Machine Tool &

Machining
Lecture 4: Milling and Milling Machines
D r Ja m e s Wa kir u
M echan ica l En g in e e r in g
Milling Machines
Milling machine is a machine tool in which metal is removed by means of a revolving cutter with many
teeth, each tooth having a cutting edge which removes metal from a workpiece.
In a milling machine the work is supported by various methods on the workable, and may be fed to the
cutter longitudinally, transversely or vertically.
In the milling process, the workpiece is normally fed into a rotating cutting tool known as milling cutter.
Equally spaced peripheral teeth on the cutter come in contact with the workpiece intermittently and
machine the workpiece. This is called intermittent cutting. In some special milling machines, the workpiece
remains stationary and the cutter is fed into the workpiece.
Milling machines are used to produce parts having flat as well as curved shapes. Intricate shapes, which
cannot be produced on the other machine tools, can be made on the milling machines.
Milling Processes—Principle of Milling
Generally there are two types of milling processes, namely :
1. Up milling (or conventional milling) process
2. Down milling (or climb milling) process.
1. Upmilling (or conventional milling) process.
In ‘‘upmilling process’’, the workpiece is fed opposite to the cutter’s tangential velocity. Each
tooth of the cutter starts the cut with zero depth of cut, which gradually increases and
reaches the maximum value as the tooth leaves the cut. The chip thickness at the start is
zero increases to maximum at the end of the cut.
Disadvantages :
1. When making deep cuts, such as in heavy slotting operations, the cutter tends to pull the
workpiece out of the vice or the fixture since the cutting force is directed upward at an
angle ; This requires secured clamping of workpiece.
2. Owing to typical nature of the cut, difficulty is experienced in pouring coolant on the
cutting edge and as a result, chips accumulate at the cutting zone and may be carried over
with the cutter, thus spoiling the surface finish. The surface becomes slightly wavy, as the
cut does not begin as soon as the cutter touches the workpiece.
Milling Processes—Principle of Milling
2. Down milling (or climb milling) process
In ‘‘down milling process’’ the workpiece is fed in the same direction as that
of the cutter’s tangential
velocity. The cutter enters the top of the workpiece and removes the chip
that gets progressively
thinner as the cutter tooth rotates.
The advantages of this milling process are :
(i) The cutting force tends to hold the work against the machine table,
permitting lower clamping forces.
(ii) This process produces better finish and dimensional accuracy.
(iii) The coolant can be fed easily. The chips are also disposed off
conveniently and they do not interfere with the cutting. Thus the machined
surface of the workpiece is not spoiled.
Classification of Milling machines
1. Column and knee type :
(i) Horizontal milling machine.
(ii) Vertical milling machine.
(iii) Universal milling machine.
(iv) Omniversal milling machine.
2. Manufacturing or fixed bed type :
(i) Simplex milling machine.
(ii) Duplex milling machine.
(iii) Triplex milling machine.
3. Planer type :
4. Special type :
(i) Rotary table milling machine.
(ii) Drum milling machine.
(iii) Planetary milling machine.
(iv) Pantograph, profiling and tracer
controlled milling machine.
Manufacturing or fixed bed type
SIMPLEX: the spindle head or the spindle travel only in one
direction, but mostly in vertical direction

DUPLEX milling machines are two machines located one

opposite the other, which can work separately or as a single
milling machine, when workpiece can be machined with 2
simultaneous spindles.

Triplex Milling Triplex milling machine have three spindle

heads one each side of table and third one is mount on cross
rail.
Horizontal Milling machines
The main parts of a horizontal milling machine (column and knee type) are briefly
described below :
1. Base : It is a heavy casting on which column and other parts are mounted.
2. Column :It houses power transmission units such as gears, belt drives and
pulleys to give rotary motion to the arbor.
3. Knee : It supports the saddle, table, workpiece and other clamping devices. It
moves on guideways of the column. It resists the deflection caused by the cutting
forces on the workpiece.
4. Saddle : It is mounted on the knee and can be moved by a handwheel or by
power. The direction of travel of the saddle is restricted to be towards or away
from the column face.
5. Table : It is mounted on the saddle and can be moved by a handwheel or by
power. Its top surface is machined accurately to hold the workpiece and other
holding devices. It moves perpendicular to the direction of saddle movement.
6. Arbor : Its one end is attached to the column and the other end is supported by
an overarm. It holds and drives different types of milling cutters.
7. Spindle : It gets power from gears, belt drives, to drive the motor. It has
provision to add or remove milling cutters onto the arbor.
 Vertical Milling machines
In vertical milling machine, the position of the spindle head is
vertical and the axis of the spindle is perpendicular to the work
table.
• In this machine both the ‘base’ and ‘column’ are integral castings.
• The ‘saddle’ is mounted on a ‘knee’ which can be mould up and
down over the guideways provided on the column face. The
saddle can be moved horizontally either by hand or by power over
the knee guideways.
• The worktable mounted on the saddle can be moved
longitudinally over the guideways provided on the top of the
saddle.
• In this machine, the workpiece can be moved both in the vertical
plane and on the horizontal plane. The machine is used to
machine grooves, slots and flat surfaces using end mill and face
mill cutters.
Other Milling machines
Universal Milling Machine
The universal horizontal milling machine differs from the plain horizontal type in that its table can be swivelled to
enable helical grooves to be milled (e.g., The helical flutes of twist drills or the teeth of helical gears).
The saddle is in two parts so that the table can be horizontally rotated.
Planer Type Milling Machines
This type of machine looks like a double column planer, but has milling heads mounted in various planes, vertical
milling heads on the cross-rail and horizontal heads at the sides (on column). This enables it to machine a
workpiece on several sides simultaneously.
These milling machines are primarily intended for producing long straight surfaces on large and heavy machine
parts
Bed Type Milling Machines
The smaller versions of planer type milling machines, having one horizontal spindle on one side or two spindles,
over each side, are called simplex, and duplex fixed bed milling machines. These machines are larger, heavier and
have greater rigidity than the column and knee type and are not adapted to tool room.
Other Milling machines
Drum Type Milling Machines
The drum type milling machines are one of continuous-operation type. They are mostly found in large-lot
and mass production shops for production of large parts such as motor blocks, gear cases, and clutch
housings. — Two flat surfaces of the workpiece can be milled simultaneously.
— The output of such machine depends upon the number of simultaneously machined parts and the speed
of rotation of the drum (feed rate).
Planetary Milling Machines
These machines are used for milling both internal and external short threads and surfaces. — The work is
held stationary and all movements necessary for the cutting are made by the milling cutters.
— At the start of a job, the rotating cutter is in centre or neutral position. It is first fed radially to the proper
depth and then given a planetary motion either inside or outside the work.
Typical applications of this machine include milling internal and external threads on all kinds of tapered
surfaces, bearing surfaces, rear axle and holes, and shell and bomb ends.
 Other Milling machines

Column and Knee

Type Milling
machine
 Other Milling machines

Bed Type Milling

machine
 Other Milling machines

CNC Milling
machine
Classification of Milling machines
Specifications of Milling machine
The following are the specifications of a column and knee type milling machine :
1. Width and length of the table.
2. Maximum distance the knee can travel.
3. Maximum longitudinal movement and cross feed of the table.
4. Number of spindle speeds.
5. Power of the main drive motor.
Types of Milling cutters
Common types of milling cutters are :
Milling Operations
1. Plain milling cutters. The milling operations are classified as follows :
2. Side milling cutters. 1. Plain or slab milling 7. End milling
2. Face milling 8. T-slot milling
3. End milling cutters. 3. Angular milling 9. Dove-tail milling
4. Face milling cutters. 4. Form milling 10. Saw milling
5. Straddle milling 11. Involute gear cutting.
5. Metal slitting cutters. 6. Gang milling
6. Angle milling cutters.
7. Formed milling cutters.
8. Wood ruff-key milling cutters.
9. T-slot milling cutter.
10. Fly cutter.
Slotter Cutter
Milling Operations
1. Plain or slab milling. Plain milling is used to machine flat and
horizontal surfaces. Here plain milling cutter is used, which is held in
the arbor and rotated. The table is moved upwards to give the Plain or slab
milling.
required depth of cut.

2. Face milling. This milling process is used for machining a flat

surface which is at right angles to the axis of the rotating cutter. The Face milling.
cutter used in this operation is the face milling cutter.

3. Angular milling. In angular milling, an angle milling cutter is used.

The cutter used may be a single or double angle cutter, depending
upon whether a single surface is to be machined or two mutually Angular milling.
inclined surfaces simultaneously.
Milling Operations
4. Form milling. This milling process is used for machining those
surfaces which are of irregular shapes. The form milling cutter used
has the shape of its cutting teeth conforming to the profile of the Form milling.
surfaces to be produced.
5. Straddle milling. Straddling milling is an operation in which a pair
of side milling cutters is used for machining two parallel vertical
surfaces of a workpiece simultaneously. The distance between the
cutters is adjusted by the spacers. This process is used to mill square Straddle milling.
and hexagonal surfaces.
6. Gang milling. is the name given to a milling operation which
involves the use of a combination of more than two cutters, mounted
on a common arbor, for milling a number of flat horizontal and
vertical surfaces of a workpiece simultaneously. This method saves
much of machining time and is widely used in repetitive work. The Gang milling.
cutting speed of a gang of cutters is calculated from the cutter of the
largest diameter.
Milling Operations
7. End milling. It is an operation of producing narrow slots, grooves
and keyways using an end mill cutter. The mill tool may be attached End
to the vertical spindle for milling the slot. Depth of cut is given by milling.
raising the machine table.

8. T-slot milling. In this milling operation, first a plain slot is cut on

T-Slot
the workpiece by a side and face milling cutter. Then the T-slot cutter milling.
is fed from the end of the workpiece.

9. Dove-tail milling. In this milling operation, the end of the cutter is

shaped to the required dove-tail angle. The cutter is passed from one
end of the workpiece to the other end. Dove-tail milling.
Milling Operations
10. Saw milling. It is an operation of producing narrow grooves and
slots on the workpiece. A slitting saw is used for saw milling.
11. Involute gear cutting. Gear milling operation, often referred as
gear cutting, involves cutting of different types of gears on a milling
machine. For this, either an end mill cutter or a form relieved cutter is
used, which carries the profile on its cutting teeth corresponding to
the required profile of the gap between gear teeth.

Saw milling.

Involute gear cutting

Work Holding Devices and machine
attachments
The following devices are used for holding the A wide variety of standard attachments, as listed below,
workpiece to be machined : are available to increase the overall usefulness of the
standard milling machine :
1. T-bolts, strap clamps and pads. 1. Vertical milling attachment.
2. Plain vice. 2. Universal milling attachment.
3. Swivel vice. 3. High speed milling attachment.
4. Universal vice. 4. Rack milling attachment.

5. Universal chuck. 5. Slotting attachment.

6. Rotary table. 6. Rotary table.

7. Universal spiral attachment.
7. Dividing head.
8. Gear cutting attachment.
8. Various types of milling fixtures
9. Dividing or indexing head.
Cutting Speed, Feed and Depth of Cut
Cutting Speed, Feed and Depth of Cut
Machining time
Machining time
Machining time
Gear cutting using milling machine
The forming process involves finish machining of gears teeth to a predetermined profile by means of form
cutters or single point reciprocating form tools. Milling machines are capable of cutting practically, every
type of gear by employing an universal indexing mechanism and a form cutter. The cutter has the required
tooth profile on it. This cutter may be operated on a vertical or horizontal type of milling machine.
In both cases, the cutter rotates on the spindle and work reciprocates under the cutter.

Gear teeth forming

Cutting spur gear on a milling machine by using an end mill cutter
Gear cutting using milling machine
Advantages :
1. All types of gears (e.g., spur, helical, worm and in special circumstances bevel gears) can be produced on
milling machines.
2. It can be employed for both roughing and finishing operations.
3. The gear cutting can be carried out on a conventional type of milling machine which is normally available
in a modern workshop.
4. Economical and suitable for one off and small batches.
Limitations :
1. Internal teeth can not be cut.
2. The pitch accuracy is very much dependent upon the accuracy of dividing head. The tooth form is not
accurate.
3. Milling is not a production process.
Generating methods/processes
Generating methods for producing gears are faster and suited for the production of large quantities. These
methods include the use of :
(i) Gear shapers and gear hobbers for spur and helical gears.
(ii) Straight-tooth bevel-gear generators for straight-tooth bevel gears.
(iii) Spiral-bevel and hypoid generators for spiral-bevel and hypoid gears
The common generating processes used for generating the gear teeth are as follows :
1. Gear shaper process.
2. Rack planing process.
3. Hobbing process.
 Gear and Rack Shaper process
Gear shaper: The principal motions involved in rotary
gear shaper cutting are :
(i) Cutting motion ;
(ii) Return stroke ;
(iii) Indexing motion ;
(iv) Completion of cutting operation.
— Often two separate cuts are made completely
around a work gear. The first-cut is for roughing, and
the second cut, which increases accuracy and
smoothness, is the finishing cut.
Rack shaper. On a rack shaper, the generating tool is a
segment of a rack. which reciprocates parallel to the
axis of the gear blank. Because it is not practical to
have more than 6 to 12 teeth on a rack cutter, the
cutter must be disengaged at suitable intervals and
returned to the starting point ; the gear blank,
meanwhile, remains fixed.

Gear generating with a rack-shaped cutter.

The operation of rotating the job through a required angle between two successive cuts is termed as indexing.
Gear Shaper process
Advantages and Limitations of Gear shaper processes :
Advantages :
1. The teeth cut on the gear carry a very accurate tooth profile.
2. Quite a fast process.
3. Suits well to both the medium and large size batch production.
4. The teeth can be easily cut upto quite close to a shoulder.
5. No need to change the cutter for cutting the teeth of different spur gears so long as their modules are same.
6. This process can be used to cut most of different types of gears, viz., spur gears, racks, doublical helical gears,
herringbone gears, internal gears, cluster gears, sprockets, etc., except of course, the worms and worm wheels.

Limitations :
1. Worms and worm wheels cannot be produced on these machines.
2. For cutting helical gears, a special guide, called helical guide, is always required to be used.
3. Because cutting takes place only during the cutting stroke, the time spent in the return stroke goes as a waste.
Gear Hobbing process
Gear hobbing is the method of generating gear teeth by the use of a rotating worm shaped cutter (hob).
The hobs are either single threaded ion or multi-threaded. A single threaded hob will complete one
revolution for generation of each tooth whereas a double threaded will generate two teeth in its one
revolution.

A gear hob.

Relative positions of hob and blank during process.

Gear Hobbing process
Advantages of hobbing :
1. It is easier to exercise control over tooth spacing, head and tooth profile.
2. High production rate (owing to the absence of indexing, reduction in cutter approach and continuous cutting action).
3. A large number of similar gears held on a mandrel can be cut at a time ; this reduces the approach time of the hob.
4. The possibility of distortion in the gear is minimum, as the heat generated due to metal cutting in uniformly distributed over the
entire work.
5. All types of spur and helical gears can be cut on metals and nonmetals.
6. High degree of accuracy can be maintained on the products over large period.
7. Irrespective of the number of teeth, the same hob can be used for generating teeth on different gears so long as they carry the same
module.
8. Gap type herringbone gears can be generated only through this process.
9. The setting and operation of hobbing machines are simpler.
10. On hobbing machines, long shafts and splines can be easily accommodated.

Limitations :
1. Internal gears cannot be cut by this method.
2. Gears which have shoulders and flanges can not be cut by hobbing.
Exercises
Exercises
Exercises
Exercises