Up milling and Down milling

Module 4
DIRECTION OF ROTATION OF CUTTER
 UPMILLING
Up milling is also termed as
1
conventional milling.
The rotary cutter moves opposite
2
the motion of feed.
Here, while cutting the workpiece
3 from right to left, cutter rotates in
anti-clockwise direction.
The material from the surface
or cutting chips are thrown in the
4
upward direction that’s why it is
called as up milling.
It requires a large amount of force
5
compared to down milling.
/ DOWNMILLING
Down milling is also called as climb
milling.
The rotary cutter moves in the same
direction as that of the feed.
In down milling, while cutting the
workpiece from right to left cutter rotates in
clockwise direction.
Here the situation is opposite to that of up
milling as cutting chips are removed in
downward direction and therefore, we
called it as down milling.
For down milling, there is a requirement of
less amount of force.
 UPMILLING / DOWNMILLING
Here, you will get the best surface
6 In up milling, you will get poorer finish.
finish.
The chip width increases from zero and Chip width changes from maximum to
7
then increases as the process goes on. minimum value.
Up milling is mostly used for rough Down milling is used for finishing
8
cutting operations. operations.
Tool wear rate is less as the direction of
Tool wear rate is more as the direction of
9 cutter is in the same direction as that of
rotary cutter is against the feed.
the feed.
Due to increasing tool wear rate, there is Due to reducing tool wear rate, there is
10
reduction in tool life. enhancement in tool life.
It is also famous as traditional way Nowadays, down milling is a better
11
of cutting the surface. choice than up milling.
12 The cutting forces acts upward. The cutting forces acts downward.
Attachments for milling
 Attachments for milling
1. Vertical milling and universal milling
attachment,
2. High speed milling attachment,
3. Rack milling
4. Slot attachments,
5. Parking bracket, rotary table,
6. Universal dividing head, vices, arbors,
adaptors and collet chucks –
 Vertical milling attachment
• This attachment converts the horizontal spindle of a
horizontal milling machine to a vertical spindle. It is clamped
to the column and driven from the horizontal spindle.

• It incorporates provisions for setting the head at any angle,

from the vertical to the horizontal, in a plane at right angles
to the machine spindle.

• End milling and face milling are more easily accomplished

with this attachment, because the cutter and the surface
being cut are in plain view.
 Vertical milling
attachment

• The speed of the vertical spindle is same as that of the machine

spindle.

• The attachment with the spindle can also be swiveled at any angle
other that at right angles to the table for machining angular
surfaces.
 UNIVERSAL MILLING ATTACHMENT

• This device is similar to the vertical spindle

attachment but is more versatile.

• The head can be swiveled to any angle in any

plane, whereas the vertical spindle
attachment only rotates in one place from
horizontal to vertical.
 ROTARY TABLE OR CIRCULAR MILLING
ATTACHMENT
• This attachment consists of a circular worktable containing T-
slots for mounting workplaces.

• The circular table revolves on a base attached to the milling

machine worktable.

• The attachment can be either hand or power driven, being

connected to the table drive shaft if power driven.

• It may be used for milling circles, angular indexing, arcs,

segments, circular slots, grooves, and radii, as well as for
slotting internal and external gears.
Spindle
Arbor
Types of milling arbors
Arbor variations
Vertical milling attachment
 HIGH-SPEED MILLING ATTACHMENT
• The rate of spindle speed of the milling machine may be
increased from 1.5 to 6 times by using the high-speed milling
attachment.

• This attachment is essential when using cutters and twist

drills which must be driven at a high rate of speed in order to
obtain an efficient surface speed.

• The attachment is clamped to the column of the machine

and is driven by a set of gears from the milling machine
spindle.
High speed milling attachment
• It is used to drive
small milling cutters
at high speed.

• It may be fitted on
vertical or horizontal
machine.

• It consists a housing
contains step-up
gearing and a small
spindle.
SLOTTING ATTACHMENT

• It’s used for cutting

at any angle in
vertical plane to
produce key ways ,
slots and corners.

• It’s provide
reciprocating drive
for single point
cutting tool.
UNIVERSAL SPIRAL ATTACHMENT

• It’s used to mill

spirals with a plain
milling machine.

• It’s useful for

cutting helical
threads , gears ,
worms and racks.
RACK MILLING ATTACHMENT

• It’s mounted between

the face of column and
outer support on a
plain or universal
milling machine.
• It consists a fixed
housing and a spindle.
• A special rack
indexing attachment
used to move the work
CIRCULAR TABLE ATTACHMENT

• It’s used for profile milling

and many other circular
operations in horizontal
plane such as slotting and
dovetailing.

• It’s consists a base, worm

drive mechanism and a
small circular work table.
 Cutter types
PLAIN MILLING CUTTER

• Solid type of cutter

made from a single
piece of steel .

• Used for plain

milling operation
INSERTED TOOTH CUTTERS

• In large milling cutters

the teeth are inserted in
a body of less
expansive material.

• The teeth are made

from HSS or tungsten
carbide.
 BRAZED-ON TIP CUTTERS

• Carbide tips are brazed on a solid cutter body.

• It’s also known as tipped solid cutters.

FACING TYPE CUTTER

• These cutters either

bolted or attached
directly to the
spindle or secured
on the stub arbor.
SHANK TYPE CUTTER

• Cutter with straight

or taper shank with
it’s body.

• Collate chuck or
adapters are used
for holding this
cutter.
DIRECTION OF HELIX OF CUTTER

• Cutter axis is held

vertically and the
helix is towards the
right side is called a
right hand helix
cutter.
DIRECTION OF HELIX OF CUTTER

• Helix is towards the

left side ,it is called
a left hand helix
cutter.
METHOD OF MOUNTING THE CUTTER

• Arbor type cutter.

• Cutter mounted on
arbor and arbor size
selected as per
cutter bore size.
 Indexing
• Indexing is the process of evenly dividing the
circumference of a circular work piece into equally
spaced divisions, such as in cutting gear teeth, cutting
splines, milling grooves in reamers and taps, and
spacing holes on a circle.

• Milling operations sometimes, require the rotation of job

correct to fractions of minutes, for each groove, slot etc.
The operation of rotating the job through a required
angle between two successive cuts is termed as indexing. 
 Indexing head
• An indexing head, also known as a dividing head or spiral
head, is a specialized tool that allows a workpiece to be
circularly indexed; that is, easily and precisely rotated to
preset angles or circular divisions.
– A device to rotate the job
– A source which can ensure that the job has been rotated through
the desired angle.

• Indexing heads are usually used on the tables of milling

machines, but may be used on many other machine tools
including drill presses, grinders, and boring machines.
Indexing Head
 Indexing head and tailstock set up
on a milling machine's table
• The workpiece is held in the
indexing head in the same
manner as a metal
working lathe.

• This is most commonly a chuck

but can include a collet fitted
directly into the spindle on the
indexing head, faceplate, or
between centers.

• If the part is long then it may

be supported with the help of
an accompanying tailstock.
 Indexing ratio
• Most dividing heads operate at a 40:1 ratio; that is 40
turns of the hand crank generates 1 revolution of the
spindle or workpiece.

• In other words, 1 turn of the hand crank rotates the

spindle by 9 degrees.

• Because the operator of the machine may want to

rotate the part to an arbitrary angle indexing plates are
used to ensure the part is accurately positioned.
Indexing plates
Brown and Sharpe indexing heads
•  The plates are marked 1, 2 and 3, or "A", "B"
and "C".

• Each plate mostly contains 6 rows of holes.

1. Plate 1 or "A" has 15, 16, 17, 18, 19, and 20 holes.
2. Plate 2 or "B" has 21, 23, 27, 29, 31, and 33 holes.
3. Plate 3 or "C" has 37, 39, 41, 43, 47, and 49 holes.
 Methods of Indexing

1. Direct indexing
2. Simple/Plain indexing
3. Differential indexing
4. Compound indexing

5. Angular indexing
 Direct indexing plate
• Most dividing heads have an indexing plate
permanently attached to the spindle. This plate is
located at the end of the spindle, very close to where
the work would be mounted.
• This plate is usually equipped with a series of holes
that enables rapid indexing to common angles, such
as 30, 45, or 90 degrees.
• Advantage of the direct indexing plate is that it is fast
and simple and no calculations are required to use it.
• Disadvantage is that it can only be used for a limited
number of angles.
 Simple Indexing
• It is also named as plain indexing.
• It overcomes the major limitation of direct
indexing that is the possibility of dividing the
circumference of the workpiece into some
fixed numbers.
• One Milling complete turn of indexing crank
revolves the work piece by 1/40 th revolution.
Simple Indexing
 Differential indexing
• If (A-N) is greater than zero, then index plate is
rotated in same direction as the crank.

• If (A-N) is less than zero, then index plate is

rotated in opposite direction as the crank.

• where; A= selected number which can be indexed.

• N= required number of division to be indexed.
 Compound Indexing
• Compound indexing is a combination of two plain
indexing procedure.
• The word compound indexing is an indicator of
compound movements of indexing crank and then plate
along with crank.
• In this case indexing plate is normally held stationary by a
lock pin. First, we rotate the indexing crank through a
required number of holes in a selected hole circle, then
crank is fixed through the pin.
• It is followed by another movement by disengaging the
rear lock pin, the indexing plate along with indexing
crank is rotated in forward or backward direction through
predetermined holes in a selected hole circle, then lock
Index Crank Movement
 Angular indexing
• Instead of rotating the job through certain division on its
periphery, sometimes it may be needed to rotate the job through
certain angle. Angular indexing is used for this purpose.

• Since the crank and spindle ratio is 40 : 1 and hence when the
crank moves through one revolution, the spindle or the job moves
through 1/40 of revolution, i.e., the job will revolve through an
angular movement of 9°.

• If it is desired to index a job by 35 degree, then the index head

movement required to perform the operation will be = (35/9) =
3(8/9) = 3 + ((8 X 3) / (9 X 3)) = 3 + (24/27), i.e., the crank must be
turned three complete revolutions plus 24 holes in the 27-holes
circle.
 Cutting Forces in Milling

1. Longitudinal (feed) Force - Fx

2. Radial (thrust) Force – Fy

3. Tangential (cutting) Force - Fz

Forces in End-milling
 Machining Time in milling
• Machining Time Tm= length of cut/ feed rate
Tm = L / (ft * Z *N)

• Ft = feed rate per tooth

• Z= No. of teeth on cutter
• N= cutter speed (rpm)
Thank you