Manufacturing Processes lab I

Milling Machine- 1
Learning Objectives:
Describe how milling machines operate,
Identify the various types of milling machines,
Select the proper cutter for the job to be done,
Calculate cutting speeds and feeds.
Milling Machine:
A milling machine is a power-driven machine used for the comple shaping of
metal parts.
Its basic form is that of a rotating cutter or endmill which rotates about the spindle
ais !similar to a drill", and a movable table to which the wor#piece is affied.
Milling products
$illing machines may be operated manually or under computer numerical control
!C%C".
Types of Milling Machines:
&here are two main types of mill' the vertical mill and the hori(ontal mill.
)ori(ontal machine
*ertical machine
Vertical Mill:
In the vertical mill the spindle ais is vertically oriented !$illing cutters are held in
the spindle and rotate on its ais".
&he spindle can generally be etended !or the table can be raised+lowered, allowing
plunge cuts and drilling.
Horizontal Mill:
A hori(ontal mill has the same sort of x,y table, but the cutters are mounted on a
hori(ontal arbor across the table. A majority of hori(ontal mills also feature a -./+-
./ degree rotary table that allows milling at shallow angles.
0lain mills are used to shape flat surfaces. Special cutters can also cut grooves,
bevels, radii, or indeed any section desired. &hese specialty cutters tend to be
epensive.
Simple mills have one spindle, and duple mills have two.
It is also easier to cut gears on a hori(ontal mill.
arious Parts of the Horizontal Mill:
Types of Move!ents:
Types of Milling Machines:



Column and 1nee Column guides the #nee in vertical !2 ais" Direction.
1nee provides the 3 and 4 movements for the table.

"ubcategories of ertical Milling:
&here are several subcategories of vertical mills' the bedmill and the &urret mill.
&urret mills, are generally smaller than bedmills, but are more versatile. In a turret
mill the spindle remains stationary during cutting operations and the table is moved
both perpendicular to and parallel to the spindle ais to accomplish cutting.
In the bedmill, however, the table moves only perpendicular to the spindle5s ais,
while the spindle itself moves parallel to its own ais.
Types of Milling Machines:
A more comple form of the milling machine is the 6niversal milling machine, in
which the rotating cutter can be oriented vertically or hori(ontally, increasing the
fleibility of the machine tool.
&he table of the universal machine can be swiveled through a small angle !up to
about ./ degrees", enabling tapered cuts to be made over the length of the table.

Typical Milling Operations:
Plain Milling :
0lain milling is the milling of a flat surface with the ais of the cutter parallel to the
machining surface. It can be carried out either on a hori(ontal machine or a vertical
machine as shown here.
Typical Milling Operations:
#n$ Milling
7nd $illing is the milling of a flat surface with the ais of the cutter perpendicular
to the machining surface as shown here.
Typical Milling Operations:
%ang Milling
8ang milling is a hori(ontal milling operation that utili(es three or more milling
cutters grouped together for the milling of a comple surface in one pass.
Different type and si(e of cutters should be selected for achieving the desire profile
on the wor#piece.
"tra$$le Milling
In straddle milling, a group of spacers is mounted in between two side and face
milling cutters on the spindle arbor as shown, for the milling of two surfaces
parallel to each other at a given distance.
&lassification of Milling:
Slab milling !the milled surface is generated by teeth located on the periphery of
the cutter body. &he ais of cutter rotation is generally in a plane parallel to the
wor#piece surface to be machined",
9ace milling !the cutter is mounted on a spindle having an ais of rotation
perpendicular to the wor#piece surface. &he milled surface results from the action
of cutting edges located on the periphery and face of the cutter ",
7nd $illing !&he cutter in end milling generally rotates on an ais vertical to the
wor#piece. It can be tilted to machine tapered surfaces. Cutting teeth are located on
both the end face of the cutter and the periphery of the cutter body".
Metho$s of Milling:
1' (p !illing:
)'*o+n !illing:
Metho$s of !illing !achine control:
$anual' $ovements are made by hand lever control".
Semi-automatic' $ovements are controlled by hand and+or power feeds".
9ully automatic' A comple hydraulic feed arrangement that follows : or ;
dimensional templates.
C%C' $achining coordinates are entered into a master computer or computer
on the machine, using a special programming language.
&utting Tools:
Cutting tools for hori(ontal milling'
a. Slab $ills
9or heavy cutting of large and flat surfaces.
b. Side and 9ace Cutters
&his type of cutter has cutting edges on the periphery and sides of the teeth
for cutting shoulders and slots.
c. Slitting Saws
9or cutting deep slots or for parting off.
&utting Tools:
Cutting tools for vertical milling'
a' #n$ Mills
Commonly used for facing, slotting and profile milling.
b' ,ough &ut #n$ Mills
9or rapid metal removal
c' "lot *rills
9or producing poc#ets without drilling a hole before hand.
$' -ace Milling &utters
9or heavy cutting.
"pin$le "pee$ :
<0$
-ee$ ,ate:
Tool
Material
High "pee$ "teel &arbi$e
Material
&utting
"pee$
-ee$
.f/
&utting
"pee$
-ee$
.f/
Mil$ "teel )0 1'12 111 1'10
3lu!inu! 111 1'10 011 1'4
Har$ene$
"teel
--- --- 01 1'1
Cutting speed and feed rate depend on the material to be cut and tool material
and also type of operation=
Test yourself:
Is this up milling or down milling>
6p milling
Is this up milling or down milling>
Up milling
?hich one is the vertical milling and which one the hori(ontal one>
Vertical milling
Horizontal milling
"pecify the 56 7 an$ 8 $irections:

@abel each of the milling operations below. Choose from 9ace milling, 7nd
milling and Slab milling.
Slab milling 9ace milling 7nd milling
Are these tools for vertical or hori(ontal milling> @abel them using' Side and
face cutter, slitting saws and slab mills.
Slab $ills
Side and 9ace Cutters
Slitting Saws
Horizontal !illing:
Specify the following vertical mill cutting tools !choose from slot drill, end mill,
face milling cutter and rough cut end mill".
7nd mill
9ace milling cutter
Determine the approimate cutting speed and feed for a AB !./: mm" diameter side
cutter !)igh Speed Steel or )SS" with .A teeth, when milling free cutting steel.
Consider the cutting speed for free cutting steel :CC fpm. &he feed rate for free
cutting steel for side cutter is between C.CC/ to C.C.. inches. Consider the midpoint
in range.
Have a loo9 at this site:
http'++www.metalwor#ing.com+tutorials+A<$4-&C-D-/:E+chF.pdf