Milling Processes

General Manufacturing Processes Engr.-20.2710

 Milling is one of the basic machining processes.

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
 The Process
 The milling process:
– Typically uses a multi-tooth
cutter
– Work is fed into the rotating
cutter
– Capable of high MRR
– Well suited for mass production
applications
– Cutting tools for this process are
called milling cutters
GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
 Classifications
 Milling operations are classified into two major
categories:
– Peripheral (side)
» Generally in a plane parallel to the axis of the cutter
» Cross section of the milled surface corresponds to the contour of
the cutter
– Face
» Generally at right angles to the axis of rotation of the cutter
» Milled surface is flat and has no relationship to the contour of the
cutter
» Combined cutting action of the side and face of the milling cutter

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
 Related Operations
– Side milling - machining a plane surface perpendicular
to the milling machine arbor with an arbor mounted
tool. This tool is called a side mill.
– Straddle milling - milling two parallel surfaces using
two cutters spaced apart on an arbor.
– Gang milling - milling multiple surface simultaneously
using multiple cutters mounted on an arbor.
– Thread milling - milling treads using the capability of a
three axis contouring CNC machine.

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
 Operating Parameters
 Rpm
– CS converted into Rpm based on cutter diameter
 Feed rate
– Feed per tooth
– Table feed rate

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
 Operating Parameters
 Feed direction -- Conventional vs. Climb
– Conventional milling
» Most common method of feed
» Feed work against the rotation of the cutter

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
 Operating Parameters
 Feed direction - Conventional vs. Climb
– Climb milling
» Load of the cutter tends to “pull” the work into the cutter
» This results in a small feed force and about 20% less Hp than
conventional milling
» Downward motion increases the load on the table ways
» This method can “pull” the work into the cutter and scrap the
work and/or damage the fixture and tool.
» Machine must be very ridged to safely utilize climb
milling(CNC machines)
» USE CAUTION!

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
 Operating Parameters
 Conventional vs. Climb Milling

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
 Operating Parameters
– Depth of cut
– Horsepower

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
 Milling machines
 Two Major Classifications - Knee & Column and Bed
– Knee & Column (Bridgeport type)
» Basic job shop type mill
» Column mounted to the base which is the major support frame.
» Construction provides controlled motion of the worktable in three
mutual perpendicular directions.
» Knee moves vertically on the ways in the front of the machine
» Table moves longitudinally on the ways on the saddle
» Saddle moves transversely on the ways on the knee
» Quill moves parallel in Z axis or, if head is rotated, X axis
» Versatile general purpose machine

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
 Milling Machines
– Bed
» Used extensively in production milling operations
» Rigid construction capable of heavy cuts
» Table is mounted directly to the bed
» Spindle head moves vertically to set depth of cut
» Head locks into position for cut
» Base of machine functions as a coolant reservoir

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
Milling Machines

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
Milling Machines

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
Milling Machines

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
 Variation of Machines
 Variations include:
» Horizontal
» Vertical
» Profilers and duplicators
» CNC
» Planner

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
 Variation of Machines
 CNC
» Horizontal, Vertical,and Planner (up to 5 axis)

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
 Process Accuracy
 Accuracy of milling machines
» Factors to consider
 Fixture

 Rigidity of machine tool

 Accuracy of the spindle

 Cutter condition

 Coolant

– Type
– Delivery method
 Material condition

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
 Process Accuracy
 +/- .0005” - Optimum situation
 +/- .001”-.002” - Typical
 +/- .001” - Flatness

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
 Milling Cutter Classifications
 Arbor
 Shank
 Face

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
Milling Cutters

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
 Workholding Devices
 Vise
 Chucks
 Rotating tables
 Angle plates
 Special fixtures
 Universal dividing head
 Modular fixturing systems
 Clamp work to table
GMP-20.271
Rensselaer Polytechnic Chiappone
Institute
Workholding Devices

GMP-20.271
Rensselaer Polytechnic Chiappone
Institute