TOPIC

Milling
Machine
CONTENT
:
Introduction of milling machine

Principle of milling machine

Types of milling machine

Milling machine operation

Milling
 Milling machine
•Important machining operations
•Workpiece feed against a rotating cylindrical
tool
•Multiple cutting edges (multipoint cutting
tool)
• Cutting tool used in milling operation is called
milling cutter
• The machine tool that performs the milling
operations by producing required relative
motion between workpiece and tool is called
milling machine.
 Milling machine
As the workpiece moves against the cutting edges of
milling cutter, metal is removed in form chips
Machined surface is formed in one or more
passes of the work.
Milling operation creates plane surfaces
The work to be machined is held in a vice, a
rotary table, a three jaw chuck, an index head,
in a special fixture or bolted to machine table.
In many applications, due to its higher
production rate and accuracy, milling machine
has even replaced shapers and slotters.
Milling machine applications
 MILLING METHODS
Two basic methods of milling
[Link]-milling or conventional milling
[Link]-milling or climb milling
[Link]-milling or conventional milling
Metal is removed by cutter rotating against the
direction of travel of the workpiece.
Needs stronger holding of the job.
Chip thickness is minimum at thestart of cut
and maximum at the end of the cut.
Disadvantage- tendency to lift work from the fixtures
and poor surface finish.
[Link] MILLING
 MILLING METHODS
[Link]-milling or climb milling
Metal is removed by cutter rotating in thesame
direction of travel of the workpiece.
teeth cut downward instead of upwards.
Chip thickness is maximum at thestart of cut
and minimum at the end of cut.
Less friction involved
Better surface finish.
Less power consumption.
[Link] MILLING
PRINCIPLE OF MILLING
 TYPES OF MILLING MACHINE
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.
According to general design, thedistinctive types
of milling machines are:
1. Column and knee type milling machines
2. Planer milling machine
3. Fixed-bed type milling machine
4. Special types of milling machines
PRINCIPLE PARTS
Base
Column
Knee
Saddle
Table
Spindle
COLUMN AND KNEE TYPE

It is the most commonly used

milling machine used for
general shop work.
The table is mounted on the
knee 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.
 CLASSIFIACTION OF COLUMN & KNEE
TYPE MILLING MACHINE

(a) Hand milling m/c.

(b) Horizontal milling m/c.
(c) Universal milling m/c.
(d) Vertical milling m/c.
(a) Horizontal Milling
machine
• The horizontal milling machine has a
spindle that is parallel to the shop
floor and an overarm that extends
over the workpiece.
• The overarm supports the arbor,
which holds the milling cutter.
• On the horizontal mill, the arbor is the
component that rotates the milling
cutter.
ACTUAL HORIZONTAL MILLING MACHINE
ARBORS

Fig : Mounting a milling cutter on an arbor for use on a horizontal milling

machine.
(B) VERTICAL MILLING MACHINE
Spindle is vertical or perpendicular to the work table.
It has all the movements of the table for proper
setting and feeding the work.
Spindle head may be swiveled at an angle, permitting
the milling cutter mounted on the spindle to work on
angular surfaces.
In some machines, spindle can also be adjusted up
or down relative to the work.
Adopted for machining grooves, slots and flat surfaces.
VERTICAL MILLING
MACHINE

MAJOR PARTS :
1. BASE
2. COLUMN
3. SPINDLE
4. SPINDLE
HEAD
5. KNEE
6. SADDLE
7. WORKTABLE
 DIFFERENCES BETWEEN HORIZONTAL &
VERTICAL MILLING MACHINES
SL. NO. HORIZONTAL MILLING VERTICAL MILLING MACHINE
MACHINE
Spindle is horizontal & parallel to Spindle is vertical & perpendicular to
01
the worktable. the worktable.

Cutter cannot be moved up &

02 Cutter can be moved up & down.
down.

Cutter is directly mounted on the

03 Cutter is mounted on the arbor.
spindle.

Spindle can be tilted for angular

04 Spindle cannot be tilted.
cutting.

Operations such as slot milling,

Operations such as plain milling,
T-slot milling, angular milling, flat
gear cutting, form milling, straddle
05 milling etc., can be performed and
milling, gang milling etc., can be
also drilling, boring and reaming can
performed.
be carried out.
(C) UNIVERSAL MILLING MACHINE
Difference from plain
horizontal machine is
addition of table swivel
housing Permits table to be
swiveled 45º in either
direction in a horizontal plane
Used for milling of
helical grooves in twist
drills, milling cutters,
and gears
 2. Fixed-bed type milling machine

•Comparatively large, heavy and rigid and differ from

column and knee type milling machines.
•Table is directly mounted on fixed bed.
•No provision isprovided for cross or verticaladjustment of
the table.
•The cutter mounted on the spindle head may be moved
vertically on the column and the spindle may be adjusted
horizontally to provide cross adjustment.
•Three types
1. Simplex 2. duplex 3. triplex
FIXED BED MILLING MACHINE
3. PLANER MILLING MACHINE
Looks like double column planer machine.
Milling heads mounted in various planes, vertical
heads on the cross-rail and horizontal heads at the
sides (on column)
This arrangement enables it to machine a workpiece on
several sides simultaneously
Used for producing long straight surfaces on large and
heavy machine parts.
 5. SPECIAL-TYPE MACHINES
Designed for individual milling
operations
Used for only one particular type of job
Completely automatic Employed when hundreds
or thousands of similar pieces are to be machined

Tracer mills (Profiling milling machines):

-Also called duplicators
-Designed to reproduce an irregular part geometry
that can be created on an template
-In two dimensions- tracer
-In three dimensions- duplicator
SPECIAL-TYPE MACHINES
CNC milling machines:
Cutter path controlled by numerical data
Suited to profile, pocket, surface contouring.
MILLING
OPERATIONS
❖ Plain or slab milling
❖ Face milling
❖ End milling
❖ Side milling
❖ Slot milling
❖ Angular milling
❖ Form milling
❖ Straddle milling
MILLING
OPERATIONS
❖ Slitting or saw milling
❖ Gear cutting
❖ Key way milling
❖ String milling
❖ Profile milling
❖ Thread milling
❖ Helical milling
❖ Cam milling
PLAIN/SURFACE/ SLAB MILLING
Plain Milling:
Process to get the flat
surface on the work piece in
which the cutter axis and
work piece axis are parallel.
The primary motion is the
rotation of the cutter. The
feed is imparted to the work
piece.
Cutter: Plain milling
cutter.
Machine:Horizontal
Milling m/c.
PLAIN/SURFACE/ SLAB MILLING
Plain mill
cutter

Work piece
FACE MILLING

Face Milling:
Operation carried out for
producing a surface,
which
flat is perpendicular to the
axis of rotating cutter.

Cutter: Face milling

cutter.

Machine: Vertical Milling

Machine
FACE MILLING
MANUFACTURING TECHNOLOGY
 END MILLING
End Milling:
Operation performed for
producing flat surfaces, key
slots, grooves or finishing
the edges of the work
piece.

Cutter: End milling cutter.

Machine: Vertical Milling

FIG. END
Machine
MILLING
SIDE MILLING

SIDE MILLING : Operation

performed for producing flat
surfaces, slots, grooves or
finishing the edges of the
work piece.

Cutter: End milling cutter.

Machine: Horizontal Milling

Machine
SLOT MILLING

Slot Milling:
Operation of
producing slots like
T-slots,plain slots
etc.,

Cutter: End milling

cutter, T-slot cutter,
side milling cutter

Machine: Vertical
FIG. T-SLOT MILLING Milling Machine
ANGULAR MILLING

Angular Milling:
Operation of producing
all types of angular cuts like
V-
notches and grooves,
serrations and
surfaces. angular

Cutter: Double angle

cutter.
Machine:Horizontal Milling
FIG. ANGULAR MILLING
Machine
FORM MILLING
Form Milling:
Operation of producing
alltypes of angularcuts
like V-notches grooves,
and
serrations and angular
surfaces.
Cutter: Double
angle cutter.
Machine:
Horizontal Milling
Machine
FORM MILLING
 STRADDLE MILLING

Straddle Milling:
Operation of machining two
parallel surfaces
simultaneously on a work
piece.

Cutter: 2 or more side &

face milling cutters

FIG. STRADDLE MILLING Machine: Horizontal

Milling Machine
GANG MILLING
Gang Milling:
Process to get different
profiles on the work
piece simultaneously
with two or more cutters
at one stretch.

Cutter: Different cutters

as required.
FIG. GANG MILLING
Machine: Horizontal
Milling Machine
Profile milling
• Outside
periphery of flat
part is cut.
• Conventional
end mill is used
to cut the
outside or inside
periphery of a
flat part.
Pocket Milling

Another form
of end milling
used to mill
shallow
pockets into
flat parts
SURFACE CONTOURING

Ball - nose cutter

is fed back and
forth across the
work along a
curvilinear path at
close intervals to
create a three
dimensional
surface.
Manufacturing Technology
Indexing
Indexing is the process of evenly dividing the circumference of a circular
work piece into equally spaced divisions, such as in cutting gear teeth,
cutting splines, milling grooves in reamers and taps, and spacing holes on a
circle.

The index head of the indexing fixture is used for this purpose.
Manufacturing Technology
Index Head
The index head of the indexing fixture (Figure ) contains an indexing mechanism which is
used to control the rotation of the index head spindle to space or divide a work piece
accurately. A simple indexing mechanism consists of a 40-tooth worm wheel fastened to the
index head spindle, a single-cut worm, a crank for turning the worm shaft, and an index
plate and sector. Since there are 40 teeth in the worm wheel, one turn of the index crank
causes the worm, and consequently, the index head spindle to make 1/40 of a turn; so 40
turns of the index crank revolve the spindle one full turn.
Manufacturing Technology
Index Plate
The indexing plate (Figure) is a round plate with a series of six or more circles of
equally spaced holes; the index pin on the crank can be inserted in any hole in any
circle. With the interchangeable plates regularly furnished with most index heads,
the spacing necessary for most gears, bolt heads, milling cutters, splines, and so
forth can be obtained.
Sector
The sector (Figure) indicates the next hole in which the pin is to be inserted and
makes it unnecessary to count holes when moving the index crank after each cut.
It consists of two radial, beveled arms which can be set at any angle to each other
and then moved together around the center of the index plate.
Manufacturing Technology
Index Plate Types
Brown and Sharpe type consists of 3 plates of 6 circles each drilled as follows:
Plate I - 15, 16, 17, 18, 19, 20 holes
Plate 2 - 21, 23, 27, 29, 31, 33 holes
Plate 3 - 37, 39, 41, 43, 47, 49 holes
Cincinnati type consists of one plate drilled on both sides with circles divided
as follows:
First side - 24, 25, 28, 30, 34, 37, 38, 39, 41, 42, 43 holes
Second side - 46, 47, 49, 51, 53, 54, 57, 58, 59, 62, 66 holes
Manufacturing Technology
Indexing Methods
Simple Indexing or Plain Indexing
In simple or plain indexing, an index plate selected for the particular application, is fitted on
the worm shaft and locked through a locking pin’
To index the work through any required angle, the index crank pin is withdrawn from the
hole of the index plate than the work is indexed through the required angle by turning the
index crank through a calculated number of whole revolutions and holes on one of the hole
circles, after which the index pin is relocated in the required hole
If the number of turns that the crank must be rotated for each indexing can be found from
the formula
N = 40 / Z
Where
Z - No of divisions or indexings needed on the work
40 – No of teeth on the worm wheel attached to the indexing plate, since 40 turns of
the index crank will turn the spindle to one full turn
Manufacturing Technology
Suppose it is desired to mill a gear with eight equally spaced teeth. l/8th of 40 or 5
turns (Since 40 turns of the index crank will turn the spindle one full turn) of the
crank after each cut, will space the gear for 8 teeth. If it is desired to space equally
for 10 teeth, 1/10 of 40 or 4 turns would produce the correct spacing.
The same principle applies whether or not the divisions required divide equally
into 40. For example, if it is desired to index for 16 divisions, 16 divided into 40
equals 2 8/16 turns. i.e for each indexing we need two complete rotations of the
crank plus 8 more holes on the 16 hole circle of plate 1(Plate I - 15, 16, 17, 18, 19,
20 holes)
Manufacturing Technology
Direct Indexing
In direct indexing, the index plate is directly mounted on the dividing head spindle ( no
worm shaft or wheel)
While indexing, the index crank pin is withdrawn from the hole of the index plate than the
pin is engaged directly after the work and the indexing plate are rotated to the desire
number of holes
In this method fractions of a complete turn of the spindle are limited to those available with
the index plate
Direct indexing is accomplished by an additional index plate fastened to the index head
spindle. A stationary plunger in the index head fits the holes in this index plate. By moving
this plate by hand to index directly, the spindle and the work piece rotate an equal distance.
Direct index plates usually have 24 holes and offer a quick means of milling squares,
hexagons, taps, and so forth. Any number of divisions which is a factor of 24 can be
indexed quickly and conveniently by the direct indexing method.
Manufacturing Technology
Differential Indexing
Sometimes, a number of divisions is required which cannot be obtained by simple indexing
with the index plates regularly supplied. To obtain these divisions, a differential index head
is used. The index crank is connected to the worm shaft by a train of gears instead of a
direct coupling as with simple indexing. The selection of these gears involves calculations
similar to those used in calculating change gear ratio for lathe thread cutting.
Gear Ratio I = 40/K ( K – Z)
Where
K – a number very nearly equal to Z
For example if the value of Z is 53, the value of K is 50
Manufacturing Technology
Indexing in Degrees
Work pieces can be indexed in degrees as well as fractions of a turn with the usual index
head. There are 360 degrees in a complete circle and one turn of the index crank revolves
the spindle 1/40 or 9 degrees. Therefore, 1/9 turn of the crank rotates the spindle 1 degree.
Work pieces can therefore be indexed in degrees by using a circle of holes divisible by 9.
For example, moving the crank 2 spaces on an 18-hole circle, 3 spaces on a 27-hole circle,
or 4 spaces on a 36-hole circle will rotate the spindle 1 degree.
Smaller crank movements further subdivide the circle: moving 1 space on an 18-hole circle
turns the spindle 1/2 degree (30 minutes), 1 space on a 27-hole circle turns the spindle 1/3
degree (20 minutes), and so forth.
Manufacturing Technology
Indexing in Degrees
Work pieces can be indexed in degrees as well as fractions of a turn with the usual index
head. There are 360 degrees in a complete circle and one turn of the index crank revolves
the spindle 1/40 or 9 degrees. Therefore, 1/9 turn of the crank rotates the spindle 1 degree.
Work pieces can therefore be indexed in degrees by using a circle of holes divisible by 9.
For example, moving the crank 2 spaces on an 18-hole circle, 3 spaces on a 27-hole circle,
or 4 spaces on a 36-hole circle will rotate the spindle 1 degree.
Smaller crank movements further subdivide the circle: moving 1 space on an 18-hole circle
turns the spindle 1/2 degree (30 minutes), 1 space on a 27-hole circle turns the spindle 1/3
degree (20 minutes), and so forth.