Experiment No.

1-b Advanced Manufacturing Processes

Experiment No. 1- b
1.0 Title of Experiment: -
Study of Milling Cutters.

2.0 Prior Concept: -

1. Single point cutting tools used for turning and
shaping operations.
2. Geometry of single point cutting tool.

3.0 New Concept: -

Rotating cutter having multi point cutting edges removes more volume of metal in short time.

4.0 Learning Objectives: -

Intellectual : -

Principle of milling process.

Types of milling cutters.

Selection of milling cutter shape and size.

Form milling cutter and their use.

Various constructions of milling cutters.
Motor skill: -

Mounting of cutters in correct position & checking it.

5.0 Lab Experiment: -

In Workshop student should be shown the available milling cutters and collect catalogues of milling
cutters & they will fill up the following table selecting cutters from the catalogue.

Job Type of Cutter to be used Size of cutter Remark

6 o MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

Advanced Manufacturing Processes Experiment No. 1-b

6.0 Questions: - (Attempt 3-5 questions as directed by teacher)

1. While selecting cutters for the operations shown above. List the factors you have considered?
2. What are the advantages of carbide tipped milling cutter?
3. Give reason- Why inserted teeth type-milling cutters preferred to solid cutters?
4. Explain the precautions you will take while mounting cutter on the machine.
5. State the use of feather key & spacers while mounting cutter.
6. Form cutters are used for cutting profiles - Give reasons.
7. From your store, get one milling cutter and sketch the geometry and give nomenclature.
8. State the formula for finding R.P.M of milling cutter required.
9. Study the different types of milling cutters and redraw any five of the following.

Milling Cutters
Plain Milling Cutters: -

Plain milling cutters (shell end mills) have only peripheral

cutting edges.
Used for roughing and finishing of plain surfaces on the
horizontal milling machines.

Interlocking plain milling cutters with helical teeth directed

against each other have the advantage that the axial
pressure is partly compensated.

Shell end mills have teeth on the periphery and also on one
end. Used for milling plain surfaces and rectangular
shoulders on the horizontal and vertical milling machines.

Side Milling Cutters: -

a) Circular saw, used for cutting off and for milling of narrow
slots.
b) Slotting cutters with straight teeth, used for milling of
shallow slots. To present side friction both side are ground
hollow.

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION o 7

Experiment No. 1-b Advanced Manufacturing Processes

Side Milling Cutters: -

C and d are side-milling cutters suitable for milling deeper

slots.

Straddle milling cutters, used for straddle milling process.

Milling Cutters with Shank: -

Milling cutters with shank. a) Shank -type are end mills with small diameter. The shank is used for
chucking. Right-hand end mills with right-hand spiral or left-hand end mills with left-hand spiral can
be pulled out of the cutter spindle by axial pressure. To prevent this, the cutter shank h2s a draw-in
screw thread, which is used for fastening the tool in the cutter spindle. Shank-type cutters with tang
are usually used just for light cuts. b) T-slot cutters are suitable for milling of T-slots. c) Two-lipped
end mills (slotting drills) have two cutting edges and are used for milling of slots and oblong holes.

Form Milling Cutters: -

8 o MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

Advanced Manufacturing Processes Experiment No. 1-b

Form (profile) milling cutters. a) Angle milling cutters are necessary for milling of vee-guides. b)
Dove-tail milling cutters are used for manufacturing of dovetail guides. c) Single-edged milling
cutters are used for smaller profile milling work.

Mounting of Milling Cutters

Cutters with Through Hole: -

Cutter with through hole is mounted on arbor.

The cutter is connected with the arbor by a feather key and held in its position by the spacers.

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION o 9

Experiment No. 1-b Advanced Manufacturing Processes

Cutters with Through Hole: -

Big inserted cutters will be mounted on the outside taper of the cutter spindle. For tight
connection with the milling spindle driving lugs a) and draw-in bolts b) are used.

Cutters with Through Hole: -

Small inserted teeth cutters and
Shell end mills are fastened on a shell end
mill arbor a) with a feather key b) on cotter
c).
Taper shank end mills will be
pushed into the taper hole of the mill
-ing spindle and held with a draw-in
bar. For mounting of smaller
an adapter a) is used.

Checking for concentric running. The rotating milling cutter should have a beat not more than 0.05
mm. The dial indicator is used for checking. The milling spindle is turned backward slowly by hand
for this purpose.

10 o MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

Advanced Manufacturing Processes Experiment No. 1-b

Rules for Mounting Cutters:

1. The proper cutter and corresponding milling arbor must be selected; feather key must not
be forgotten.
2. Tapers on milling arbor and milling spindle head must be protected against damage.
3. Before the assembly, all fitting surfaces have to be cleaned, e.g. milling arbor, taper on
spindle head, spacers and milling cutters (true running).
4. The rotary direction of the milling machine and cutting direction of milling cutter must
correspond with each other (breakage of cutter).
5. The axial force of spiral toothed milling cutters must be directed against milling spindle.

(Space for answer)

MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION o 11

Experiment No. 1-b Advanced Manufacturing Processes

(Space for answer)

12 o MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION