WHAT IS MILLING PROCESS?

a mechanical procedure that involves rotating the cutters to remove material from the work piece in the direction of the
tool axis' angle with the work piece. One may do a variety of tasks and procedures with the aid of milling machines,
ranging from little to enormous products.

DIFFERENT TYPES OF MILLING MACHINE

Horizontal Milling Machine

In horizontal milling machine the axis of rotation of the spindle is horizontal to the table. And due the axis of spindle
horizontal, it is called as horizontal milling machine.

Vertical Milling Machine

The milling machine in which the spindle axis is perpendicular to the table is called vertical milling machine.

Ram-Type Milling Machine

A milling machine which has a ram on the top of the column is called ram type milling machine. Generally ram is used in
vertical milling machine. It can be moved on the column in transverse direction (i.e. in and out when operated from the
knee side).

Knee-Type Milling Machine

The milling machine which has a knee like projection at the middle is called knee-type milling machine. It is characterised
by a vertical adjustable work table resting on a saddle supported by a knee.

Bed Type Milling Machines

Unlike conventional milling machines, which have their worktables on top, bed-type milling machines have their
worktables on the bed itself. The absence of the knee enables longitudinal mobility on a bed-style machine.

Planer-Style Milling Machines

A bed-style machine resembles a milling machine with a planer-style. The inclusion of cutters and heads on this sort of
milling machine, however, gives it greater milling possibilities.

MILLING MACHINE PARTS AND THEIR FUNCTION

Base and column:

The base and column of a milling machine act as supports for the other components. The column has an oil reservoir and
pump for lubricating the spindle. In addition to having a coolant reservoir and a pump to provide coolant during
machining processes, the column sits on a base.

Knee:

The gearing system is contained inside a knee. Dovetail methods secure the knee to the column. A vertical positioning
screw, commonly referred to as an elevating screw, supports and adjusts it. The elevating screw is used to raise or lower
the lever with the aid of a hand or power feed in order to modify the knee up and down.

Swivel and Saddle Table:

The table is supported by the saddle, which is on the knee. In horizontal milling m/c, the saddle moves on the knee and
the dovetail are parallel to the spindle's axis. The saddle, which could rotate (swivel) horizontally in both directions, is
where the swivel table is connected.
Power Feed Mechanism:

The knee contains the power feed mechanism. Transverse (in and out), longitudinal (left and right), and vertical (up and
down) feeds are all controlled by the power feed mechanism. The feed selection lever is positioned on the machine to
indicate on the feed selection plates the desired rate of feed.

Table:

On top of a saddle is a rectangular casting that is called a table. The work or mechanisms for holding work are placed on
the table. Several T-slots are available for holding work and work holding devices (jigs and fixtures). It may be powered
or manipulated manually. It engages and rotates the longitudinal hand crank to move the table by hand. It contacts the
longitudinal direction feeding control lever to move it mechanically.

Spindle:

A milling machine's spindle is used to support and move its cutting tools. It is supported by a column and fixed on
bearings. An electric motor drives the spindle through gear trains, which are located on the column. The spindle face has
an internal taper cut into it, and it is located close to the table. Two keys are located at the front face and give a cutter
holder or arbor a positive drive.

Overarm or Overhanging Arm:

The overarm, which is located on the upper face of the column, is a horizontal beam. It could be a single casting that
slides along the dovetail manner on the column's top face.

Arbor Support:

Arbor support is a casting that holds a bearing and supports an arbor's outer end. Aligning the arbor's outer end with the
spindle also helps. Arbor support stops the arbor's outer end from springing during cutting operations. In general, milling
machines employ one of two types of arbor supports. The first one features a bearing hole that can only be as large as
an inch in diameter. The second one features a bearing hole that may be up to 23/4 inches in diameter.
MILLING OPERATION:

Face Milling

This operation makes flat surfaces at the face of workpiece. This machining operation is done on the surfaces which are
perpendicular to the axis of the cutter. The operation is performed by the face milling cutter mounted on stub arbor of
the machine.

Side Milling

It is the machining process which produces flat vertical surface at the sides of a workpiece. This operation is performed
by using side milling cutter.

Plain Milling

It is a Process of milling flat surfaces keeping the axis of the cutter parallel to the surface being milled. It is also called
surface milling or slab milling. A plain milling cutter is used for the plain milling.

Straddle Milling

it is a process in which two side milling cutter are used to machined two opposite sides of a workpiece simultaneously.
The straddle milling operation is shown in the figure given below.

Angular Milling

It is a process of milling flat surfaces which are neither Parallel nor perpendicular to the axis of the milling cutter. It is
also called as angle milling. A single angle milling cutter is used to perform this operation.

Gang Milling

It is the machining process in which two or more milling cutters are used together to perform different milling operation
simultaneously. In gang milling the cutters are mounted on the arbor.

Form Milling

It is the process of machining special contour (outline) composed of curves, straight lines, or entirely of curves, at a
single cut. Formed milling cutters shaped to the contour to be cut are used to perform this operation. This operation is
accomplish by using convex, concave and corner rounding milling cutters.

Profile Milling:

This milling operation is used to cut a profile on the workpiece.

End Milling

It is the process of producing flat surfaces which may be horizontal, vertical and at any angle taking worktable as a
reference. End milling cutters are used to accomplish this operation.

Saw Milling

It is machining process which is used to produce narrow grooves or slots on the workpiece.

Milling Key Ways, Grooves and Slots

This milling operation is used to produce key ways, grooves and slots on the workpiece.

Gear Milling

It is the milling process which is used to cut gears on the workpiece. This operation is done by using formed milling
cutters called involute gear cutters.
Helical Milling

This milling operation is done to produce objects having helical design such as helical gears, twisted drills etc. it is done
on the periphery of the cylindrical workpiece.

Helical Milling

This milling operation is done to produce objects having helical design such as helical gears, twisted drills etc. it is done
on the periphery of the cylindrical workpiece.

Thread Milling

It is the process of milling used to cut threads on the cylindrical workpiece.

FOUR CLASSIFICATION OF MILLING OPERATIONS:

Direct - machining flat surfaces which are at right angle to the axis of the cutter.

Simple -machining flat surfaces which are parallel to the axis of the cutter.

Angular - machining flat surfaces which are at an inclination to the axis of the cutter.

Differential - machining surfaces having an irregular outline.