Milling machine

A milling machine is a machine tool used to machine solid materials. Milling machines exist in
two basic forms: horizontal and vertical, which refers to the orientation of the cutting tool spindle.
Both types range in size from small, bench mounted devices to room-sized machines. Unlike a
drill press, which holds the workpiece stationary as the drill moves vertically to penetrate the
material, milling machines also move the workpiece against the rotating cutter, which cuts on its
flanks as well as its tip. Workpiece and cutter movement are precisely controlled to less than
0.001 in (0.025 mm), usually by means of precision ground slides and leadscrews or analogous
technology. Milling machines may be manually operated, mechanically automated, or digitally
automated via computer numerical control (CNC).
Milling machines can perform a vast number of operations, some very complex, such as slot and
keyway cutting, planning, drilling, die sinking, rebating, routing, etc. Cutting fluid is often pumped
to the cutting site to cool and lubricate the cut and to wash away the resulting swarf.

Types of milling machines

There are two main types of mill: the vertical mill and the horizontal mill. In the vertical mill the
spindle axis is vertically oriented. Milling cutters are held in the spindle and rotate on its axis. The
spindle can generally be extended (or the table can be raised/lowered, giving the same effect),
allowing plunge cuts and drilling. There are two subcategories of vertical mills: the bedmill and the
turret mill. Turret mills, like the ubiquitous Bridgeport, are generally smaller than bedmills, and are
considered by some to be 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 axis to
accomplish cutting. In the bed mill, however, the table moves only perpendicular to the spindle's
axis, while the spindle itself moves parallel to its own axis. Also of note is a lighter machine,
called a mill-drill. It is quite popular with hobbyists, due to its small size and lower price. These
are frequently of lower quality than other types of machines, however.
A horizontal mill has the same sort of x–y table, but the cutters are mounted on a horizontal arbor
across the table. A majority of horizontal mills also feature a +15/-15 degree rotary table that
allows milling at shallow angles. While endmills and the other types of tools available to a vertical
mill may be used in a horizontal mill, their real advantage lies in arbor-mounted cutters, called
side and face mills, which have a cross section rather like a circular saw, but are generally wider
and smaller in diameter. Because the cutters have good support from the arbor, quite heavy cuts
can be taken, enabling rapid material removal rates. These are used to mill grooves and slots.
Plain mills are used to shape flat surfaces. Several cutters may be ganged together on the arbor
to mill a complex shape of slots and planes. Special cutters can also cut grooves, bevels, radii, or
indeed any section desired. These specialty cutters tend to be expensive. Simplex mills have one
spindle, and duplex mills have two. It is also easier to cut gears on a horizontal mill.
A more complex form of the milling machine is the Universal milling machine, in which the rotating
cutter can be oriented vertically or horizontally, increasing the flexibility of the machine tool. The
table of the universal machine can be swiveled through a small angle (up to about 15 degrees),
enabling the axis of the spindle to coincide with the axis of a helix to be milled with the use of a
gear driven indexing attachment.

Milling machines are among the most versatile and useful machine tools due to their capabilities
to perform a variety of operations. They can be broadly classified into the following types:

 Column and knee type of milling machines

This is the most common milling machine, which has 5 basic components, They are the
work table, saddle, head, knee, and over arm. Considered as the simplest machine
type, its cutting device is vertically suspended to allow drilling of metals. This is
typically used when creating car parts because it is small and handy.

 Bed type

The worktable is located on the bed itself, instead of being paced on top, its usual
position. The knee part of the machine is omitted to allow movement in a
longitudinal direction.

 Rotary table

A rotary table is used in machining and metalworking. Machining is the general term for
creating mechanical devices used as tools to solve problems by forming
components for manufacturing. Metalworking is the general term for manipulating
metals for use in problem-solving and tool-making. A rotary table is a circular
surface that is mounted onto a milling machine or lathe. It provides precise
metalworking capabilities with specific measurements and the ability to rotate.
 Tracer controlled
This type of machine has the ability to reproduce parts based on a master model.
Most of the industrial sectors, especially the automotive industry, choose this type
of machine because it make production and specialization of machine parts easier.
With the vast classifications of milling machines, you need to choose the one you
need according to how you intend to use it. However if you find it difficult to
decide, do not hesitate to seek the help of a specialist who can help you select the
one that will give you maximum benefits.

Other milling machine variants and terminology

 Box or column mills are very basic hobbyist bench-mounted milling machines that feature
a head riding up and down on a column or box way.
 Turret or vertical ram mills are more commonly referred to as Bridgeport-type milling
machines. The spindle can be aligned in many different positions for a very versatile, if
somewhat less rigid machine.
 Knee mill or knee-and-column mill refers to any milling machine whose x-y table rides up
and down the column on a vertically adjustable knee. This includes Bridgeport.
 C-Frame mills are larger, industrial production mills. They feature a knee and fixed
spindle head that is only mobile vertically. They are typically much more powerful than a
turret mill, featuring a separate hydraulic motor for integral hydraulic power feeds in all
directions, and a twenty to fifty horsepower motor. Backlash eliminators are almost always
standard equipment. They use large NMTB 40 or 50 tooling. The tables on C-frame mills are
usually 18" by 68" or larger, to allow multiple parts to be machined at the same time.
 Planer-style mills are large mills built in the same configuration as planers except with a
milling spindle instead of a planing head. This term is growing dated as planers themselves
are largely a thing of the past.
 Bed mill refers to any milling machine where the spindle is on a pendant that moves up
and down to move the cutter into the work. These are generally more rigid than a knee mill.
 Ram type mill refers to a mill that has a swiveling cutting head mounted on a sliding ram.
The spindle can be oriented either vertically or horizontally, or anywhere in between. Van
Norman specialized in ram type mills through most of the 20th century, but since the advent
of CNC machines ram type mills are no longer made.
  Jig borers are vertical mills that are built to bore holes, and very light slot or face milling.
They are typically bed mills with a long spindle throw. The beds are more accurate, and the
hand wheels are graduated down to .0001" for precise hole placement.
 Horizontal boring mills are large, accurate bed horizontal mills that incorporate many
features from various machine tools. They are predominantly used to create large
manufacturing jigs, or to modify large, high precision parts. They have a spindle stroke of
several (usually between four and six) feet, and many are equipped with a tailstock to perform
very long boring operations without losing accuracy as the bore increases in depth. A typical
bed has X and Y travel, and is between three and four feet square with a rotary table or a
larger rectangle without a table. The pendant usually provides between four and eight feet of
vertical movement. Some mills have a large (30" or more) integral facing head. Right angle
rotary tables and vertical milling attachments are available for further flexibility.
 Floor mills have a row of rotary tables, and a horizontal pendant spindle mounted on a
set of tracks that runs parallel to the table row. These mills have predominantly been
converted to CNC, but some can still be found (if one can even find a used machine
available) under manual control. The spindle carriage moves to each individual table,
performs the machining operations, and moves to the next table while the previous table is
being set up for the next operation. Unlike other mills, floor mills have movable floor units. A
crane drops massive rotary tables, X-Y tables, etc., into position for machining, allowing large
and complex custom milling operations.

Parts of milling machine

• Base
The base of the machine is Grey iron casting accurately machined on its top and bottom surface
and serves as a foundation member for all the other parts which rest upon it. It carries the column
at its one end. In some machines, the bage is hollowed and working as a reservoir for cutting
fluid.

• Column
The column is the main supporting frame mounted vertically on the bage. The column is box
shaped. Heavily ribbed inside and houses all the driving mechanisms for the spindle and table
feed. The front vertical face of the column is accurately machined and is provided with dovetail
guide ways of supporting knee. The top of the column is finished to hold an over-arm that extends
outward at the front of the machine.

• Knee
The knee is the rigid gray iron casting that slides up and down on the vertical way of the column
face. The adjustment of height is effected by elevating screw on the base that also supports the
knee. The knee houses the feed mechanism of the table, and in different controls to operate it.
The top face of the knee forms slid way for the saddle to provide cross travel of the table.

• Saddle
The saddle is placed on the top of the knee, which slides on guide ways set exactly at 90 to
column face. A cross feed screw near the top of the knee engages a nut of the bottom of the
saddle to move it horizontally, by hand or power, to apply cross feed. The top of the saddle is
accurately machined to provide guide ways for the table.

• Table
The table rest on ways on the saddle and travels longitudinally. The top of the table is accurately
finished and T-slots are provided for clamping the work and other fixtures on it. A lead screw
under the table engages a nut on the saddle to move the table horizontally by hand or power. The
longitudinal travel of the table may be limited by fixing trip dogs on the side of the table. In
universal machines, the table may also be swiveled horizontally. For this purpose the table is
mounted on a circular bage which in its turn is mounted on the saddle. The circular bage is
graduated in the degree.

• Over hanging arm

Over hanging arm is mounted on the top of column extends beyond the column face and serve as
a bearing support may be provided nearest to the cutter. More than one bearing support may be
provided for the arbor.

Parallels or parallel bars, as they are sometimes called, are used primarily to raise the height of
the workpiece. Parallels are precision ground bars which will assure that the position of the
workpiece is parallel to the machine table surface or the bottom surface of the vise opening.

Milling-Machine Accessories and Attachments

The usual milling-machine attachments are the vise and the dividing head, both for holding work.
Milling-Machine Cutters, Arbors and Collets.

Parallel

Parallels or parallel bars, as they are sometimes called, are used primarily to raise the height of
the workpiece. Parallels are precision ground bars which will assure that the position of the
workpiece is parallel to the machine table surface or the bottom surface of the vise opening.

Vise

A vise is used for fixing of the material, and it is fixed to the table of the milling machine firmly. In
the case of the cutting of a large-sized material, the vise can be remived from the table. But when
the vise is installed again, it has to be fix accurately in the x-axis. We should not remove the vise
except unavoidable cases.
Dividing head
Dividing head or indexing head is a special work holding device, which is bolted on the machine
table. The work may be mounted on a chuck fitted on the dividing head spindle or may e
supported between a live and dead center. The dead center is mounted on a foot stock as in a
lathe tail stock that is bolted on the machine table after correctly aligning its spindle axis with the
dividing head spindle. The attachment is principally used for dividing the periphery f a work piece
in equal number of divisions for machining equally spaced slots, or groves. The worm and worm
gear driving mechanism of the attachment can be linked with the table lead screw for cutting
equally spaced helical grooves on the periphery of a cylindrical work piece.

Vertical head
Vertical head
The vertical milling attachment can converted a horizontal milling machine into a vertical milling
machine by orienting the cutt9ing spindle acids from horizontal to vertical for performing specific
operation. The attachments consist of a right angle gearbox, which is attached to the nose of the
horizontal milling machine spindle by bolting it on the column face. The speed of the vertical
spindle is same as that of the machine spindle. The attachment with the spindle can also be
swiveled at any angle other that at right angles to the table for machining angular surfaces.

Rotary table
Rotary table
Rotary table or circular milling attachment is especial work holding device, which is bolted on the
top of the machine table. It provides rotary motion to the table. The attachment consists of a
circular table having T-Slots mounted on the graduated base. The circular table may be rotated
by hand, and in special case by power by linking the rotary table driving mechanism with the
machine lead screw
 Slotting attachment
Slotting attachment
A slotting attachment converts the rotary motion of the spindle into reciprocating motion of the
ram by means of an eccentric or crank housed with in the attachment, thus a milling machine can
be converted into a slotter by accepting a single point slotted tool at the bottom end of the ram
and is conveniently used for cutting internal or external key ways, spines, etc. The attachment is
bolted on the face of the column and can also be swiveled at an angle for machining angular
surfaces. The length of stroke of the ram can also be adjusted.

Rack milling attachment

Rack milling attachment
A rack milling attachment is bolted to the face of the column and is used for cutting rack teeth on
a job mounted on the table. The attachment consisting of a gear train enables the spindle axis to
be oriented at rightly angles to the machine spindle. In a horizontal plan. The successive rack
teeth are cut by using a rack indexing attachment. The slanted rack teeth or skew rake may be
machined when the attachment is mounted on universal milling when the table may be swiveled
to the required helix angle

Milling cutters

There are 13 different kinds of milling cutters used in various milling machines. They each cut
materials differently. They are: end mill, roughing end mill, slab mill, face mill, hollow mill, slot drill,
ball nose cutter, side-and-face cutter, involute gear cutter, fly cutter, woodruff cutter, dovetail
cutter, and hob.
Milling cutters are essential cutting tools needed in a milling machine. Different types of milling
cutters are available in many sizes and shapes to efficiently perform any type of cutting work.
Read on to know the different types of milling cutters.

End mill

This is a tool with cutting teeth on one end and on its sides. Made of a high speed steel (HSS),
the end mill cutter is the most common tool used in a vertical milling machine.

Roughing end mill

A roughing end mill removes a huge chunk of material in a wavy cutting pattern. This cutting mill
produces a rough surface finish and is also known as ripping cutters. The wavy teeth minimize
the vibrations and chatter sounds that occur during the cutting process.

Slab mill

A cylindrical cutting tool that can be used individually or with other cutting tools for cutting
horizontal surfaces, the slab mill is made from a HSS.

Face mill

Face mill cutters are capable of holding multiple tip inserts. This economical type of cutting tool
has tips that are can be replaced when they become blunt. A face mill can perform various cutting
actions due to the versatility of the inserts and tips that it can work with.
Hollow mill

A hollow milling cutter is a pipe shaped tool with thick walls. The cutting teeth, however, are on
the inside surface area. This cutting tool is essentially used in finishing cylindrical protrusions.

Slot drill

A slot drill is a cutting tool that directly cuts straight into a material. It commonly has two or more
fluted cutters and a singular tooth located at the center of the end face. Slot drills are generally
used for making cuts in a keyway slot.

Ball nose cutter

The ball nose cutter is a hemispherical end cutter with a similar function to that of a slot drill. This
is an ideal cutting tool for machines that shapes three dimensional contouring forms and shapes.
Ball nose cutters are also commonly called ball mills.

Side-and-face cutter

The cutting of a side-and-face cutter is located on its circumference and side portion. They are
available in different widths and diameters. The side teeth functions to cut only one side of the
material.
Involute gear cutter

This twelve teeth cutting gear comes in eight cutter sizes. A circular cutting tool, it has cutting
edges on its circumference.

Fly cutter

A fly cutter is an inexpensive tool that functions like a face mill. It is composed of one or two tool
bits that rotate to remove shallow and facing cuts.

Woodruff cutter

Woodruff cutters are small tip cutters that are used in cutting keyways. It is an essential tool in
key engineering.
Dovetail cutter

Dovetail cutters are cutting tools that produce a dovetail slot patterns.

Hob

Hobs are cutters used in a hobbing machine. These cutters are used to make gears abd provide
the appropriate shape specification of each workpiece. It is also important to consider the least
cost and the correct cutting specifications of a cutting work when choosing a milling cutter.
Remember to always work safely with the every cutting tool.

Safety for using milling machine

• Wear appropriate safety glasses.

• Ensure that the milling machine has a start/stop button within easy reach of the operator.
• Ensure that the work piece and cutter are mounted securely before taking a cut.
• Check that work is mounted squarely.

• Mount work in a vise that is bolted or held magnetically to the table. Use proper hand
tools to make adjustments. Refer to Hand Tools for more information.
• Hold milling cutters with a cloth to avoid being cut when handling them.
• Move table as far as possible from cutter while setting up work to avoid injuring your
hands.
• Mill the largest surface first.
• Keep hands, brushes and rags away from the revolving milling cutter.
• Use a vacuum, brush or rake to remove cuttings only after the cutters have stopped
moving.
• Change cutting compounds periodically.
• Keep cutters sharpened correctly and in good condition.
• Keep working surface clear of scraps, tools and materials.
• Keep floor around the milling machine free of oil and grease.
• Use lifting equipment when appropriate to move heavy work to or from milling machines.
Refer to Materials Handling for more information.
Before starting the machine, what should you check?

Before starting, make sure that:

• all guards are in place

• work is properly secured in place
• bolts used to hold down work clear the tooling
• tooling and supporting pieces are properly tightened in position
• table stops are secured properly
• handles on all feed screws are in neutral
• table is free of stock, tools or other loose material
• the arbor and arbor support are clear of the work

What should you consider when setting the cutting speed?

Ensure that the following factors are considered when setting cutting speed:

• material to be machined
• type of cutter
• finish required
• depth of cut
• rigidity of machine and work piece

What are some things you should avoid doing?

• Do not wear gloves, rings, watches or loose clothing. Tie back long hair.
• Do not attempt to mount, measure or adjust work until cutter is completely stopped.
• Do not use an excessively heavy cut or feed as it can cause the cutter to break. The
flying pieces could cause serious injury.
• Do not reach over or near a revolving cutter. Keep hands at least 30 cm (12 in.) from a
revolving cutter.
• Do not lean or rest hands on a moving table.
• Do not make any adjustments while the machine is running.
• Do not use paper shims to check the distance from the cutter to the stock.
• Do not move the operating levers without knowing what they control and what action is
going to take place.
• Do not leave machine unattended while it is run