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Submitted By : Group VI
Mehul Raina -133 Varun Mutreja - 134 Sahil Sehgal -135 Pranay Pandey - 136 Rohan Nayyar - 137 Anirudh R - 138

Milling is another basic machining process by which surface is generated progressively by the removal of chips from a work piece as it is fed against a rotating cutter. Milling operations can be classified into two broad categories

1. Peripheral Milling 2. Face Milling

Peripheral Milling

 Operation performed by milling cutter to produce a

machined surface parallel to axis of rotation of cutter

Cutting force is not uniform throughout the length of

the cut by each tooth

Quality of surface generated and shape of the chip

formed depends upon the rotation of cutter relative to direction of feed movement
It can be either UP milling or DOWN milling

Also called conventional milling, - Wheel rotation opposite of the feed - The chip formed by each cutter tooth starts out very thin and increases its thickness - The length of the chip is relatively longer - Tool life is relatively shorter - Need more clamping force to hold the work part still.

Also called climb milling, - Wheel rotation is parallel to the feed - The chip formed by each cutter tooth starts out thick and leaves out thin - The length of the chip is relatively short - Tool life is relatively longer - Need less clamping force to hold the work part still.

Face Milling

 The generated surface is at right angles to the cutter

axis
It is the combined result of actions of the portions of the

teeth located on both periphery and the face of the cutter

Most of the cutting is done by the peripheral portions of

the teeth, with the face portions provides the surface finish.

MILLING MACHINES

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The milling machine supplies an accurate rotating spindle for the cutter and a table (vise) to fix and position the work part. Types of Milling Machines are -:

Column & Knee Type

Fixed Bed Type Planer Type

Special Type

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Column & Knee Milling Machine

General purpose Column, spindle, cutter, table, knee, base are the common parts of the vertical and horizontal milling machines The milling machines having only the three mutually perpendicular table motions (x-y-z axes) are called plain column and knee type Vertical type is especially well suited for face and end milling operations

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Horizontal Milling Machine

In horizontal, arbor supports the cutter and an over arm supports arbor

The vertical column houses the electrical, main drive, spindles etc mounted on a heavy base

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Vertical Milling Machine

In vertical, milling cutters can be mounted directly in the spindle Housing (Head) can be fixed or Swiveling type

Fixed Type - Head is always vertical and can be adjusted up and down Swiveling Type Head can be swiveled to any desired angle

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Universal Milling Machine

Has a table that can be rotated in a horizontal plane to any specified angle

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Bed Type Milling Machine

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Bed Type Milling Machines:

Designed for mass production Achieves heavier feed rates and depth of cuts, high MRR Work table is directly fixed on the bed of the machine tool The cutter mounted in a spindle head that can be

adjusted vertically along the machine column

Three types are available w.r.t. the count of spindles

available
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Simplex
Fixed bed replaces saddle and knee. The table has longitudinal travel only Spindle head carries spindle to which arbor is fitted to carry cutter that moves up and down along column ways

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Duplex: Has two spindles, permitting simultaneous milling of two surfaces at a single pass

Triplex: Has three spindles, permitting simultaneous milling of three surfaces at a single pass

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Planer type milling machines

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 Consists of a fixed bed carrying a table having longitudinal movements Consists of 2 vertical columns on each side of the bed Cross rail fitter across columns can be raised or lowered Each column carries a milling head(side/horizontal) moving upwards or downwards

All cutters can be operated simultaneously to machine 4 surfaces at a time

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CNC Milling Machines

Cutter path controlled by numerical data Suited to profile, pocket, surface contouring.

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Milling Operations

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1. Plain Milling(Slab Milling)

Operation of

production of plane flat surface parallel to axis of rotation of plain milling cutter
Cutter width extends

beyond the work piece on both sides

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2. Face Milling
The face milling

cutter is rotated about an axis perpendicular to the work surface

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More Examples on Face Milling

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3. End Milling
Combination of

peripheral and face milling Cutter has teeth both on end face and periphery Vertical milling machine is most suitable for end milling operation

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4. Side Milling
Operation of

production of flat vertical surface on side of work piece by using side milling cutter
Depth of cut

adjusted by rotating vertical feed screw

of the table

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5. Straddle Milling
Operation of

production of flat vertical surfaces on both side of the workpiece by using two side milling cutters mounted on the same arbor

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6. Angular Milling
Operation of

production of angular surface on a workpiece other than at right angles to the axis of milling machine spindle

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7. Gang Milling
Operation of milling

several surfaces of the workpiece simultaneously by feeding the table against a number of cutters having same or different diameters

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8. Form Milling
It is the operation of

production of irregular contours using form cutters The contours maybe convex, concave or any other shape

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9. Profile Milling
It is the operation of

reproduction of an outline of a template or complex shape of a master die on a workpiece

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10.Milling Keyways, Grooves & Slots

Operation of

production of keys, grooves and slots of varying shapes and size by using a plane milling cutter, a metal slitting saw, an end mill or by side milling cutter

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11. Thread Milling

Operation of production

of threads by using a single or multiple thread milling cutter. It is performed in special thread milling machine to produce accurate threads

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Bibliography
Reading Material Wikipedia www.howstuffworks.com www.custompart.net Workshop Tech - Hajra Choudhury Vol 2 Images/Videos Google Image Search Efunda.com Youtube.com

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