MACHINING PROCESSES AND MACHINE

TOOLS

Unit 4 - MILLING
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MILLING MACHINE
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MILLING MACHINE
Introduction

• Milling is the cutting operation that removes metal by

feeding the work against a rotating cutter having single
or multiple cutting edges.
• Flat or curved surfaces of many shapes can be
machined by milling with good finish and accuracy.
• A milling machine may also be used for drilling, slotting,
making a circular profile and gear cutting by having
suitable attachments.
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MILLING MACHINE
Working Principle
• The work piece is holding on the worktable of the machine.
• The table movement controls the feed of work piece against
the rotating cutter.
• The cutter is mounted on a spindle or arbor and revolves at
high speed.
• Except for rotation the cutter has no other motion.
• As the work piece advances, the cutter teeth remove the metal
from the surface of work piece and the desired shape is
produced.
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MILLING MACHINE
Introduction
MILLING METHODS
• There are two distinct methods of milling classified as
follows:
1. Up-milling or conventional milling, and
2. Down milling or climb milling.
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UP-Milling or Conventional Milling Procedure

• In the up-milling or conventional milling, the metal is
removed in form of small chips by a cutter rotating against
the direction of travel of the workpiece.
• In this type of milling, the chip thickness is minimum at the
start of the cut and maximum at the end of cut.
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Down-Milling or Climb Milling

• Down milling is also known as climb milling.
• In this method, the metal is removed by a cutter rotating in
the same direction of feed of the workpiece.
• The effect of this is that the teeth cut downward instead of
upwards.
• Chip thickness is maximum at the start of the cut and
minimum in the end.
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MILLING MACHINE
Horizontal Milling Machine Construction

The main part of machine is

Base,
Column,
Knee,
Saddle,
Table,
Overarm,

Arbor Support and Elevating

Screw.
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MILLING MACHINE
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MILLING MACHINE
Construction
Base:
• It gives support and rigidity to the machine and also acts as a
reservoir for the cutting fluids.
Column:
• The column is the main supporting frame mounted vertically
on the base.
• The column is box shaped, heavily ribbed inside and houses
all the driving mechanisms for the spindle and table feed.
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MILLING MACHINE
Construction
Knee:
• The knee is a rigid casting mounted on the front face of
the column.
• The knee moves vertically along the guide ways and this
movement enables to adjust the distance between the
cutter and the job mounted on the table.
• The adjustment is obtained manually or automatically by
operating the elevating screw provided below the knee.
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MILLING MACHINE
Construction

Saddle:
• The saddle rests on the knee and constitutes the
intermediate part between the knee and the table.
• The saddle moves transversely, i.e., crosswise (in or out)
on guide ways provided on the knee.
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MILLING MACHINE
Construction
Overarm:
• The Overarm is mounted at the top of the column and is guided in perfect
alignment by the machined surfaces. The Overarm is the support for the
arbor.

Arbor support:
• The arbor support is fitted to the Overarm and can be clamped at any
location on the Overarm. Its function is to align and support various
arbors. The arbor is a machined shaft that holds and drives the cutters.
Elevating screw:

• The upward and downward movement to the knee and the table is given
by the elevating screw that is operated by hand or an automatic feed.
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MILLING MACHINE
Construction

Table:
• The table rests on guide ways in the saddle and
provides support to the work.
• The table is made of cast iron, its top surface is
accurately machined and carriers T-slots which
accommodate the clamping bolt for fixing the work.
• The worktable and hence the job fitted on it is given
motions in three directions:
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TYPES OF MILLING MACHINES

• According to general design, the distinctive types of milling
machines are
1. Column and knee type milling machines
(a) Hand milling machine
(b) Horizontal milling machine
(c) Universal milling machine
(d) Vertical milling machine
2. Planer milling machine
3. Fixed-bed type milling machine
(a) Simplex milling machine.
(b) Duplex milling machine.
(c) Triplex milling machine.
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TYPES OF MILLING MACHINES

• According to general design, the distinctive types of milling
machines are,
4. Machining center machines
5. Special types of milling machines
(a) Rotary table milling machine.
(b) Planetary milling machine.
(c) Profiling machine.
(d) Duplicating machine.
(e) Pantograph milling machine.
(f) Continuous milling machine.
(g) Drum milling machine
(h) Profiling and tracer controlled milling machine
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TYPES OF MILLING MACHINES

Column and knee type milling machines
Vertical milling machine Horizontal milling machine
 38-102

Horizontal Milling Machine

 38-103

Vertical Milling Machine

 38-104

Omniversal Milling Machine

 38-105

Fixed Bed Type Milling Machine

 38-106

Duplex Head Milling Machine

 38-107

Plano type Milling Machine

 Special Purpose Milling Machin
38-

e
1 08

1.Rotary Milling Machine

Drum Type Milling Machine 38-109
 38-110

Work holding devices

• T bolt and clamps
• Angle plates
• V blocks
• Machine vices
• Milling fixture
• Dividing heads ( Indexing Head)
 38-111

Indexing head
 38-112

Tool (or) cutter holding Devices

• Arbors
Standard arbor
Stub arbor
• Adaptors.
• collets
 38-113

Arbor
Standard Stub
arbor arbor
 38-114

Adaptor
 38-115

Spring collet
 CNC Vertical Mill

Head Column

Saddle Table

Knee
Spindle Speed
 CNC Vertical Mill: Axes & Tools
Spindle

Tool Holder
+ Z-axis

Cutter

Alternate
Tools (in
quick-
change + X-axis
magazine)

Air Vise
– Y-axis
Milling Parameters Illustrated

Two forms of milling: (a) peripheral milling, and (b) face milling
OPERATIONS PERFORMED ON MILLING MACHINE

Slab / Plain Milling

The basic form of
peripheral milling in
which the cutter width
extends beyond the
workpiece on both sides
slab milling
OPERATIONS PERFORMED ON MILLING MACHINE

Slotting
Width of cutter is less
than workpiece width,
creating a slot in the
work

slotting
OPERATIONS PERFORMED ON MILLING MACHINE
Conventional Face Milling

Cutter overhangs work

on both sides

conventional face milling

OPERATIONS PERFORMED ON MILLING MACHINE
End Milling

Cutter diameter is
less than work
width, so a slot is
cut into part

End milling
OPERATIONS PERFORMED ON MILLING MACHINE
Profile Milling

A form of end
milling in which the
outside periphery
of a flat part is cut

Profile milling
OPERATIONS PERFORMED ON MILLING MACHINE
Pocket Milling

Another form of
end milling used
to mill shallow
pockets into flat
parts

Pocket milling
OPERATIONS PERFORMED ON MILLING MACHINE
Surface Contouring
Ball-nose cutter is fed
back and forth across the
work along a curvilinear
path at close intervals to
create a three
dimensional surface form

Surface contouring
MILLING CUTTERS
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MILLING MACHINE - TYPES OF MILLING CUTTERS

Plain milling cutter Shell end mill Side milling cutter

End Metal- saw Angle milling Form milling

mill slitting cutter
Types of milling cutters
Plain Milling Cutters
• Most widely used
• Cylinder of high-speed steel with teeth cut on periphery
• Used to produce flat surface
Several types
• Light-duty
• Light-duty helical
• Heavy-duty
• High-helix
Light-Duty Plain Milling Cutter
• Less than ¾ in. wide, straight
teeth
• Used for light milling
operations
• Those over ¾ in have helix
angle of 25°
• Too many teeth to permit chip
clearance
Heavy-Duty Plain Milling Cutters
• Have fewer teeth than light-duty type
• Provide for better chip clearance

• Helix angle varies up to 45°

• Produces smoother surface because of shearing action and reduced
chatter

• Less power required

High-Helix Plain Milling Cutters
• Have helix angles from 45° to over 60 °
• Suited to milling of wide and intermittent surfaces
on contour and profile milling
• Usually mounted on milling machine arbor
• Sometimes shank-mounted with pilot on end and
used for milling and gated slots.
Standard Shank-Type Helical Milling Cutters
• Also called as arbor-type cutters
Used for
• Milling forms from solid metal
• Removing inner sections from solids
• Inserted through previously drilled hole and
supported at outer end with type A arbor support
Side Milling Cutters
• Comparatively narrow cylindrical milling cutters with
teeth on each side and on periphery
Straight
• Used for cutting slots and
for face and straddle milling
operations
• Free cutting action at high
speeds and feeds
• Suited for milling deep, narrow slots
Staggered
Half-Side Milling Cutters
• Used when only one side of cutter required
• Also make with interlocking faces so two cutter
may be placed side by side for slot milling
• Have considerable rake
• Able to take heavy cuts.
Face Milling Cutters
• Generally over 6 in. in diameter
• Have inserted teeth made of high-speed
steel held in place by wedging device
• Most cutting action occurs
at beveled corners and
periphery of cutter
• Makes roughing and finishing cuts in
one pass
 Shell End Mills
• Face milling cutters under 6 in.
• Solid, multiple-tooth cutters
with teeth on face and
periphery
• Held on stub arbor
• May be threaded or use key in
shank to drive cutter
Angular Cutters
Single-angle
▫Teeth on angular surface
▫May or may not have teeth on flat
▫45° or 60°

Double-angle
▫Two intersecting angular surfaces
with cutting teeth on both
▫Equal angles on both side of line
at right angle to axis
Types of Formed Cutters

Concave Convex Gear Tooth

Metal-Slitting Saws
T-Slot Cutter
• Used to cut wide horizontal groove at bottom of T-
slot
• After narrow vertical groove machined with end mill or side
milling cutter
• Consists of small side milling cutter with teeth on
both sides and integral shank for mounting
Dovetail Cutter
• Similar to single-angle milling cutter with integral
shank
• Used to form sides of dovetail after tongue or groove
machined
• Obtained with 45º, 50º, 55º, or 60º angles
Woodruff Key seat Cutter
•Similar in design to plain and side milling cutters
• Small (up to 2 in) solid shank, straight teeth
• Large mounted on arbor with staggered teeth
•Used for milling semi cylindrical key seats in
shafts
• Designated by number system
MILLING CUTTER Nomenclature
 68-144

Index Head Parts

• Headstock with index plates • Universal chuck

• Headstock change gears • Footstock
• Quadrant • Center rest
A – large index
plate
B - crank
C – small index
plate
D - crank

G – gear housing
Machining Calculations: Milling

• Spindle Speed - N v (rpm)

N
π D
v = cutting speed
D = cutter
diameter
• Feed Rate - fr (mm/min -or- in/min)
fr  nt f
Ntooth
f = feed per
nt = number of
teeth
Machining Calculations: Milling
• Machining Time - Tm (min)
L  d D - d 
▫ Slab Milling: Tm 
fr -or-
L = length of cut
d = depth of cut
L  2 wD - w
Tm 
▫ Face Milling: fr
w = width of cut LD
2 form is multi-pass Tm 
nd
fr
• Material Removal Rate - MRR
(mm3/min -or- in3/min)
MRR  w d fr
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GEAR GENERATION AND FINISHING

OPERATIONS
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INTRODUCTION
• Gear is one of the important machine tool
elements which is an integral and inevitable part
of power transmission system.
• A gear is a round blank having teeth along its
periphery.
• Gears are used to transfer power or torque from
prime mover to the place where it is to be used.
• Along with the transmission of power gears also
transfer the accurate velocity ratio between two
shafts.
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INTRODUCTION
• Power Transfer between Driver and Driven
Gears
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METHOD OF GEAR MANUFACTURING

• In broader sense the gears can be manufactured by
the following three methods.
(a) Casting
(b) Plastic Moulding
(c) Machining
Gear Forming
Gears Shaping
(a) Gear cutting by gear shaper.
(b) Rack planning process.
(c) Hobbing process
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METHOD OF GEAR MANUFACTURING

Gear forming- where the profile of the teeth are
obtained as the replica of the form of the cutting tool
(edge); e.g., milling, broaching etc.

Gear generation- where the complicated tooth profile

are provided by much simpler form cutting tool (edges)
through rolling type, tool – work
motions, e.g., hobbing, gear shaping etc
 METHOD OF GEAR MANUFACTURING

In broader sense the gears can be manufactured by

the following three methods.
(a)Casting
(b)Plastic Moulding
(c)Machining
(a) Gear Forming – Gear Cutter
(b) Gear Generation – Gear Hobber
GEAR FORMING
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Gear Shaping :
1.Gear Cutting by Gear Shaper
• Process of Gear Cutting by Shaper Cutter
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Gear Cutting by Gear Shaper

• Setup for Gear Shaping Machine
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Gear Cutting by Gear Shaper

Advantages of Gear Shaping Process
• Shorter product cycle time and suitable for making
medium and large sized gears in mass production.
• Different types of gears can be made except worm
and worm wheels.
• Close tolerance in gear cutting can be maintained.
• Accuracy and repeatability of gear tooth profile can
be maintained comfortably.
• For same value of gear tooth module a single type
of cutter can be used irrespective of number of
teeth in the gear.
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Gear Cutting by Gear Shaper

Limitations of Gear Shaping Process
• It cannot be used to make worm and work wheel
which is a particular type of gear.
• There is no cutting in the return stroke of the gear
cutter, so there is a need to make return stroke
faster than the cutting stroke.
• In case of cutting of helical gears, a specially
designed guide containing a particular helix and
helix angle, corresponding to the teeth to be made,
is always needed on urgent basis.
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2. Gear Shaping by Rack Shaped Cutter

• Gear Cutting by Rack Shaped Cutter
 160

2. Gear Shaping by Rack Shaped Cutter

• Rack Planning Process
• This process is used for shaping of spur and helical
gear teeth with the help of a rack type cutter.
 161

3. Gear Hobbing Process

 162

3. Gear Hobbing Process

 163

3. Gear Hobbing Process

• Setup for Gear Hobbing Machine
 164

3. Gear Hobbing Process

Advantages of gear hobbing process
• Gear hobbing is a fast and continuous process so it
is realized as economical process as compared to
other gear generation processes.
• Lower production cycle time, i.e. faster production
rate.
• Hob is multipoint cutting tool having multi cutting
teeth or edges at a time few number of cutting
edges work so lots of time is available to dissipate
the generated heat. There is no over heating and
cutting tool.
 165

GEAR FINISHING OPERATIONS

• Surface of gear teeth produced by any of the
generating process is not accurate and of good
quality (smooth).
• Commonly used gear finishing operations are
described below.
▫ Gear Shaving
▫ Roll Finishing of Gear Tooth
▫ Gear Burnishing
▫ Gear Honning
 166

GEAR FINISHING OPERATIONS

Gear Shaving
• Gear shaving is a process of finishing of gear tooth
by running it at very high rpm in mesh with a gear
shaving tool.
• A gear shaving tool is of a type of rack or pinion
having hardened teeth provided with serrations.
• These serrations serve as cutting edges which do a
scrapping operation on the mating faces of gear to
be finished.
 167

GEAR FINISHING OPERATIONS

Gear shaving tool with serrated teeth is explained by
illustration in Figure
 168

GEAR FINISHING OPERATIONS

Roll Finishing of Gear Tooth
• This process involves use of two hardened rolling dies
containing very accurate tooth profile of the gear to be
finished.
• The gear to be finished is et in between the two dies as
shown in Figure and all three are revalued about their
axis.
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GEAR FINISHING OPERATIONS

Gear Burnishing
• The gear to be finished is mounted on a vertical
reciprocating shaft and it is kept in mesh with three
hardened burnishing compatible gears.
Gear Grinding
▫ In this operation abrasive grinding wheel of a particular
shape and geometry are used for finishing of gear teeth
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GEAR FINISHING OPERATIONS

Gear Burnishing
Lapping of a Gear
▫ The process of lapping is used to improve surface
finish of already made teeth.
▫ In this process the gear to be lapped is run under
load in mesh with cast iron toothed laps.
▫ Abrasive paste is introduced between the teeth.
▫ It is mixed with oil and made to flow through the
teeth. One of the mating members (either gear or
lapping tool) is reciprocated axially along with the
revaluations.
 171

GEAR FINISHING OPERATIONS

Gear Burnishing
 172

GEAR FINISHING OPERATIONS

GEAR HONING
• It is used for super finishing of the generated gear
teeth.
• Honing machines are generally used for this operation.
• The hones are rubbed against the profile generated on
the gear tooth.
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