EX.

NO:08

DATE:

8. STUDY OF MILLING MACHINE

AIM

To study the construction details and working principle of milling machine.

INTRODUCTION
Milling is a machining operation in which a work part is fed past a rotating cylindrical tool with
multiple cutting edges. The axis of rotation of the cutting tool is perpendicular to the direction of
feed. This orientation between the tool axis and the feed direction is one of the features that
distinguish milling from drilling. In drilling, the cutting tool is fed in a direction parallel to its
axis of rotation. The cutting tool in milling is called a milling cutter and the cutting edges are
called teeth. The machine tool that traditionally performs this operation is a milling machine.

The geometric form created by milling is a plane surface. Other work geometries can be created
either by means of the cutter path or the cutter shape. Owing to the variety of shapes possible and
its high production rates, milling is one of the most versatile and widely used machining
operations.
MILLING MACHINES
Milling machines must provide a rotating spindle for the cutter and a table for fastening,
positioning, and feeding the work part. Milling machines can be classified as horizontal or
vertical.

A horizontal milling machine has a horizontal spindle, and this design is well-suited for
performing peripheral milling (e.g., slab milling, slotting, side and straddle milling) on work
parts that are roughly cube-shaped.
A vertical milling machine has a vertical spindle, and this orientation is appropriate for face
milling, end milling, surface contouring, and die sinking on relatively flat work parts. The Type
of milling machines are shown in Fig. 1.1:

Fig 1.1 Type of Milling Machine

PRINCIPAL PARTS OF A MILLING MACHINE

1. Base: It is the foundation of the machine upon which all other parts are mounted. It is
generally made of grey cast iron to absorb shock and vibration. Sometime it also serves as a
reservoir for cutting fluid.

2. Column: It is the main supporting frame mounted vertically on one side of the base. The motor
and other driving mechanisms are contained in it. It supports and guides the knee in its vertical
travel. It carries the jack for elevating the knee.

3. Knee: The Knee projects from the column and slides up and down on its face. It supports the
saddle and table. It is partially supported by the elevating screw which adjusts its height. It
carries the table feed mechanism and controls to feed in longitudinal, cross, vertical, and rotation
etc., by hand power or machine power.

4. Saddle: The saddle supports and carries the table and is adjustable transversely on ways on top
of the knee. It is provided with graduation for exact movement and can be operated by hand or
power.

5. Table: The table rests on ways on the saddle and travels longitudinally in a horizontal plane. It
supports the work pieces fixtures etc.

DIRECTION OF FEED

One final consideration concerning feed is the direction in which the work is fed into the cutter.
The most commonly used method is to feed the work against the rotation direction of the cutter
(conventional or up milling) (Fig. 1.2a). However, if the machine is equipped with a backlash
eliminator, certain types of work can best be milled by climb milling (Fig. 1.2b).

Fig. 1.2 Direction of Feed

Climb milling, which can increase cutter life up to 50 percent, is effective for most milling
applications. To know whether climb or conventional milling is being used, look at the
relationship between the cutter rotation and the direction of the machine table/work feed. Climb
milling is being used when the cutter and the work piece are going in the same direction (Fig.
1.2b). Conventional milling is when the cutter and the work piece are going in opposite
directions.
TYPES OF MILLING OPERATIONS
There are two basic types of milling operations, shown in Figure 1.3: (a) peripheral milling and
(b) face milling.

Fig, 1.3 Milling Operations

a) Peripheral Milling
In peripheral milling, also called plain milling, the axis of the tool is parallel to the surface being
machined, and the operation is performed by cutting edges on the outside periphery of the cutter.
Several types of peripheral milling are shown in Figure 1.4:

Fig. 1.4 Peripheral Milling

b) Face Milling
In face milling, the axis of the cutter is perpendicular to the surface being milled, and machining
is performed by cutting edges on both the end and outside periphery of the cutter. As in
peripheral milling, various forms of face milling exist, several of which are shown in Figure 1.5:
 Fig. 1.5 Face Milling

WORK HOLDING DEVICES ON THE MILLING MACHINE

1. Vise
The most common method of work holding on a milling machine is a vise. Vises are simple to
use and can quickly be adjusted to the size of the work piece. A vise should be used to hold work
with parallel sides if it is within the size limits of the vise.

2. V Blocks
V-Blocks hold and support round work for milling or drilling, V-Blocks come in many different
sizes. On milling machines, V-Blocks are typically clamped directly to the table.

3. Angles Plates
An angle plate is an L shaped piece of Cast Iron or Steel that has tapped holes or slots to
facilitate the clamping of the work piece.

4. Parallels

Parallels are pieces of steel bar stock accurately machines so that the opposing sides are parallel
to each other.

5. Clamps

Work that is too large or has an odd configuration is usually bolted directly to the table

This method of work holding takes the most ingenuity and expertise.

PRECAUTIONS:

1. The milling machine must be stopped before setting up or removing a work piece, cutter or
other accessory

2. Never stop the feeding of job when the cutting operation is going on, otherwise the tool will
cut deeper at the point where feed is stopped.
3. All the chips should be removed from the cutter. A wiping cloth should be placed on the cutter
to protect the hands.

4. The cutter should be rotated in the clockwise direction only for right handed tools.

5. The work piece and cutter should be kept as cool as possible (i.e. coolant should be used
where necessary to minimize heat absorption).

6. The table surface should be protected with a wiping cloth.

7. Tool must be mounted as close to the machine spindle as possible.

Result:
EX.NO: 09
DATE:
9. SURFACE MILLING

AIM:
To Machine a flat surface using milling machine (Conventional /Climb Method).
MATERIALS REQUIRED:
Work piece of required dimensions.
TOOLS REQUIRED:
Milling machine, Vernier caliper,

SKETCH:

In Peripheral Milling, Milled Surface is parallel To Cutter Axis. In Up milling or conventional

milling cutter rotates opposite to direction of feed of work piece. In down milling or climb
milling cutter rotates in same direction of travel of work piece.
PROCEDURE:
1. Before setting up a job, be sure that the work piece, table, the taper in the spindle, and the
arbor or cutter shank are free from chips, nicks, or burrs. Do not
select a milling cutter of larger diameter than is necessary.
2. Check the machine to see if it is in good running order and properly lubricated, and that it
moves freely, but not too freely in all directions.
3. Consider direction of rotation. Many cutters can be reversed on the arbor, so be sure you know
whether the spindle is to rotate clockwise or counterclockwise.
4. Feed the work piece in a direction opposite the rotation of the milling cutter (conventional
milling).Do not change feeds or speeds while the milling machine is in operation. When using
clamps to secure a workpiece, be sure that they are
tight and that the piece is held so it will not spring or vibrate under cut.
5. Use recommended cutting oil liberally. Use good judgment and common sense in planning
every job.
6. Set up every job as close to the milling machine spindle as circumstances will permit.
RESULT:
Thus a flat surface is machined to required dimensions using milling machine.

EX.NO: 10

DATE:
10. GEAR CUTTING

AIM:
To machine a spur gear to the given module and number of teeth in the given work piece.
MATERIALS REQUIRED:
Blank of Dia 50 mm and length 50 mm
TOOLS REQUIRED:
Milling machine, Vernier caliper, Mandrel.

SKETCH:

PROCEDURE:
1. Calculate the gear tooth proportions.
Blank diameter = ( Z + 2) m
Tooth depth = 2.25 m
Tooth width = 1.5708 m where, Z = Number of teeth required, m = module
2. Indexing calculation Index crank movement = 40 / Z
3. The dividing head and the tail stock are bolted on the machine table. Their axis must be set
parallel to the machine table.
4. The gear blank is held between the dividing head and tailstock using a mandrel. The mandrel
is connected with the spindle of dividing head by a carrier and catch plate.
5. The cutter is mounted on the arbor. The cutter is centered accurately with the gear blank.
6. Set the speed and feed for machining.
7. For giving depth of cut, the table is raised till the periphery of the gear blank just touches the
cutter.
8. The micrometer dial of vertical feed screw is set to zero in this position.
9. Then the table is raised further to give the required depth of cut.
10. The machine is started and feed is given to the table to cut the first groove of the blank.
11. After the cut, the table is brought back to the starting position.
12. Then the gear blank is indexed for the next tooth space.
13. This is continued till all the gear teeth are cut.

CALCULATION:

Z = No. of teeth = 23
m = module = 2 mm
Blank Diameter = (Z + 2) m= (23 + 2) 2 = 50 mm
Tooth Depth = 2.25 m= 2.25 * 2 = 4.5 mm
Indexing Calculation = 40 / Z = 40 / 23 = 1 17/23

RESULT:

Thus the required gear is machined using the milling machine to the required number of teeth.