SHAPER AND MILLING MACHINES

Copyright © 2010 Pearson Education South Asia Pte Ltd

Introduction
 Machining operations can produce many other parts
with more complex shapes
 Complex shapes need to be produced to very close
tolerances and a fine surface finish
 Die casting and precision forging can achieve such
goals to some degree

Copyright © 2010 Pearson Education South Asia Pte Ltd

Milling and Milling Machines
 Milling is machining operation for a variety of
configurations with the use of a milling cutter

Copyright © 2010 Pearson Education South Asia Pte Ltd

Milling and Milling Machines:
Peripheral Milling
 The axis of cutter rotation is parallel to the workpiece
surface
 The cutter body has a number of teeth along its
circumference
 When the cutter is longer than the width of the cut, the
process is called slab milling

Conventional Milling and Climb Milling

 The cutter rotation can be clockwise
or counter-clockwise

Copyright © 2010 Pearson Education South Asia Pte Ltd

Milling and Milling Machines:
Peripheral Milling
Conventional Milling and Climb Milling
 In conventional milling (also called up milling), the
maximum chip thickness is at the end of the cut
 Advantages are:
1. Tooth engagement is not
a function of workpiece’s
surface characteristics
2. Contamination or scale (oxide layer) on the surface
does not adversely affect tool life
 In climb milling (also called down milling), cutting starts
at the surface of the workpiece where the chip is
thickest
Copyright © 2010 Pearson Education South Asia Pte Ltd
Milling and Milling Machines:
Face Milling
 In face milling, the cutter is mounted on a spindle
having an axis of rotation perpendicular to the
workpiece surface
 As the relative motion between the cutter teeth and the
workpiece, face milling leaves feed marks on the
machined surface

Copyright © 2010 Pearson Education South Asia Pte Ltd

Milling and Milling Machines:
Face Milling
 Lead angle of the insert in face milling has a direct
influence on the undeformed chip thickness
 As lead angle increases, the undeformed chip
thickness decreases and the length of contact
increases
 Cutter diameter and their position relative to the milled
surface will determine the angle at which an insert
enters and exits the workpiece

Copyright © 2010 Pearson Education South Asia Pte Ltd

Milling and Milling Machines:
Face Milling
 The same insert may engage the workpiece at different
angles, depending on the relative positions of the cutter
and the workpiece width
 The first contacts are at an angle and away from the tip
of the insert

Copyright © 2010 Pearson Education South Asia Pte Ltd

Milling and Milling Machines:
End Milling
 End milling is versatile and capability to produce
various profiles and curved surfaces
 An end mill has a straight shank or tapered shank
which is mounted into the spindle of the milling
machine
 End milling can produce a variety of surfaces at any
depth, such as curved, stepped, and pocketed

Copyright © 2010 Pearson Education South Asia Pte Ltd

Milling and Milling Machines:
End Milling
High-speed End Milling
 High-speed end milling has applications as the milling
of large aluminum-alloy aerospace components and
honeycomb structures with high spindle speeds
 Machines must have high stiffness and accuracy
 The production of cavities in metalworking dies (die
sinking) can be done
 The machines have four-axis
or five-axis movements

Copyright © 2010 Pearson Education South Asia Pte Ltd

Milling and Milling Machines:
Milling Machines
 Milling machines are among the most versatile and
useful machine tools
 Standard milling machines are now being replaced with
computer controls and machining centers

Column-and-knee-type Machines
 Column-and-knee-type machines are common milling
machines

Copyright © 2010 Pearson Education South Asia Pte Ltd

Milling and Milling Machines:
Milling Machines
Bed-type Milling Machines
 The worktable replaces the knee
and can move only longitudinally

Other Types of Milling Machines

 Planer-type milling machines are
equipped with several heads and
cutters to mill different surfaces
 Computer numerical-control (CNC)
machines are for low
production quantities

Copyright © 2010 Pearson Education South Asia Pte Ltd

Shaper