Milling

Machine
The milling machines are also known as the multi-tasking machines (MTMs) which are multi-
purpose machines capable of milling and turning the materials as well. The milling machine has
got the cutter installed up on it which helps in removing the material from the surface of the work
piece. When the material gets cooled down then it is removed from the milling machine.

Construction:

1.Base: It gives support and rigidity to the machine and also acts as a reservoir for the cutting
fluids.
2.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.
3.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.
4.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.
5.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:
a) Vertical (up and down) movement provided by raising or lowering the knee.
b) Cross (in or out) or transverse motion provided by moving the saddle in relation to knee.
c) Longitudinal (back and forth) motion provided by hand wheel fitted on the side of feed screw.
In addition to the above motions, the table of a universal milling machine can be swiveled 45° to
either side of the center line and thus fed at an angle to the spindle.
6.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.
7.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.
8.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.

MILLING OPERATIONS:
Plain or slab milling: Machining of a flat surface which is parallel to the axis of the rotating
cutter.

Face milling: Machining of a flat surface which is at right angles to the axis of the rotating
cutter.
Angular milling: Machining of a flat surface at an angle, other than a right angle, to the axis of
revolving cutter.

Straddle milling: Simultaneous machining of two parallel vertical faces of the work-pieces by a
pair of side milling cutters.

Form milling: Machining of surfaces which are of irregular shape. The teeth of the form milling
cutter have a shape which corresponds to the profile of the surface to be produced.
Gang milling: Simultaneous machining of a number of flat horizontal and vertical surfaces of a
work piece by using a combination of more than two cutters mounted on a common arbor.

Milling Machine
Types
The types of milling machines are the following:
Column and knee type milling machine:
It is a very common machine type.
In this machine, a vertical column is attached to the bed which consists of all gear drives which
rotate the knee and saddle.
A knee is situated on the base which provides vertical motion to the work piece or which moves
up and down.
A saddle is attached to the upper section of the knee which can move in the transverse direction.
The table is placed over which can hold the work piece by use of climbing bolts.
Column and knee type milling machine: diagram
Vertical milling machine:

The spindle of this machine is in a vertical position.

No arbor is required in this machine.
The cutter tool has the cylindrical shape and the cutting edges are situated at the circumference of
the cylindrical face.

Horizontal milling machine:

As the name implies, the spindle is situated horizontally.

The spindle rotates horizontally.
An arbor is attached to the machine which holds the cylindrical disk shape cutter which cuts the
metal work piece.
Universal milling machine:
It is the same as the horizontal mill machine, except there is an arrangement of swing up the table
to 45 degrees in either direction.

Fixed bed milling machine:

In this type of machine, the bed of the machine is fixed to the machine.
There is no arrangement of the knee and saddle which can move vertically and transversally.
The worktable is directly situated at the fixed bed.
The spindle of this machine is mounted on a movable spindle head.
It can move in the vertical and horizontal direction and to perform the cutting operation.
Simplex milling machine:
In the simplex machine, spindle head or the spindle travel only in one direction.
Mostly it travels in the vertical direction.

Duplex milling machine:

In this machine, the spindle travels both vertical and horizontal directions.
Triplex milling machine:
In the triplex machine, the spindle can move in all three directions along X, Y, and Z-axis.

Planner milling machine:

The planner milling machine is mostly used for facing operations in mass production.
These machines are similar to the bed type mill machine, except it can be mounted with various
cutters and spindle heads to the machine.
These cutters in the machines can perform the facing operations simultaneously which is a great
function.
Special milling machine:
These machines are the modern milling machines that are developed to easy milling operations
according to the jobs.
Tracer milling machine:
This machine performs all difficult operations like, die making the job by synchronizing the
tracing unit. This can develop any difficult shape.
This is mostly used in the automobile and aerospace industries.

CNC milling machine:

CNC is the most versatile milling machine which is control by a computer.
It is an upgraded version of the bed type mill machine, in which the spindle can move in all three
directions and the table can rotate 360 degrees.

These all movement is hydraulically controlled which is commanded by a computer.

In this, any difficult geometry can make on it.
A sketch of the work piece is loaded to the computer which is cut on the work piece by the
cutters automatically.
Nomenclature of Milling
Cutter:
A milling cutter can be considered as the cluster of single point cutting tool. Above figure shows
a plain milling cutter. The various parts of milling cutter teeth are cutting edge, face, filling, and
body. The teeth of milling cutter either straight (the cutting edge is parallel to the axis of
rotation) or helical shaped.

Elements of plain milling cutter

Body of cutter: It is the main frame of milling cutter, on which the teeth rest.

Periphery: It is defined as the locus of cutting edges of tooth of cutter.

Cutting edge: It is the portion that touches the work piece during cutting action. It is the
intersection of teeth face and tooth flank.

Fillet: portion where one teeth joins the face of another tooth. It is a reinforcement to cutting
tooth.

Face of teeth: it is the surface upon the chip is formed while cutting. It may be curved or
flat.
Back of tooth: it is the created by fillet and the secondary clearance angle.

Land: it is the narrow surface on the back of cutting edge. Land is the result of providing the
clearance angle.

Bottom Land: the blank space between the consecutive teeth.

Root diameter: diameter passing through centre of cutter and joining two ends of the
periphery.

Root diameter: passing through centre of cutter and joining two bottom fillet.

Angles of milling cutter

Lip angle: It is the angle between the face of the teeth and the land of the teeth. Land is a narrow
surface on the back of teeth.

Relief angle: it is the angle between the tangent to the outside diameter of the cutter at cutting
edge and the land of the tooth. The function relief angle is to avoid the interference between the
land of the tooth and the work surface. The relief angle varies with the type of material to be
machined.

Radial rake angle: it is the angle between the face of teeth and the radial line passing through
the cutting edge of the tooth. The radial rake angle may be positive, negative or zero. It is
provided free cutting by allowing chips to flow smoothly on the face of the cutter.

Zero rake angle: tooth face and radial line coincide.

Positive rake angle: tooth body and tooth face is the same side of the radial line.
Negative rake angle: tooth surface and radial angle are on opposite side of the radial line.
Axial rake angle: angle between the line of peripheral cutting edge and axis of the cutter. It is an
angle in a plane perpendicular to the radial plane.

Clearance angle: it is the angle between the back of the tooth and the tangent to the outside
diameter at the cutting edge of the tooth. It is divided into two according to the clearance surface.
(Primary clearance angle and secondary clearance angle)
 Planer
Machine
Planer is a machine tool used for producing accurate flat surfaces and cutting slots. It is similar to
the shaper machine but in case of size, the planer machine is larger. The work piece slots move
here from one point to another for operation, whereas in the shaper machine the work piece slots
were in a stationary position.
The Planer machine was invented by General Bentham invented planer. It is one of the important
machine tool in Manufacturing Process.

Construction:

Bed:
Bed is a rigid part of the machine on which all the parts are carried. This is very large in size and
heavyweight.
Column / Housing:
The housings is called columns and It is also called uprights and are rigid box-like vertical
structures placed on each side of the bed and fastened to it. Here pulley and gear are also
attached.
Table:
It supports the work and reciprocates along with the ways of the bed. The table is made up of high
quality cast iron. Here the table upper surface parts are very fine and accurate because here we
fix the work piece for the planner operation.
Cross rail:
In cross rail, tool holders are attached where we can fix the tool for operation. It connects between
two housing and also provides supports to the housing.
Tool Head:
Here the tools (Single Point cutting tool) are fixed.

Planer Machine
Operation:
The operation performs here to remove the material as we do in the shaper machine, but the main
thing is in the shaper machine there is only having one cut section and whereas in the Planner
machine having multiple cutting sections which provide a greater surface finish and fast work to
obtain a flat surface result.
There are two operations we perform here:

Vertical Flat Operation:

When we perform vertical flat operation on the planner machine, a work piece is planned by
adjusting the saddle horizontally along the cross rail until the tool is in a position to give the
required depth of cut. The vertical slide is adjusted perpendicular to the planer table and the apron
is swiveled in a direction so that the tool will swing clear out of the machined surface during the
return stroke.

Horizontal flat Operation:

When we perform horizontal flat operation on the planner, the work piece is given reciprocating
movement along with the table and the tool is fed crosswise to perform operation.
Quick-Return Mechanism for a
Planer Machine:
The following methods are employed for achieving the quick motion in backward stroke and
slow motion in forward stroke of the planer table: 1. D.C. Reversible Motor 2. Fast and Loose
Pulleys
3. Hydraulic System.

D.C. Reversible Motor:

In this method, a special motor which can change its speed according to the field current applied,
is used. The motor speed can be changed very quickly from full speed forward to speed in reverse
direction and the reversals nearly instantaneous.
At the end of the stroke, the trip changes over the supply to the motor and it moves accordingly.
Power from the motor is conveyed to the table rack by a reduction gearing and a worm in mesh
with the table rack.
This method is most commonly used on modern planers because it gives a wide range of table
speeds and more responsive control.

Fast and Loose Pulleys:

The planers of old type use this type of drive. This makes use of 3 pulley drives with one belt.
In this mechanism belt shifting fork is connected to dogs fitted at
the end of stroke in the planer bed. These automatically shift the
belt from pulley R, to pulley K after the end of every stroke.
When belt is on pulley R, it constitutes forward stroke. Motion
from pulley is transmitted to the rack from gear A to gear B, gear
C, gear D and is thus very much reduced speed.
When belt is on pulley K then motion is transmitted to rack pinion
through cast gear E with pulley if and the gear D. In this case as
motion is transmitted without any reduction, therefore, it
constitutes return stroke. The direction of reversing may be
followed from arrows shown in Fig. 15.4. When no motion is
required, the belt is on loose pulley.

Hydraulic System:
Hydraulic drive for shaper and planer is exactly similar and has already been discussed in the
chapter of shaper. Nearly all the modern planers use the hydraulic system because of the various
advantages associated with it. In this system also the trip dogs fastened to the table are used to
regulate the stroke length and to change the position of the table.
 Shaper
Machine
The shaper is a machine tool used primarily for:
1. Producing a flat or plane surface which may be in a horizontal, a vertical or an angular plane.
2. Making slots, grooves and keyways
3. Producing contour of concave/convex or a combination of these.

Working Principle:
The job is rigidly fixed on the machine table. The single point cutting tool held properly in the
tool post is mounted on a reciprocating ram. The reciprocating motion of the ram is obtained by a
quick return motion mechanism. As the ram reciprocates, the tool cuts the material during its
forward stroke. During return, there is no cutting action and this stroke is called the idle stroke.
The forward and return strokes constitute one operating cycle of the shaper.

Construction:
The main parts of the Shaper machine is Base, Body (Pillar, Frame, Column), Cross rail, Ram
and tool head (Tool Post, Tool Slide, Clamper Box Block).
Base: The base is a heavy cast iron casting which is fixed to the shop floor. It supports the body
frame and the entire load of the machine. The base absorbs and withstands vibrations and other
forces which are likely to be induced during the shaping operations.
Body (Pillar, Frame, and Column): It is mounted on the base and houses the drive mechanism
compressing the main drives, the gear box and the quick return mechanism for the ram
movement. The top of the body provides guide ways for the ram and its front provides the guide
ways for the cross rail.
Cross rail: The cross rail is mounted on the front of the body frame and can be moved up and
down. The vertical movement of the cross rail permits jobs of different heights to be
accommodated below the tool. Sliding along the cross rail is a saddle which carries the work
table.
Ram and tool head: The ram is driven back and forth in its slides by the slotted link mechanism.
The back and forth movement of ram is called stroke and it can be adjusted according to the
length of the work piece to be-machined.

Extrusion
Process:
Extrusion is a metal forming process in which metal or work piece is forced to flow through a die
to reduce its cross section or convert it into desire shape. This process is extensively used in pipes
and steel rods manufacturing. The force used to extrude the work piece is compressive in nature.
This process is similar to drawing process except drawing process uses tensile stress to extend the
metal work piece. The compressive force allows large deformation compare to drawing in single
pass. The most common material extruded are plastic and aluminum.

Working Principle:
Extrusion is a simple compressive metal forming process. In this process, piston or plunger is
used to apply compressive force at work piece. These process can be summarized as follow.
First billet or ingot (metal work piece of standard size) is produced.
This billet is heated in hot extrusion or remains at room temperature and placed into an extrusion
press (Extrusion press is like a piston cylinder device in which metal is placed in cylinder and
pushed by a piston. The upper portion of cylinder is fitted with die).
Now a compressive force is applied to this part by a plunger fitted into the press which pushes the
billet towards die.
The die is small opening of required cross section. This high compressive force allow the work
metal to flow through die and convert into desire shape. Now the extruded part remove from
press and is heat treated for better mechanical properties.
Types of Extrusion:
Extrusion process can be classified into following types.
According to the direction of flow of metal
Direct Extrusion:
In this type of extrusion process, metal is forced to flow in the direction of feed of punch. The
punch moves toward die during extrusion. This process required higher force due to higher
friction between billet and container.

Indirect Extrusion:
In this process, metal is flow toward opposite direction of plunger movement. The die is fitted at
opposite side of punch movement. In this process, the metal is allowed to flow through annular
space between punch and container.
Hydrostatic Extrusion:
This process uses fluid to apply pressure on billet. In this process, the friction is eliminated
because the billet is neither contact with cylinder wall or plunger. There is a fluid between the
billet and plunger. The plunger applies force on fluid which further applied on billet. Normally
vegetable oils are used as fluid. This process accomplished by leakage problem and uncontrolled
speed of extrusion.

According to the working temperature

Hot Extrusion:
If the extrusion process takes place above recrystallization temperature which is about 50-60% of
its melting temperature, the process is known as hot extrusion.
Advantages:

Low force required compare to cold working.

Easy to work in hot form.
The product is free from stain hardening.
Disadvantages:

Low surface finish due to scale formation on extruded part.

Increase die wear.
High maintenance required.
Cold Extrusion:
If the extrusion process takes place below crystallization temperature or room temperature, the
process is known as cold extrusion. Aluminum cans, cylinder, collapsible tubes etc. are example
of this process.

Advantages:

High mechanical properties.

High surface finish
No oxidation at metal
surface.
Disadvantages:
High force required.
Product is accomplished
with strain hardening.
 Rolling
Mills
Rolling is defined as a process to form metals where the metal strip is pressed by two or multiple
rollers, thus the uniform thickness is formed. To do this, the temperature is essential.

Working Principle of Rolling Process:

The rolling process is a metal forming process, in which stock of the material is passed between
one or more pairs of rollers in order to reduce and to maintain the uniform thickness.
This process is mainly focused on the cross-section of the ingot or the metal which is forming.
Mainly by this process, we reduce the thickness of the metal work piece.
Now, the rolling processes are mainly focused on the increasing length and the decreasing
thickness without changing the width of the work piece.

There are certain types of the rolling process, whereas, in the hot rolling process, the metal is
heated at its desirable temperature, when the metal is properly heated then the metal should be
passed between the one or more rolling mills to gain the proper desirable shape.
This process is vastly used in respect of any other rolling process. In this process, the metal is
heated above the recrystallization temperature. In the hot working process, the metal is changing
its grain structure because of the heat, now there were a new set of strain-free grains in the metal
and this process needs less amount of force which correspondingly reduces the quality of the
surface finish, of that metal.
Now there is another rolling process, which is a cold rolling process. This rolling process is done
below the recrystallization temperature of the metal it varies upon the metal, room temperature
can also be a below recrystallization temperature.

In this process, the force is much more required than the hot working process to pass the metal
from the rollers and this process offers good surface finish.

Types of Rolling Mills:

There are five rolling mills which are commonly used for rolling metals:

1. Two-High Rolling Mills:

In this type of mill, the rollers are both adjustable. In these mills, rotation of that two rolls is made
in two different directions. In this operation, the metal is passed between two rollers that rotate at
the same speed but it is in the opposite direction.

It is used in slabbing, plumbing, rail, plate roughing work and many other areas. As there is the
need for a reversible drive, this mill is cheaper compared to the others.
In (Non-reversible) mills, two rolls continuously revolve in the same direction and we can't
reverse the direction of the rollers. In this operation, the motive power is less costly.

2. Three-High Rolling Mills:

In this mill, the three rolls stand in parallel one by others. The rolls are rotating in opposite
directions. In this mill, between the first and the second rolls, the material passes. If the second
roll rotates in a direction then the bottom roll rotates in another direction. The material is rolled
both in forward and return in three high rolling mills.

At first, it passes forward through the last and second roller and then comes back through the first
and second roller. In that mill, the thickness of the material is reduced and being uniform by each
pass. Here transition system and a motor are needed which is less powerful.

3. Four High Rolling Mills:

In this type of mill, there are four parallel rolls one by another. In this operation, the rotation of
the first and the fourth rolls take place in the opposite direction of the second and the third rolls.
The second and third rolls are smaller to provide rigidity in necessity. So those are known as
back up rolls.
It is used in the hot rolling process of the armor and in the cold rolling process of sheets, strips,
and plates.

4. Tandem Rolling Mills:

In this type of rolling mill, there are two or more sets of rolls in the parallel alignment which
make the continuous passes and successively decrease the thickness and make that uniform.

5. Cluster Rolling Mills:

In this type of rolling mill, there are two basic roles that are backed up by two or more rolls
which are bigger than those two basic rolls. These backed up rolls give more pressure to the
basic rolls to heavily press the strip.
 Advantages and Disadvantages of
C.N.C Machine
CNC Machine:
The term CNC is an acronym for Computer Numerical Control. In the realm of CNC machining,
both the tool and the work pieces are controlled with the assistance of a numerical program. It is
important here to note that the complete process of CNC machining is reliant on CAD and CAM.
The term CAD denotes Computer Aided Design whereas the term CAM denotes Computer Aided
Manufacturing. CAD is really helpful in making 3-D designs. CAM helps to turn the 3-D design
into a reality. Specialized software drives the computerized machining. The software contains
customized G-code. G-code is the programming language which facilitates coordination, location
and feed rate in a precise manner. The automatic machining procedure can execute actions like
holds and reaches which are beyond the capabilities of manually operated machines.
CNC machines are an indispensable part of the manufacturing industry because they can design
complex shapes and designs with 100% precision and efficiency. Nowadays, it is common to find
CNC machines comprising multiple axes that can adjust to varied angles to engrave on harder
surfaces.
It is also worthwhile here to note that CNC machines can automate those tasks that need several
cuts. Codes and programming are an important part of CNC machining. Programming in CNC
includes high-speed movements that are necessary to create detailed customization. CNC
machining is a favored choice among manufacturers as they can fabricate metal parts as well as
plastic parts.

Advantages
The following list illustrates the advantages of CNC machines in modern day industrial settings.

Redundancy, precision and consistency

It is important to note here that CNC machining makes use of computer-aided programming. The
operator has to just program the machine once to get the desired output. The CNC machine can
then perfectly replicate the design irrespective of order quantities.
Highly precise components
Autonomous machining coupled with digital templates of CNC practically eliminates human
errors and helps to achieve accuracy in complex work environments.
Uniform outputs
One of the main advantages of CNC machines is that they provide you with uniformity in designs
and layouts. Note that even the most skilled technicians on a conventional machine would
produce and design components that would vary slightly. CNC machines ensure that each part is
a perfect match to the exact specifications of the prototype.

Requires fewer labors

CNC machines need fewer technicians to execute the production tasks. It is worthwhile here to
mention that one skilled operator can run various CNC machines simultaneously. On the other
hand, a manual machine needs a minimum of one skilled operator along with a supervisor. Hence,
it is evident that CNC machines help you to save on manpower costs.

Retention of designs
Once a design has been loaded into the CNC software and a perfect variance has been created, the
program can easily retrieve the design to execute it. In other words, there is no need to keep up
with the versions of design change.

Lower costs
It is quite evident that CNC machines emphasize on precision, speed and efficiency. Moreover,
CNC machines also reduce the need of skilled personnel. All these factors add up to the bottom
line of your business. You can use the amount of money saved for other crucial business
purposes. In simple words, saving money is one of the great advantages of using CNC machines.

Hassle-free maintenance
It is interesting to note here that the G-code software automatically updates when the need arises.
CNC machines facilitate hassle-free maintenance which exudes practicality. Minor adjustments in
the form of changing the cutting implements and light cleaning is all which is required.

Disadvantages
Disadvantages associated with CNC machines are following:

Makes manual skills obsolete

There is no denying the fact that CNC machines make manual skills obsolete. It is quite common
for the machinists to put rigorous years of hard work in mathematics and science to be qualified
as a skilled professional.

Wide scale unemployment

There is no doubt that CNC machines have created immense opportunities for all types of
industries. At the same time, the extensive adoption of CNC machines has led to the downfall of
conventional machining. This has given rise to unemployment in various industries and
countries.

Cost
CMC machines are quite expensive and need a greater initial investment than machines which
are operated manually. Not all industries can easily afford CNC machines. Also industries in
demand should opt for CNC machining as it can fine-tune their production.

Loss of skills
With the popularity of CNC machining, there has been a gradual decline in the demand of
manual machine operators. This can ultimately lead to the complete loss of the skills that have
been preserved for so long.