Milling

 What is milling?
 A manufacturing process in which a rotating,
multitooth cutter removes material while
traveling along various axes with respect to the
workpiece.

Page 22-1
 Milling operations

 Slab milling (Figure a)

 Arbor, cutter
 Face milling (Figure b)
 Spindle and cutter
 End milling (Figure c)
 Spindle, shank, end mill

Page 22-2
 Slab Milling
 Also called peripheral milling
 The axis of cutter rotation is parallel to the workpiece
surface to be machined
 The cutter has a teeth along its circumference where
each tooth acts as a single point cutting tool
 Conventional vs. Climb milling
 Conventional milling
• Also called up-milling: the rotation of the cutter is such that it first
engages the workpiece at the bottom.
• The cut is not a function of the surface characteristics
• Common method of milling.
• Proper clamping is necessary to prevent the upward rotation of the
cutter.
 Climb milling
• Also called down-milling: the rotation is such that the cutter first
engages the workpiece at the top.
• Cutting forces holds the workpiece in place. However, a rigid setup is
important since there are high impact forces.

Page 22-3
 Conventional and Climb
Milling
(a) Schematic illustration of conventional milling and climb
milling. (b) Slab milling operation, showing depth of cut, d,
feed per tooth, f, chip depth of cut, tc, and workpiece speed, v.
(c) Schematic illustration of cutter travel distance lc to reach full
depth of cut.

Page 22-4
 Milling Parameters
 The velocity at the point of  Material Removal Rate
contact rad
v  r  length l w d
s MRR w d  v
t
v  D N N = angular speed in rpm. This
version of the formula is used in the
book. It includes the unit conversion  Definitions of symbols
from rpm to radiance per minute.
The units of the velocity are  Definition of Symbols
distance/min.  tc: chip thickness
 f: feed per tooth of cutter
 tcThe2chip
f  d thickness can be found  D: depth of cut
D  N: angular speed in rpm
 n: number of teeth on cutter periphery
 v: linear speed (feed rate)
 Feedv perAstooth
tc gets larger the  t: cutting time
f forces on the cutter tooth
N n increases  L: length of the workpiece
 Lc: extent of the cutter's first contact
with the workpiece (illustration on next
page)
 t Cutting
( l  lc) time
It is assumed that lc<<l
 w: width of cut
v
Page 22-5
 Illustration of Lc

Lc: extent of the cutter's

first contact with the
workpiece

Lc
Page 22-6
Summary of Milling Parameters and
Formulas
TABLE 23.1
N = Rotational speed of the milling cutter, rpm
f = Feed, mm/tooth or in./tooth
D = Cutter diameter, mm or in.
n = Number of teeth on cutter
v = Linear speed of the workpiece or feed rate, mm/min or in./min
V = Surface speed of cutter, m/min or ft/min
=D N
f = Feed per tooth, mm/tooth or in/tooth
=v /N n
l = Length of cut, mm or in.
t = Cutting time, s or min
=( l+lc ) v , where lc =extent of the cutter’s first contact with workpiece
3 3
MRR = mm /min or in. /min
=w d v , where w is the width of cut
Torque = N­m or lb­ft
( Fc ) (D/2)
Power = kW or hp
= (Torque) ( ), where  = 2 N radians/min
Note: The units given are those that are commonly used; however, appropriate units must
be used in the formulas.

Page 22-7
 Example
 A slab milling operation is being • Specific energy: 1.1 hp*min/in3
○ Table 20:2 (annealed mild steel)
carried out on a 12-in long, 4 in  Find
wide annealed mild steel block at • Material Removal Rate
a feed f=0.01 in/tooth and a • Power
depth of cut d=1/8 in. The cutter • Torque
is D=2in in diameter, and has 20 • Cutting time
straight teeth, rotates at N =
100rpm, and is wider than the in
v  f  N n v  20
block to be machined. Calculate min
the material Removal rate, 3
estimate the power and torque in
required for this operation, and MRR  w d  v MRR  10
min
calculate the cutting time.
 Given:
• w=4in Power  spec_enrg  MRR Power  11 hp
• L=12 in
• f=0.01 in/tooth Power 33000
• d=1/8 in Torque   Torque  577.7 lb ft
• D=2 in
N 2 
• n = 20 teeth Lc  D d
• N = 100 rpm Lc  0.5 in
• Cutter width > block width
( L  Lc)
t   60
n t  37.5 seconds
Page 22-8
 Face Milling
 Cutter is mounted on a spindle  Leaves feed marks on the
having an external axis of machined surface
rotation perpendicular to the  Terminology in figure
workpiece surface  Lead angles: 0-45o. Low angle
 Workpiece moves along a  low vertical force
straight path at a linear speed, v.
 Direction of cutter
 Conventional milling (Fig. c)
• up-milling
 Climb milling (Fig. b)
• down-milling

Figure 23.8 Terminology for a

face-milling cutter.
Page 22-9
 Face Milling

d w

Figure 23.6 A face-milling cutter with indexable inserts.

Source: Courtesy of Ingersoll Cutting Tool Company.
Page 22-10
 Cutter and Insert Position in Face
Milling
Figure 23.10 (a) Relative position
of the cutter and insert as it first
engages the workpiece in face
milling, (b) insert positions
towards the end of the cut, and (c)
examples of exit angles of insert,
showing desirable (positive or
negative angle) and undesirable
(zero angle) positions. In all
figures, the cutter spindle is
perpendicular to the page.

Third example in figure c: the

insert exits the workpiece
suddenly as opposed to exiting
with an angle.

Page 22-11
 End milling
 The cutter, called an end
mill, rotates about an axis
perpendicular to the
workpiece surface
(typically – can be at an
angle)
 Ball nose: A type of end
mill in which the bottom
surface is rounded
 Used in the production of
curved surfaces for dies
and molds

Page 22-12
 Other Milling Operations and Cutters
 Straddle milling: two or more
cutters are mounted on an
arbor and are used to machine
two parallel surfaces on the
workpiece
 Easier to keep tolerances than if
milling one surface at a time
 Form milling: produces
curved profiles. Also used in
machining gear teeth.
 Circular cutters can be used
for slotting and slitting.
 Slitting saws are typically <
5mm.
 T-slot cutters: used to mill T-
slots which are used in
clamping workpieces to the
work table. (figure next page)

Page 22-13
Other Milling Operations and Cutters

 Shell
T-slotmilling
cutter
 Has
Noteaorder
hollow
of inside.
cuts: Mounted on a shank.
• 1Allows
st
: cut slott
the same
so theshank
T-cutter
to be
canused
move
for different size cutters
• 2nd: finish the T-slot

Figure 23.12 (a) T-slot cutting

with a milling cutter. (b) A
shell mill.

Page 22-14
 Tool holders

 Milling cutters are classified as

 Arbor cutters
• Mounted on an arbor
• Used in slab, face, straddle, and form milling
 Shank cutters
• The cutter and the shank are one piece.
• Examples include end mills
• Straight shanks
♦
Mounted collet chucks or special end mill holder
• Tapered shanks
○ Tapered for better clamping.
○ Common on larger end mills
○ Mounted in tapered tool holders
Page 22-15
Arbor

Figure 23.13 Mounting a

milling cutter on an arbor for
use on a horizontal milling
machine.

Page 22-16
 Milling Process Capabilities

 Process capabilities include

 Surface finish, dimensional tolerance, production
rate, and cost consideration
 Feed rate (typical): 0.1 mm/tooth – 0.5 mm/tooth
 Depth of cut (typical): 1-8 mm
 Cutting speeds (varies much): 30m/min to
3000m/min

Page 22-17
 Capacities and Maximum
Workpiece Dimensions for
Machine Tools

TABLE 23.2 Typical Capacities and Maximum Workpiece Dimensions for
Some Machine Tools
Maximum dimension Power Maximum
Machine tool m (ft) (kW) speed
Milling machines (table travel)
   Knee­and­column 1.4 (4.6) 20 4000 rpm
   Bed 4.3 (14)
   Numerical control 5 (16.5)
Planers (table travel) 10 (33) 100 1.7
Broaching machines (length) 2 (6.5) 0.9 MN
Gear cutting (gear diameter) 5 (16.5)
Note: Larger capacities are available for special applications.

Page 22-18
 TABLE 23.3 Approximate Cost of Selected Tools for Machining*
Tools Size (in.) Cost ($)
Drills, HSS, straight shank 1/4 1.00–2.00
1/2 3.00–6.00
Coated (TiN) 1/4 2.60–3.00
1/2 10–15
Tapered shank 1/4 2.50–7.00
1 15–45
Approximate 2 80–85
3 250
Cost of Reamers, HSS, hand
4
1/4
950
10–15
Selected Chucking
1/2
1/2
10–15
5–10
Tools for 1
1  1/2
20–25
40–55
End mills, HSS 1/2 10–15
Machining 1 15–30
Carbide­tipped 1/2 30–35
1 45–60
Solid carbide 1/2 30–70
1 180
Burs, carbide 1/2 10–20
1 50–60
Milling cutters, HSS, staggered tooth, wide 4 35–75
8 130–260
Collets (5 core) 1 10–20
*Cost depends on the particular type of material and shape of tool, its quality,
and the amount purchased.

Page 22-19
 TABLE 23.4
General­purpose starting
conditions Range of conditions
Feed Speed Feed Speed
Workpiece mm/tooth m/min mm/tooth m/min
material Cutting tool (in./tooth) (ft/min) (in./tooth) (ft/min)
Low­C and free­ Uncoated carbide, 0.13–0.20 120–180 0.085–0.38 90–425
machining steels coated carbide, (0.005–0.008) (400–600) (0.003–0.015) (300–1400)
cermets
Alloy steels
   Soft Uncoated, coated, 0.10–0.18 90–170 0.08–0.30 60–370

General    Hard
cermets
Cermets, PCBN
(0.004–0.007)
0.10–0.15
(0.004–0.006)
(300–550)
180–210
(600–700)
(0.003–0.012)
0.08–0.25
(0.003–0.010)
(200–1200)
75–460
(250–1500)

Recommendati Cast iron, gray
   Soft Uncoated, coated,
cermets, SiN
0.10–10.20
(0.004–0.008)
120–760
(400–2500)
0.08–0.38
(0.003–0.015)
90–1370
(300–4500)

ons for Milling    Hard

Stainless steel,
Cermets, SiN,
PCBN
Uncoated, coated,
0.10–0.20
(0.004–0.008)
0.13–0.18
120–210
(400–700)
120–370
0.08–0.38
(0.003–0.015)
0.08–0.38
90–460
(300–1500)
90–500

Operations austenitic
High­temperature
alloys, nickel base
cermets
Uncoated, coated,
cermets, SiN,
(0.005–0.007)
0.10–0.18
(0.004–0.007)
(400–1200)
30–370
(100–1200)
(0.003–0.015)
0.08–0.38
(0.003–0.015)
(300–1800)
30–550
(90–1800)
PCBN
Titanium alloys Uncoated, coated, 0.13–0.15 50–60 0.08–0.38 40–140
cermets (0.005–0.006) (175–200) (0.003–0.015) (125–450)
Aluminum alloys
   Free machining Uncoated, coated, 0.13–0.23 610–900 0.08–0.46 300–3000
PCD (0.005–0.009) (2000–3000) (0.003–0.018) (1000–10,000)
High silicon PCD 0.13 610 0.08–0.38 370–910
(0.005) (2000) (0.003–0–015) (1200–3000)
Copper alloys Uncoated, coated, 0.13–0.23 300–760 0.08–0.46 90–1070
PCD (0.005–0.009) (1000–2500) (0.003–0.018) (300–3500)
Thermoplastics and Uncoated, coated, 0.13–0.23 270–460 0.08–0.46 90–1370
thermosets PCD (0.005–0.009) (900–1500) (0.003–0.018) (300–4500)

Source: Based on data from Kennametal Inc.
Note: Depths of cut, d , usually are in the range of 1–8 mm (0.04–0.3 in.). PCBN: polycrystalline cubic boron nitride;
PCD: polycrystalline diamond.
Note: See also Table 22.2 for range of cutting speeds within tool material groups.

Page 22-20
 General Troubleshooting Guide for
Milling Operations
TABLE 23.5
Problem Probable causes
Tool breakage Tool material lacks toughness; improper tool angles; cutting
parameters too high.
Tool wear excessive Cutting parameters too high; improper tool material; improper tool
angles; improper cutting fluid.
Rough surface finish Feed too high; spindle speed too low; too few teeth on cutter; tool
chipped or worn; built­up edge; vibration and chatter.
Tolerances too broad Lack of spindle stiffness; excessive temperature rise; dull tool; chips
clogging cutter.
Workpiece surface Dull tool; depth of cut too low; radial relief angle too small.
burnished
Back striking Dull cutting tools; cutter spindle tilt; negative tool angles.
Chatter marks Insufficient stiffness of system; external vibrations; feed, depth, and
width of cut too large.
Burr formation Dull cutting edges or too much honing; incorrect angle of entry or
exit; feed and depth of cut too high; incorrect insert geometry.
Breakout Lead angle too low; incorrect cutting edge geometry; incorrect angle
of entry or exit; feed and depth of cut too high.

Page 22-21
 Surface Features and Corner
Defects

Figure 23.14 Surface features and corner defects in face milling operations; see also Fig. 23.7. For
troubleshooting, see Table 23.5. Source: Kennametal Inc.

Page 22-22
 Design and Operating Guidelines for
Milling
 Similar to the guidelines for turning
 Use standard milling cutters
 Chamfers should be used instead of radii because of the
difficulty of smoothly matching various intersecting
surfaces
 Internal cavities and pockets with sharp corners should
be avoided since cutters have a finite radius
 Workpieces should be sufficiently rigid to minimize any
defects resulting from clamping and cutting forces.
 Minimizing vibrations
 Cutters should be mounted close to spindle to reduce tool
deflection
 Tool holders and fixtures should be as rigid as possible
 If vibration occurs
• Modify tool shape and/or process conditions
• Used a cutter with fewer teeth or with random tooth spacing

Page 22-23
 Milling Machines
 Column-and-knee type machines
 Most common
 The spindle may be horizontal or vertical
 Machine consists of
 A work table: on which the workpiece is clamped.
 A saddle: supports the table and moves in a perpendicular direction
 Horizontal spindle
A knee: supports the saddle and allows for vertical movement (depth of cut)
 An overarm: in horizontal machines. It can accommodate different arbor lengths
 A head: contains a spindle and cutter holder
 Plain miling machines: 3 axes
 Universal column-and-knee milling machines: 4 th axes (rotational)

vertical spindle

Page 22-24
 Other types of milling machines
 Bed-typed milling
 A bed is used instead of the knee. No vertical
movement is possible.
 The work table is mounted directly on the bed.
 Used in high production runs for simple parts.
Figure 23.17 Schematic
illustration of a bed-type
milling machine. Note the
single vertical-spindle cutter
and two horizontal spindle
cutters. Source: ASM
International.

Page 22-25