machines
Horizantal Column and Knee type

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Type of Milling Machines
Vertical Milling Machine

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 Dr. Ikbal Bahar Laskar
Type of Milling Machines
2. Planer milling machine
3. Fixed-bed type milling machine
(a) Simplex milling machine.
(b) Duplex milling machine.
(c) Triplex milling machine.
4. Machining center machines
5. Special types of milling machines
(a) Rotary table milling machine.
(b) Planetary milling machine.
(c) Profiling machine.
(d) Duplicating machine.
(e) Pantograph milling machine.
(f) Continuous milling machine.
(g) Drum milling machine
(h) Profiling and tracer controlled milling machine

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 Dr. Ikbal Bahar Laskar
Type of Milling Machines
Column and knee type milling machines
Fig. shows a simple column and knee type milling machine. It is
the most commonly used milling machine used for general shop
work.
In this type of milling machine the table is mounted on the knee
casting which in turn is mounted on the vertical slides of the main
column.
The knee is vertically adjustable on the column so that the table can
be moved up and down to accommodate work of various heights.
The column and knee type milling machines are classified on the
basis of various methods of supplying power to the table, different
movements of the table and different axis of rotation of the main
spindle
Column and knee type milling machines

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 Dr. Ikbal Bahar Laskar
Column and knee type milling machines
Column and knee type milling machine comprises of the following important parts-

1. Base 2. Column

3. Saddle 4. Table

5. Elevating screw 6. Knee

7. Knee elevating handle 8. Cross feed handle

9. Front brace 10. Arbor support

11. Arbor 12. Overhanging arm

13. Cutter 14. Cone pulley

15. Telescopic feed shaft.

Column and knee type milling machines

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 Dr. Ikbal Bahar Laskar
Column and knee type milling machines
The principal parts of a column and knee type milling machine are

Base
It is a foundation member for all the other parts, which rest upon it. It carries
the column at its one end. In some machines, the base is hollow and serves as
a reservoir for cutting fluid.

Column
The column is the main supporting member mounted vertically on the base. It
is box shaped, heavily ribbed inside and houses all the driving mechanism for
the spindle and table feed. The front vertical face of the column is accurately
machined and is provided with dovetail guideway for supporting the knee.
Column and knee type milling machines

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 Dr. Ikbal Bahar Laskar
Column and knee type milling machines

Knee
The knee is a rigid grey iron casting which 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. The knee houses
the feed mechanism of the table, and different controls to operate it.

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.

Column and knee type milling machines

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 Dr. Ikbal Bahar Laskar
Column and knee type milling machines
Table: The table rests on ways on the saddle and travels longitudinally. 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. For this purpose the table is mounted on a circular base.
The top of the table is accurately finished and T -slots are provided for
clamping the work and other fixtures on it
Overhanging arm: It is mounted on the top of the column, which extends
beyond the column face and serves as a bearing support for the other end of
the arbor.
Front brace: It is an extra support, which is fitted between the knee and the
over-arm to ensure further rigidity to the arbor and the knee. Column and knee type milling machines

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 Dr. Ikbal Bahar Laskar
Column and knee type milling machines
Spindle: It is situated in the upper part of the column and receives power from
the motor through belts, gears. and clutches and transmit it to the arbor.
Arbor: It is like an extension of the machine spindle on which milling cutters
are securely mounted and rotated. The arbors are made with taper shanks for
proper alignment with the machine spindles having taper holes at their nose.
The draw bolt is used for managing for locking the arbor with the spindle and
the whole assembly.

Column and knee type milling machines

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Column and knee type milling machines
(a) Hand milling machine
(b) Plain or Horizontal milling machine
(c) Universal milling machine
(d) Vertical milling machine

Hand milling machine

It is the simplest of all the milling machines and smallest in size. All the operations, except the rotation of arbor are performed by hand . The
table, carrying the work over it, is moved by hand to feed the work. The machine is specially useful in producing small components like
Hexagonal or square head on bolts, cutting slot on screw head , cutting key ways etc.

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 Dr. Ikbal Bahar Laskar
Column and knee type milling machines
Plain or Horizontal milling machine
Overarm provides support for the yoke. The arbor carrying the
cutter rotates about a horizontal axis. The table can be given
straight motion in three directions; longitudinal, cross and
vertical but can not be swivel. For giving vertical movement
on the table the knee itself, together with the whole unit above
it, slides up and down along the ways provided in front of the
column. For giving cross movement to the table , the saddle is
moved towards or away from the column along with the
Column and knee type horizontal milling machines
whole unit above it.

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 Dr. Ikbal Bahar Laskar
Column and knee type milling machines
Vertical milling machine : it derive its name from the vertical position of the spindle

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 Dr. Ikbal Bahar Laskar
Column and knee type milling machines
Universal Milling Machine
Universal Milling Machine: it is most versatile of all the
milling machine and after lathe it is most useful Machine
Tool as it is capable of performing most of the operation.
Its table can be swiveled on the saddle in a horizontal plane.
For this circular guideways are provided on the saddle along
which can be swivel.
A graduated circular base is incorporated under the table
with a datum mark on the saddle, to read directly the angle
through which the table has been swivel.
Its overarm can be push back or removed and a vertical
Universal Milling Machine
milling head can be fitted in place of the arbor to use it as a
vertical milling machine

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 Dr. Ikbal Bahar Laskar
Column and knee type milling machines
Universal Milling Machine
A universal milling machine can be distinguished from a plain
milling machine in that the table of a universal milling
machine is mounted on a circular swiveling base which has
degree graduations and the tale can be swivel to any angle
upto 45 deg on either side of normal position.
The table can be swiveled about a vertical axis and set an
angle other than right angles to the spindle. Thus in a
universal milling machine, in addition to three movement as
incorporated in a plain milling machine, the table may have
fourth movement when it is fed at an angle to the milling
cutter.

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 Dr. Ikbal Bahar Laskar
Column and knee type milling machines
Universal Milling Machine
This additional features enable it to perform helical
milling operation which can not perform in plain
milling .
The capacity of a universal milling machine is
considerably increased by the use of special attachment
such as dividing head or index head , vertical milling
attachment, rotary attachment, slotting attachment , etc.
The machine can produce spur, spiral, bevel gears, twist
drills, reamers, milling cutters, etc.

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 Dr. Ikbal Bahar Laskar
Column and knee type milling machines
Comparison between plain and universal milling
1. The plain milling machine is provided with three table movements, longitudinal, cross and vertical,
whereas a universal milling machine has a fourth movement of the table in addition to the above three. The
table can be swivelled horizontally and can be fed at an angle to the milling machine spindle.
2. The universal milling machine is provided with auxiliaries such as dividing head equipment, vertical
milling attachment, rotary table, etc. these extras and special design of the machine itself make it possible
to produce spur, spiral bevel gears, twist drill reamers, milling cutters and all type of milling, drilling and
shaping operations.
3. The plain milling machine is more rigid and heavier in construction than a universal machine of the same
size and is intended for heavier milling operation. The plain type is particularly adapted for manufacturing
operations, whereas the universal machine is intended more for tool room work and for special machining
operation.

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 Dr. Ikbal Bahar Laskar
Column and knee type milling machines
Omniversal milling machine
In this machine, the table besides having all the movements of a universal milling machine, can be tilted in a
vertical plane by providing a swivel arrangement at the knee. Also the entire knee assembly is mounted in such a
way that it may be fed in a longitudinal direction horizontally. The additional swiveling arrangement of the table
enables it to machine taper spiral grooves in reamers, bevel gears, etc. It is essentially a tool room and
experimental shop machine.

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 Dr. Ikbal Bahar Laskar
Fixed bed type or manufacturing type milling machine
Fixed bed type plain Milling Machine
Main parts of this type of machine are shown by means of
block diagram. It differs from column and knee type plain
milling machine in that the table is mounted on fixed bed
instead of the saddle and knee and has a longitudinal travel
only.
It can neither move up and down nor crosswise. A rigid
vertical column carries parallel vertical ways on which is
mounted the adjustable spindle head or spindle or spindle
carrier. This spindle head carries the spindle to which the
arbor can be mounted to carry the cutter
The carrier can be moved up and down along the column Fixed bed type plain Milling Machine
ways.

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Fixed bed type or manufacturing type milling machine
Duplex- Head Fixed Bed Type plain Milling Machine
It is another useful form of fixed bed type Milling
machine. In construction, it is similar to the fixed
bed type plain milling machine, except that it two
vertical column instead of one.
The columns are one each on both side of the fixed
bed as shown in Fig. both the columns carry
parallel vertical ways, on which are mounted the
two adjustable spindle heads or spindle carriers, as
shown.

Duplex- Head Fixed Bed Type plain Milling Machine

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Fixed bed type or manufacturing type milling machine
Duplex- Head Fixed Bed Type plain Milling Machine
Both these carriers carry a horizontal spindle each
on which cutters can be mounted. The spindle
carriers can be adjusted vertically up and down to
adjust the cutters to the work.
The table has a longitudinal movement only and
can not moved in any other direction. This
machine enables machining of two surfaces
simultaneously.

Duplex- Head Fixed Bed Type plain Milling Machine

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Fixed bed type or manufacturing type milling machine
Triplex- Head Fixed Bed Type plain Milling Machine
It is similar in construction and operation to the Duplex head milling machine described above. The only
difference lies in the number of spindles. It carries , in addition to the two horizontal spindles , one vertical
spindle also. Thus, three surfaces can be simultaneously machined on this type of machine.

Rise and Fall type Milling Machine

This particular type of Fixed bed milling enables enables machining of surfaces lying in different plane. As usual, it
consists of a fixed bed carrying the table which has a longitudinal movement only. The spindle carrier carries a
horizontal table . An automatic cycle, operated either hydraulically or electrically, synchronizes the vertical
movement of the spindle carrier and longitudinal movement of the table , such that it enables machining of surfaces
which lie in different places, blind or hidden portions and curved profiles, etc. in all other aspects it resembles the
fixed bed type plain milling machine

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Planer type Milling Machine
Its derives its name from its appearance, construction and
up to a certain extent, the working also. It is very much
similar to a Double Housing Planing machine, the only
difference being in the Tool heads. In this case, the
spindle carriers are mounted, in place of the planer tool
posts, which are operated by individual motors. This type
of milling machine represents the largest size of feed bed
type Milling Machines. Because of their planer type
construction, they are frequently known as Plano-mills.

Planer type Milling Machine

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Planer type Milling Machine
A typical type of Plano-mill is shown by a block diagram in
the Figure. It consists of a fixed bed, carrying the table,
which has a longitudinal movement only. Two vertical
columns, one each on the two sides of the bed, carry a
Milling head each. A bridge or cross rail is fitted, as shown,
across the columns or housings, as they are better known in
this case. This cross rail can be raised or lowered to suit the
height of the work. The vertical milling heads are fitted on
the cross rail, which can travel along it. The side milling
heads can move up and down along the respective
Planer type Milling Machine
housings. All the four cutter can be operated simultaneously
to machine four surfaces of the work at a time.

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 Dr. Ikbal Bahar Laskar
Planer type Milling Machine
This cross rail can be raised or lowered to suit the height of the work. Two vertical Milling
heads are fitted on the cross rail, which can travel along it. The two side milling heads can
move up and down along the respective housings. All the four cutters can be operated
simultaneously to machine four surfaces on the work at a time.
The main difference between a Planer and this machine is in table movement. The table in
this machine moves slow and provides feed only while that in a planer moves faster and
provides the cutting speed to the operation.
The work can be machined in four different ways, according to requirements, as follows:
(1) By moving the table, the cutters rotating in position
(2) By keeping the table stationary and feeding the cutters by moving the Milling heads
(3) By moving the table and Milling heads simultaneously.
(4) By keeping the table stationary, moving the cross- rail downwards and the side cutter
up and down.

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Planer type Milling Machine

These milling machines are constructed for very heavy duty work where generally flat surfaces are to be machined.
The Milling heads mounted on these machines can be of fixed type or swiveling type, the latter type facilitating
machining of inclined surfaced also. Number of these heads depend upon the number of surfaces to be machined at a
time. Sometimes a single horizontal arbor is mounted on these machines to carry several cutters for gang milling

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Production Milling Machines
Rotary table or continuous milling machine
It is largely used in mass production of machined components through
milling. Its construction is quite heavy and robust. Specialty of the
machine lies in the fact that process of machining is continuous and
there is no idle machine time. It is practically observed that this machine
gives three times more production than planomill and acquires less floor
area.
A simple design of this machine is shown in Figure. It consists of a
heavy and sturdy vertical column. A spindle carrier mounted on the
column carries two vertical spindles. Each spindle carries a cutter at its
bottom . One of these is a roughing cutter and other a finishing cutter. Rotary table or continuous milling machine
These cutters can be adjusted on the work by moving the spindle carrier
up and down. A heavy rotating circular table is mounted on the base.

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 Dr. Ikbal Bahar Laskar
Production Milling Machines
Rotary table or continuous milling machine
The table rotate about vertical axis. A number of fixtures are mounted on the table to carry
the components to be machined. These fixtures, as the table revolves, reach before the
operator one after the other. He loads the fixtures with the components , which pass under
two cutter. The roughing cutter is the first to operate, followed by the finishing cutter.
When the finished components reach before the operator he unload them and loads new
unfinished job in their place. Thus the process continuous without stopping the machine.
In absence of this , a vertical milling machine, mounted with a circular attachment, can be
used for this purpose; of course not with the same advantage and efficiency. One defect Rotary table or continuous milling machine
will always be there that only a single cutter will be mounted on the vertical spindle of the
machine.
A more useful and relatively heavier design of rotary table milling machine is the double
station type in which two double spindle milling heads perform the milling operation and
the other two similar heads perform the finishing operation. It carries a bridge type
overhead construction, which carries the vertical milling heads with a circular table
revolving under them.
31-07-2021 Jorhat Engineering College, Jorhat, Assam, India
 Dr. Ikbal Bahar Laskar
Production Milling Machines
Drum type milling machine
It is another heavy duty production machine in which two
end faces of the work pieces are machined
simultaneously. It consists of two vertical columns
mounted on a sturdy base. A heavy Drum is mounted
centrally, between the columns, which rotates about a
horizontal axis.
The milling heads are mounted on two columns. These
heads carry horizontal spindles and can be adjusted in a
vertical direction along the column. A typical design
carrying 4 spindles is shown in figure. Cutters mounted
on these spindles are face mills. Drum type milling machine

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 Dr. Ikbal Bahar Laskar
Production Milling Machines
Drum type milling machine
The upper two spindles carry rouging cutters and lower two
finishing cutters. Well designed fixtures are mounted along the
periphery of the drum to carry the jobs to be machined. The
drum rotates continuously and the work pieces are mounted on
the fixtures on the rear side of the machine.
They come in contact with the upper cutters, first, which rough
machine the faces, and then the lower cutters which provide the
finishing cuts. They are unloaded and replaced by new job
again on the rear side of the machine. It is reckoned that this
machine gives a production double that of rotary table machine.

Drum type milling machine

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 Dr. Ikbal Bahar Laskar
Production Milling Machines
Tracer Controlled milling Machine

It is also known by various other names viz., Duplicator,

Diesinker, Contour Milling or keller machine, etc. it is,
infact, an improved design of a vertical milling machine
and its specific use is the production of dies used in
press work, Die casting, forging, etc..
Its table can be given the longitudinal and cross feeds
simultaneously or independently as desired. The
simultaneous feeding enables the diagonal motion.

Tracer Controlled milling Machine

31-07-2021 Jorhat Engineering College, Jorhat, Assam, India

 Dr. Ikbal Bahar Laskar
Production Milling Machines
Tracer Controlled milling Machine

The vertical spindle, carrying the cutter, can be adjusted in a vertical

direction at a desired height.
A template, which is an exact three dimensional replica of the shape to be
produced, is fitted to the machine.
The contact finger of hydraulic tracer unit or tracer head make a light
contact with the contour of the template and guide the cutter movement ,
synchronizing with the table movement, to produce a similar machined
surface as on the template.

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 Dr. Ikbal Bahar Laskar
Special Purpose Milling Machine
Thread Milling Machine

The Thread Milling Machine is used to cut threads and worms, etc., by
means of the milling cutters. This operation is known as Thread milling
and ensures greater accuracy and better finish than the other common
methods pf thread cutting e.g., on laths or by taps and dies etc.
two types of cutters are generally used in thread milling. One of these
consists of a single row of teeth mounted on the periphery of the
cylinder and the other consists of a number of such rows, spaced at a Thread milling by (a) single cutter (b) multi cutter
distance equal to pitch from one another. The single cutter is generally
used for cutting threads of coarse pitches and on long screw parts such
as lead screw and Worms, etc. the other form, shown in Figure is used
for comparatively shorter length.

31-07-2021 Jorhat Engineering College, Jorhat, Assam, India

 Dr. Ikbal Bahar Laskar
Special Purpose Milling Machine
Profile Milling Machine

This machine is made in both vertical and horizontal types, i.e carrying vertical and horizontal spindle.
Machining is done in two dimensions only. The machine may have one to four spindles, carrying the
revolving cutters as usual.
the cutter movement is guided by the path of a tracer which travels along the outside surface of a
template , thus acquiring the same path as the shape of this template. End mill cutters are used on this
machine. The tracer mechanism can be operated by hand or hydraulically. A device is usually incorporated
which enables an automatic disengagement of the tracer mechanism from the operation when it losses contact
with the surface of the template.

31-07-2021 Jorhat Engineering College, Jorhat, Assam, India

 Dr. Ikbal Bahar Laskar
Special Purpose Milling Machine
Turret Type Milling Machine
It is basically column and knee type Vertical milling machine. As usual, it
carries a strong base, an adjustable knee, a plain or universal table, a
sturdy vertical column and two milling heads instead of one. At the top of
the column is provided a horizontal Ram, which can be adjusted forward
and backward horizontally.
One milling head is mounted at the two ends of the ram. The ram,
carrying the Milling heads, can be rotated about a vertical axis and locked
in any desired position. similarly it can be moved horizontally and locked
in any desired position.
Both the tool heads can be swiveled about a horizontal axis, while their
Turret Type Milling Machine
spindles can rotate and also move inwards and outwards. The cutters are
mounted at the lower end of these spindles.

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 Dr. Ikbal Bahar Laskar
Special Purpose Milling Machine
Turret Type Milling Machine
The work is held firmly on the table and the rotating cutter fed into it.
The movements of the table, milling heads, knee, etc., together
facilitate milling in horizontal or vertical or angular directions. Also
because of the rotation and horizontal sliding of the arm , two different
types of cutter can be used without changing the cutters or the setting
of the work.
This makes this machine highly versatile and flexible to render it
highly useful when a variety of jobs are to machined, as usually
required in tool and die making.

Turret Type Milling Machine

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 Dr. Ikbal Bahar Laskar
Special type milling machine
Pantogram Milling
A pantograph is a mechanical linkage connected in a manner
based on parallelograms so that the movement of one pen, in
tracing an image, produces identical movements in a second pen.

If a line drawing is traced by the first point, an identical, enlarged,

or miniaturized copy will be drawn by a pen fixed to the other.
Using the same principle, different kinds of pantographs are used
for other forms of duplication in areas such as sculpture, minting,
engraving, and milling

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 Dr. Ikbal Bahar Laskar
Special type milling machine
Pantogram Milling machine
Before the advent of control technologies such as NC and CNC and PLC,
duplicate parts being milled on a milling machine could not have their
contours mapped out by moving the milling cutter in a "connect-the-dots"
("by-the-numbers") fashion.
The only ways to control the movement of the cutting tool were to dial the
positions by hand using dexterous skill (with natural limits on a
human's accuracy and precision) or to trace a cam, template, or model in
some way, and have the cutter mimic the movement of the tracing stylus.
If the milling head was mounted on a pantograph, a duplicate part could be
cut simply by tracing a template. This was essentially the same concept as
reproducing documents with a pen-equipped pantograph, but applied to
the machining of hard materials such as metal, wood, or plastic.

31-07-2021 Jorhat Engineering College, Jorhat, Assam, India

 Dr. Ikbal Bahar Laskar
Special type milling machine
Pantograph Milling machine

31-07-2021 Jorhat Engineering College, Jorhat, Assam, India

 Dr. Ikbal Bahar Laskar
Production Milling Machines
Tracer Controlled milling Machine

It is also known by various other names viz., Duplicator,

Diesinker, Contour Milling or keller machine, etc. it is,
infact, an improved design of a vertical milling machine and
its specific use is the production of dies used in press work,
Die casting, forging, etc..
Its table can be given the longitudinal and cross feeds
simultaneously or independently as desired. The
simultaneous feeding enables the diagonal motion.

Tracer Controlled milling Machine

31-07-2021 Jorhat Engineering College, Jorhat, Assam, India

 Dr. Ikbal Bahar Laskar
Production Milling Machines
Tracer Controlled milling Machine

The vertical spindle, carrying the cutter, can be adjusted in a

vertical direction at a desired height.
A template, which is an exact three dimensional replica of the
shape to be produced, is fitted to the machine.
The contact finger of hydraulic tracer unit or tracer head make a
light contact with the contour of the template and guide the cutter
movement , synchronizing with the table movement, to produce a
similar machined surface as on the template.
Tracer Controlled milling Machine

31-07-2021 Jorhat Engineering College, Jorhat, Assam, India

 Dr. Ikbal Bahar Laskar
Special Purpose Milling Machine
Profile Milling Machine
This machine is made in both vertical and horizontal types, i.e carrying vertical and horizontal spindle. Machining is done
in two dimensions only. The machine may have one to four spindles, carrying the revolving cutters as usual.
the cutter movement is guided by the path of a tracer which travels along the outside surface of a template , thus
acquiring the same path as the shape of this template. End mill cutters are used on this machine. The tracer mechanism
can be operated by hand or hydraulically. A device is usually incorporated which enables an automatic disengagement of
the tracer mechanism from the operation when it losses contact with the surface of the template.

Profile Milling
31-07-2021 Jorhat Engineering College, Jorhat, Assam, India
 Dr. Ikbal Bahar Laskar
Special Purpose Milling Machine
Planetary Milling Machine
It is a unique machine in the sense that the work is held stationary while the
revolving cutter or cutters move in a planetary path to finish a circular surface on
the work, either internally or externally. Many of the operations would be lathe
operations, if the nature of workpiece permits. The cutter may be plain, form or
thread cutter and may work on either the inside or the outside of the work or inside
and outside [Link] machine is particularly adapted to work which is
Planetary Milling Machine
heavy, difficult, delicate to hold or work too unbalanced to be rotated itself.
Other applications of this machine are milling of internal and external threads on all
kinds of tapered surfaces, bearing surfaces, rear axle end holes, aero plane crank
cases, shell and bomb ends. These machines are available in either horizontal or
vertical spindle models and may be tooled for magazine loading if the type of work
permits.

31-07-2021 Jorhat Engineering College, Jorhat, Assam, India

 Dr. Ikbal Bahar Laskar
Special Purpose Milling Machine
Double end milling Machine Headstock
It is similar to a drum type milling machine in working principle
and resembles a lathe. With two headstock in appearance. Each of
these headstock like structures called spindle carriers, carries a
spindle which can be adjusted to the work.
The cutters are mounted on these spindles. A long and slender drum
is mounted centrally between the two spindle carriers, which
revolve around a horizontal axis.
The workpiece is held in this drum such that it revolves alongwith
the latter, past the rotating cutters, to enables machining of its two
side surfaces simultaneously.
This machine is specially used for those jobs which are relatively
larger and smaller in diameter.

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 Dr. Ikbal Bahar Laskar
Milling operation
A large variety of components are machined on a Milling Machine involving various types of operation.
These operations are broadly as follows
1. Plain or Slab Milling
2. Face Milling
3. Angular Milling
4. Form Milling
5. Straddle Milling
6. Gang Milling.

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 Dr. Ikbal Bahar Laskar
Plain Milling

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 Dr. Ikbal Bahar Laskar
Face Milling

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 Dr. Ikbal Bahar Laskar
Angular Milling

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 Dr. Ikbal Bahar Laskar
Form Milling

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 Dr. Ikbal Bahar Laskar
Straddle Milling

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 Dr. Ikbal Bahar Laskar
Gang Milling

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 Dr. Ikbal Bahar Laskar
Slot and groove milling
Slot and groove milling is the operation of producing slots in solid workpieces on a milling machine. These slots can be of varied
Shapes, such as plain grooves, T- slots, Dovetail slots, etc. similarly groove milling is the operation of producing grooves of
different shapes such as plain grooves, curved grooves, V- grooves etc.

Plain Slot

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 Dr. Ikbal Bahar Laskar
Slot and groove milling
Dovetail groove

(a) Roughed machined rectangular slot (b) rough machined dovetail slot (c) Finish machining
dovetail slot with the help of a Dovetail milling cutter

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 Dr. Ikbal Bahar Laskar
Keyway Milling

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 Dr. Ikbal Bahar Laskar
Slitting or Saw milling

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 Dr. Ikbal Bahar Laskar
Side Milling
In this operation, a side milling cutter is used to machine a flat vertical surface on a side of the workpiece.
When parallel two Vertical flat surface are required, the usual time saving practice is to use a pair of two side milling cutters
to machine both the Surface simultaneously.
The space between the two cutters can be easily adjusted as per requirement using the spacer. This operation is then known
as Straddle milling.

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 Dr. Ikbal Bahar Laskar
End Milling
In this machine , and end mill is used to machine and produce a flat surface or a pair of parallel flat surface.

Fig. producing a single flat surface by using an End Mill cutter

Gear Milling
This operation often refer to Gear Cutting, involves cutting of different types of gear on a milling machine.
For this, either an End mill cutter or form relieved cutter is used, which carries the profile on its cutting teeth corresponding to the
required profile of the gap between gear teeth.
For dividing the periphery of the gear blank into required number of equispaced parts an indexing mechanism or dividing Head is
used

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 Dr. Ikbal Bahar Laskar
Keyway Milling

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 Dr. Ikbal Bahar Laskar
Side Milling
In this operation, a side milling cutter is used to machine a flat vertical surface on a side of the workpiece.
When parallel two Vertical flat surface are required, the usual time saving practice is to use a pair of two side milling cutters
to machine both the Surface simultaneously.
The space between the two cutters can be easily adjusted as per requirement using the spacer. This operation is then known
as Straddle milling.

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 Dr. Ikbal Bahar Laskar
Indexing or dividing Head

1. Plain Dividing Head

2. Universal Dividing Head

3. Optical Dividing Head

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 Dr. Ikbal Bahar Laskar
Indexing or dividing Head
Universal Dividing Head:

Universal Dividing Head

Internal Mechanism of of universal dividing head

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 Dr. Ikbal Bahar Laskar
Indexing or dividing Head
Universal Dividing Head:

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 Dr. Ikbal Bahar Laskar
Indexing or dividing Head

1. Plain Dividing Head

2. Universal Dividing Head

3. Optical Dividing Head

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 Dr. Ikbal Bahar Laskar
Indexing or dividing Head
Indexing in Milling
Indexing is an operation of dividing a periphery of a cylindrical workpiece into equal number of divisions by the help of index
crank and index plate. Because the operator of the machine may want to rotate the part to an arbitrary angle indexing plates are
used to ensure the part is accurately positioned.
The operation of rotating the job through a required angle between two successive cuts is termed as indexing. This is
accomplished with the help of a milling attachment known as dividing head, which is an accessory to the milling machine.

Blank Gear

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 Dr. Ikbal Bahar Laskar
Indexing or dividing Head
Universal Dividing Head:

Universal Dividing Head

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 Dr. Ikbal Bahar Laskar
Indexing or dividing Head
Universal Dividing Head:

31-07-2021 Jorhat Engineering College, Jorhat, Assam, India

 Dr. Ikbal Bahar Laskar
Indexing or dividing Head
Universal Dividing Head:

31-07-2021 Jorhat Engineering College, Jorhat, Assam, India

 Dr. Ikbal Bahar Laskar
Indexing or dividing Head
Indexing in Milling

Gear

Blank

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 Dr. Ikbal Bahar Laskar
plain or simple indexing
40
For two divisions on the work, the crank will make = 20 turn
2
For each division
40
For 4 divisions on the work, the crank will make = 10 turn
4
For each division
40
For 10 divisions on the work, the crank will make 10 = 4 turn
For each division
40
Similarly for n divisions on the work, the crank will make 𝑛

Let us consider that the work has to divided into 23 equal divisions,
Then the corresponding crank movement will be given by:
40 No.1= 15, 16, 17, 18, 19, 20
Crank movement= 23 = 117 23
No2: 21, 23, 27, 29, 31,33.
No 3: 37, 39, 41, 43, 47, 49

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 Dr. Ikbal Bahar Laskar
plain or simple indexing
Ex. It is required to divide the periphery of the job into 60 equal divisions. Find the crank movement.
40 2 2 6 12
Solution: Required movement= 60= 3 =3 × 6 = 18
i.e12 holes on 18 Holes circle

Example: required 35 divisions on a plate. Find the indexing movement

40 8
Solution: Required movement= 35= 7 =117
1 1 3 3
= × =
7 7 3 21
1 full turn and 3 holes on 21 holes circle (plate No. 2)

No.1= 15, 16, 17, 18, 19, 20

No2: 21, 23, 27, 29, 31,33.
No 3: 37, 39, 41, 43, 47, 49

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 Dr. Ikbal Bahar Laskar
Elements of a plain milling cutter
Body of cutter: the part of the cutter left after exclusion of the teeth and
the portion to which the teeth are attached.

Cutting edge : the edge formed by the intersection of the face and the
circular land or the surface left by the provision of primary clearance.

Face: the portion of the gash adjacent to the cutting edge on which the chip
impinges as it is cut from the work.

Fillet: the curved surface at the bottom of gash which joins the face of one
tooth to the back of the tooth immediately ahead.

Gash: the chip space between the back of one tooth and the face of next
tooth.

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Elements of a plain milling cutter
Land: the part of the back of tooth adjacent to the cutting edge
which is relieved to avoid interference between the surface being
machined and the cutter.
Lead: the axial advance of the helix of the cutting edge in one
complete revolution of the cutter.

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 Dr. Ikbal Bahar Laskar
Elements of a plain milling cutter

Outside diameter: the diameter of the circle passing through the

peripheral cutting edge.
Root diameter: the diameter of the circle passing through the
bottom of the fillet.
Cutter angles: similar to a single point cutting tool, the milling
cutter teeth are also provided with rake, clearance and other cutting
angles in order to remove metal efficiently. The following are the
different cutter angles.

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 Dr. Ikbal Bahar Laskar
Elements of a plain milling cutter
Relief angle: the angle in a plane perpendicular to the axis, which
is the angle between the land of a tooth and the tangent to the
outside diameter of cutter at the cutting edge of that tooth.
Primarily clearance angle: the angle formed by the back of the
tooth with a line drawn tangent to the periphery of the cutter at the
cutting edge.
Secondary clearance angle: the angle formed by the secondary
clearance surface of the tooth with a line drawn tangent to the
periphery of the cutter at the cutting edge.

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 Dr. Ikbal Bahar Laskar
Elements of a plain milling cutter
Rake angle: the angle measured in the dimetral plane
between the face of the tooth and a radial line passing
through the tooth cutting edge. The rake angles which
may be which may be positive, negative or zero.
Zero rake: if the radial line and tooth face coincide in
Positive Rake
the diameter plane, the rake angle is zero. Zero Rake
Positive rake: if the tooth face is tilted, so that the face
and the tooth body are on the same side of radial line,
then the rake angle contained by the radial line and the
tooth face is positive.
Negative rake: if the tooth face is tilted, so that the face
Negative Rake
and the tooth body are on the opposite side of the rake
angle.

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 Dr. Ikbal Bahar Laskar
Elements of a plain milling cutter
Lip angle: the included angle between the land and the face of the tooth
or alternatively the angle between the tangent to the back at the cutting
edge and the face of the tooth.
Helix angle: the cutting edge angle which a helical cutting edge makes
with a plane containing the axis of cylindrical cutter.

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 Dr. Ikbal Bahar Laskar
Cutting speed

Cutting Speed: the speed of milling cutter is its peripheral linear speed resulting from rotation. It is expressed in meters per
Π𝐷𝑁
minuteThe cutting speed can be derived from the formula 𝐶𝑠 =
1000

Where, Where, D is the diameter of the cutter, N is the cutter speed in r.p.m., 𝐶𝑠 the cutting speed in m per min.

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Feed
Feed: the feed in milling machine is defined as the rate with which the workpiece advances under the cutter. The feed is
expressed in a milling machine by the following three different methods.

Feed per tooth (𝑺𝒁 ): the feed per tooth is defined by the distance the work advances in the time between engagement by the
two successive teeth. It is expressed in millimeters per tooth of the cutter.

Feed per cutter revolution (𝑺𝒓𝒆𝒗 ): : the feed per cutter revolution is the distance the work advances in the time when the
cutter turns through one complete revolution. It is expressed in mm per revolution of the cutter.

Feed per minute (𝑺𝒎 ): : the feed per minute is defined by the distance the work advances in one minute.. It is expressed in
millimeters per minute (mm/Min).

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Feed

Feed per tooth (𝑺𝒁 ): the feed per tooth is defined by the distance the work advances in the time between engagement by the
two successive teeth. It is expressed in millimeters per tooth of the cutter.

Feed per cutter revolution (𝑺𝒓𝒆𝒗 ): : the feed per cutter revolution is the distance the work advances in the time when the
cutter turns through one complete revolution. It is expressed in mm per revolution of the cutter.
Feed per revolution (𝑺𝒓𝒆𝒗 ) = Feed per tooth x Z, where, Z= number of teeth in the cutter

Feed per minute (𝑺𝒎 ): : the feed per minute is defined by the distance the work advances in one minute.. It is expressed in
millimeters per minute (mm/Min).
Feed per minute (𝑺𝒎 ) = Feed per revolution x N, where, N= number of revolution per min of the cutter
Feed per minute (𝑺𝒎 ) = Feed per tooth x Z x N

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 Dr. Ikbal Bahar Laskar
Number of Cutter teeth
The number of teeth on a milling cutter should be properly designed properly for effective machining operation. Knowing the
speed and feed to which the cutter will be subjected while in operation, the number of cutter teeth can be derived from the formula.
The number of cutter teeth is calculated from the equation.

𝑺𝒎
Z=
𝑺𝒛 ×𝑵
The coarse teeth cutter having lesser number of teeth on their periphery are efficient in metal machining. The following are the
advantages of a coarse teeth cutter.
1. Greater chip space may be provided.
2. Cutter teeth cross section may be increased thereby increasing its strength.
3. Greater amount of rake angle can be provided on the cutter.
4. Less power is require to drive the cutter.
5. Less sliding friction is produced between the teeth and the work. This reduces the development of heat.
6. Longer life of the cutter may be obtained as the number of regrinds can be increased.

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Machining Time

The following factors are to be consider in estimating the machine time in any type of milling machine:

1. Total length of job to be machine.

2. Approach i.e., the distance through which the cutter has to move before the full depth of cut is acquired

3. The distance through which the cutter has to move further, after the job length is over, to be clear of the j

4. Number of cuts

5. Cutting speed

6. The amount of feed per minute.

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 Dr. Ikbal Bahar Laskar
Machining Time

The time required to mill a surface for any operation can be calculated from the formula:

𝑳 𝑳
T= =
𝑺𝒛 ×𝒁×𝑵 𝒇

Where, T= the time required to complete the cut in minutes.

L = the length of table travel to complete the cut in mm or total distance of the table or cutter travel.

𝑺𝒛= the feed per tooth in mm.

Z= the number of teeth in the cutter

N= the r.p.m of the cutter

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Machining Time (plain milling)

Milling operations being performed by using the plain and face milling
cutters
Let 𝒍𝟏 = length of the job to be machined in mm
𝒍𝟐 = Approach in mm
𝒍𝟑 = overrun of the cutter in mm
If L be the total distance of table or cutter travel, then :
Plain milling
L= 𝒍𝟏 + 𝒍𝟐 + 𝒍𝟑

Now in plain milling, if D mm be the diameter of the cutter and d mm be the depth of cut
Then the approach 𝒍𝟐 is given by
ሺ𝑙2 )^2 = ሺ𝐷 Τ2)^2 − ሺ𝐷 Τ2 − 𝑑)^2

𝑙2 = √𝑑ሺ𝐷 − 𝑑 ൯

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 Dr. Ikbal Bahar Laskar
Machining Time (face milling cutter)
Milling operations being performed by using the plain and face milling cutters
Let 𝑳= length of the job to be machined in mm
𝑨= Approach length in mm
If L be the total distance of table or cutter travel, then :
Total length= 𝑳 + 𝑨
Machining time= Total length/feed

Approach length for face milling cutter

A= 𝐷/2 - C
𝐶 = √ሺሺ𝐷/2)2 − ሺ𝐵/2)2 )
A= 𝐷/2 - √ሺሺ𝐷/2)2 − ሺ𝐵/2)2 )

31-07-2021 Jorhat Engineering College, Jorhat, Assam, India

 Dr. Ikbal Bahar Laskar

Thank You

31-07-
Jorhat Engineering College, Jorhat, Assam, India