Arab Academy for Science, Technology,

and Maritime Transport

Material Removal Processes (IM 213)

Department of Industrial & Management Engineering

College of Engineering and Technology

Lecture 5: Milling Processes

Milling
 Milling is a machining by cutting process where the cutting
tool carries out rotatory motion and the workpiece a linear
motion.
 The process is used to machine external surfaces, slots,
contoured surfaces, threads and gears.
 Types of milling :
1- Horizontal Milling (Plain).
 UP Milling.
 Down Milling.
2- Vertical Milling (Face).

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Products of Milling

3
 1-Plain (Horizontal) Milling

bw

Plain milling cutters

.

4
Horizontal Milling Cutter

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Features
 The cutting teeth are arranged on the
surface of the cylindrical tool
 There is a contact between the cylindrical
surface of the cutter and the machined
surface
 The machined surface is parallel to the
cutter axis of rotation

Horizontal
Milling
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Milling Cutters

bw
t

t bw

Side milling cutters

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Milling Cutters

t
t

bw bw

Milling saw Angle milling cutter

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Form Milling Cutters

t
t

bw bw

Convex cutter Concave cutter

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Up and Down Milling

Up Milling Down Milling

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Up and Down Milling

Milling cutter

WP WP

Feed Feed

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 Advantages of Up Milling

 Does not require backlash eliminator in the milling

machine.
 Safer in operation due to the separating forces
between the cutter and workpiece.
 Fragments of BUE are absent from the milled
surfaces.
 The life of the cutter is not affected by the sandy or
scaly surfaces.
 Loads are not acting suddenly on the teeth.
 Looseness in moving parts are not detrimental to
the cutting motion.

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Advantages of Down Milling
 It is possible to use simplified fixtures to mill
parts that cannot be easily held on the
machine.
 Milled surfaces are not affected by the
revolution marks and are easily polished.
 Requires lower machining power.
 The tendency of vibrations and chattering is
low.
 Cutting edge blunting is less possible.
 Leads to better surface quality.
 Requires more rigid equipment
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General Comment
 Down milling is preferred since it provides
favorable cutting conditions that lead to better
surface quality.
 However, it requires more rigid equipment
without looseness in the feeding mechanism
because the cutter tends to climb on the
workpiece.

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Cutting Speed and W.P Feed
 d= outer diameter of the milling cutter
 N= rotational speed (rev/min)
 f= feed rate (mm/min)
 s= feed per revolution
 Zc= number of teeth per cutter
 t= depth of cut
 he=maximum chip thickness

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Cutting Speed and W.P Feed
The cutting speed V

 .d .N
V m/min
1000
In case of the linear workpiece feed rate f in mm/min, and a
milling cutter having Zc teeth, the feed per revolution S equals

f
S
N
mm/rev
The feed per tooth Sz in mm/tooth becomes;

f
S  mm/tooth 16
z
NZ
c
Chip Formation-Plain Milling

d, Zc

Sz
bw

d/2- t
2.f t
t h 
e NZ d
c
Feed, f

Sz
Sz
c
c
hm 2 he
Maximum Chip Thickness
Assuming a straight tooth cutter, the contact angle between
the workpiece material and the tooth 
c
d 2t 2t
cos   OR cos  1 
c c
d 2 d

The maximum chip thickness, he can be calculated from,

h f
sin  e h  S sin  sin
c S e z c N .Z c
z
c
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Maximum Chip Thickness

BUT

2t 2 t
sin  1  (1  ) sin  2
c d c d

f 2. f t
h  sin h 
e N .Z c
c e NZ d
c

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Maximum Force/tooth
 Ks= specific cutting energy (N/mm2)
 Fe=Max. tangential force on a single tooth (N)
 bw= W.P Width (mm)
 l= W.P Length (mm)
 Ze= number of tooth cutting simultaneously.

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Maximum Force/tooth
The maximum tangential force on a single tooth is

F  k .b .h
e s w e N/tooth

2.f t
h  mm
e NZ d
c

2f t
F k b N/tooth
e s w NZ d
c
Mean Tangential Force/tooth

F  k .b .h
m s w m N/tooth

h  h /2
m e mm

• hm = mean chip thickness =0.5 maximum chip thickness

f t
F  k .b N/tooth
m s w N.Z d
c 22
Number of Teeth Cutting
Simultaneously

Z t
Z  c
e  d

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Number of Active Teeth

 t
Z  c Z c  sin  sin  2
c
e 2. c c d

Z Where 
t c is contact angle,
Z  c
e  d Zc is the number of cutter teeth

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Total Mean Force & Power

k .t. f .b
F  s w
N
mt  .d .N
F V
mt
N  kW
c 3
60x10

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Motor Power & VRR

N
N  c
m  kW
m

VRR  f .t.b mm3/min

w

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Surface Roughness (Horizontal Milling)

S 2
R  z
t 4d

f
S 
z
NZ
c

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Why Practical Roughness Differs From
Theoretical Ones?

 Run-out of the milling cutter tooth tips due

to the sharpening and mounting errors, bent
arbor, and its varying rigidity.
 Rounding of the cutting edge and tooth
wear.
 Irregularities of the cutting edge.
 Built up edge formation.
 Vibrations of the machine tool and
workpiece-tool systems.

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Factors Affecting Surface Roughness

 Workpiece feed rate f

 Number of cutter teeth Zc,
 Cutter rotational speed N.
 Workpiece material
 Cutter material
 Tooth shape
 Coolant type, and the method of coolant
application.

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Milling Time

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Machining Time Calculation
L
t  m L  l l l
m min m a o mm
f
Lm: total length of cutter travel, mm
la : length of cutter approach, mm
l : length of the surface being milled, mm
lo : length of cutter overrun, mm

l  l    t (d  t ) mm CORRECTION
a o

 ranges between 2 to 5 mm OR 1.5% of “l”

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t  (l  2(  t (d  t ) ) / S .Z .N
m z c
2-FACE (VERTICAL) MILLING

bw

Face milling cutter

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 Features
 The cutting edges are situated on the face of
the end mill and, partially, on its cylindrical
surface.
 There is a contact between the face of the
milling cutter and the machined surface.
 The milled surface is generated at right
angle to the cutter axis of rotation

Vertical
Milling
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End Mills

bw

t
d

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Face Milling Operations

Full face milling Part face milling

Unilateral Bilateral

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 Face Milling Operations
 Full-face milling: when the milling width is equal to
the milling cutter diameter.

 Part-face milling: when the milling width is smaller

than the cutter diameter d.
1. Unidirectional part-face: when the milling cutter
protrudes beyond the workpiece surface in one side.
2. Bilateral part-face: when the milling cutter
protrudes beyond the workpiece surface in two
sides. This may be symmetrical or nonsymmetrical.

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