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MAHA BARATHIO ENGINEERING
COLLEGE,
CHINASALEM TK.,VILLUPURAM DT.,
Pre pared by:-
l.NARAYANAN,M.E.,
ASST. PROFESSOR
Dept. of mechanical Engg
unit-3
Milling machines
l.NARAYANAN,M.E.,
ASST. PROFESSOR
Dept. of mechanical Engg.
CONTENTS
Milling
Milling Machines
Milling Operations
Specifications of Milling Machine
Grinding
Abrasives & Bonding Materials
Grinding Machines
MILLING
Milling: is a metal cutting operation in
which the excess material from the work
piece is removed by rotating multipoint
cutting tool called milling cutter.
Milling machine: is a power operated
machine tool in which work piece mounted
on a moving table is machined to various
shapes when moved under a slow revolving
serrated cutter.
CLASSIFICATION OF MILLING
MACHINES
1. Column and knee milling machines
a. Plain column & knee type milling machine
- Horizontal spindle type
- Vertical spindle type
2. Bed type milling machine
3. Planer type milling machine
4. Special purpose milling machine
a. Tracer controlled milling machine
b. Thread milling machine
c. CNC milling machine
HORIZONTAL MILLING MACHINE
FIG. HORIZONTAL MILLING MACHINE
MAJOR PARTS :
1.BASE
2.COLUMN
3.SPINDLE
4.OVERARM
5.KNEE
6.SADDLE
7.WORKTABLE
Collar
VERTICAL MILLING
MACHINE
MAJOR PARTS :
1.BASE
2.COLUMN
3.SPINDLE
4.SPINDLE
HEAD
5.KNEE
6.SADDLE
7.WORKTABLE
DIFFERENCES BETWEEN HORIZONTAL &
VERTICAL MILLING MACHINES
SL. NO. HORIZONTAL MILLING MACHINE VERTICAL MILLING MACHINE
01
Spindle is horizontal &
parallel to the worktable.
Spindle is vertical &
perpendicular to the worktable.
02
Cutter cannot be moved up
& down.
Cutter can be moved up &
down.
03
Cutter is mounted on the
arbor.
Cutter is directly mounted on
the spindle.
04 Spindle cannot be tilted.
Spindle can be tilted for
angular cutting.
05
Operations such as plain
milling, gear cutting, form
milling, straddle milling,
gang milling etc., can be
performed.
Operations such as slot
milling, T-slot milling, angular
milling, flat milling etc., can be
performed and also drilling,
boring and reaming can be
carried out.
PRINCIPLE OF MILLING
COMPARISON BETWEEN UP MILLING & DOWN MILLING
SL.
NO.
UP MILLING
(CONVENTIONAL MILLING)
DOWN MILLING
(CLIMB MILLING)
01 Work piece fed in the
opposite direction that of the
cutter.
Work piece fed in the same
direction that of the cutter.
02 Chips are progressively
thicker.
Chips are progressively thinner.
03 Strong clamping is required
since the cutting force is
directed upwards & tends to
lift the work piece.
Strong clamping is not required
since the cutting force is directed
downwards & keep the work piece
pressed to the table.
04 Gives poor surface finish,
since chips gets accumulated
at the cutting zone.
Gives good surface finish, since
the chips are thrown away during
cutting.
05 Used for hard materials. Used for soft materials and
finishing operations.
MILLING OPERATIONS
Plain or slab milling
Face milling
End milling
Side milling
Slot milling
Angular milling
Form milling
Straddle milling
Gang milling
Slitting or saw milling
Gear cutting
PLAIN/SURFACE/ SLAB MILLING
FIG. PLAIN MILLING
Plain Milling:
Process to get the flat
surface on the work
piece in which the
cutter axis and work
piece axis are parallel.
Cutter: Plain/ Slab
milling cutter.
Machine: Horizontal
Milling m/c.
PLAIN/SURFACE/ SLAB MILLING
FIG. PLAIN MILLING
Work piece
Plain mill cutter
FACE MILLING
FIG. FACE MILLING
Face Milling:
Operation carried out
for producing a flat
surface, which is
perpendicular to the
axis of rotating
cutter.
Cutter: Face milling cutter.
Machine: Vertical Milling
Machine
END MILLING
FIG. END MILLING
End Milling:
Operation performed
for producing flat
surfaces, slots,
grooves or finishing
the edges of the work
piece.
Cutter: End milling
cutter.
Machine: Vertical
Milling Machine
SIDE MILLING
FIG. END MILLING
SIDE MILLING : Operation
performed for
producing flat
surfaces, slots,
grooves or finishing
the edges of the work
piece.
Cutter: End milling
cutter.
Machine: Horizontal
Milling Machine
SLOT MILLING
FIG. T-SLOT MILLING
SLOT Milling:
Operation of
producing slots like T-
slots, plain slots,
dovetail slots etc.,
Cutter: End milling
cutter, T-slot cutter,
dovetail cutter or side
milling cutter
Machine: Vertical
Milling Machine
ANGULAR MILLING
FIG. ANGULAR MILLING
Angular Milling:
Operation of
producing all types of
angular cuts like V-
notches and grooves,
serrations and angular
surfaces.
Cutter: Double angle
cutter.
Machine: Horizontal
Milling Machine
FORM MILLING
End Milling:
Operation of producing
all types of angular cuts
like V-notches and
grooves, serrations and
angular surfaces.
Cutter: Double angle
cutter.
Machine: Horizontal
Milling Machine
FIG. FORM MILLING
STRADDLE MILLING
FIG. STRADDLE MILLING
Straddle Milling:
Operation of machining
two parallel surfaces
simultaneously on a work
piece.
Cutter: 2 or more side &
face milling cutters
Machine: Horizontal
Milling Machine
STRADDLE MILLING
GANG MILLING
FIG. GANG MILLING
Gang Milling:
Process to get
different profiles on
the work piece
simultaneously with
two or more cutters
at one stretch.
Cutter: Different
cutters as required.
Machine: Horizontal
Milling Machine
GANG MILLING
CLASSIFICATION OF MILLING CUTTERS
1.Plain milling cutter
2.Face milling cutter
3. End milling cutter
4.Angle milling cutter
5.T-slot milling cutter
6.Slitting milling cutter
7.Form milling cutter
8.Fly cutter
9.Woodruff key slot milling cutter
1.Plain milling cutter
The most common
milling cutter is known
as a plain milling
cutter. It is merely a
metal cylinder having
teeth cut on its
periphery for
producing a flat
horizontal surface
1(a).SLAB MILLING CUTTER
• Cutter width extends beyond the work piece
on both sides
• Process where axis of cutting tool is
parallel to the work piece surface to be
machined
• Used to create flat surfaces or slots
• Cutter may have either straight or
helical teeth
1(a).SLAB MILLING CUTTER
1.Plain milling cutter
2.SIDE MILLING CUTTER
Side milling cutters have teeth on its
periphery and also on one or both of
its sides. They are intended for
removing metal from the sides of the
work piece. There are different types
of side milling cutters namely face
and side milling cutter, half side
milling cutter.
2.SIDE MILLING CUTTER
3.END MILLING CUTTERS
These cutters have cutting
teeth on the end as well as on
the periphery of the cutter. It
is made of two parts – body
and shank. The shanks of the
cutter may be straight or
taper.
3.END MILLING CUTTERS
4.Metal slitting saw
• It is intended for cutting narrow,
deep slots and for parting off
operation. The teeth are cut on the
circumference of the cutter. The
width of the cutter is limited. The
outside diameter of the cutter will
be up to 200mm and width of the
cutter ranges from 0.75mm to
7mm.
4.Metal slitting saw
5.Angle milling cutter
The teeth of the angle milling
cutter are not parallel to the axis but
are at an angle to it. By using angle
milling cutter, inclined surfaces,
bevels and helical grooves are
machined. There are two types of
angle milling cutter
1. Single angle milling cutter and
2.double angle milling cutter.
5.Angle milling cutter
6. ‘T’ – Slot milling cutter.
It is a special form of end
mills intended for machining
‘T’- slots. It looks like a side
milling cutter with a shank. The
cutters have cutting teeth on
the periphery as well as on
both sides of the cutter.
6. ‘T’ – Slot milling cutter.
7. Fly cutter
Fly cutter is the simplest form of cutter. It
consists of a single point cutting tool
attached to the end of the arbor. The
cutting edge may be formed to reproduce
a contoured surface. They are used when
standard cutters are not available. The
work is done very slowly because of a
single cutting edge.
Fly cutter
8.Formed cutter
Formed cutters have irregular
profiles on their cutting edges to
produce required outlines on the
work. Concave and convex milling
cutters are used to produce
convex and concave surfaces
respectively.
SPECIFICATIONS OF MILLING MACHINE
1. Size of the work table: expressed in length x
width Eg: 1500 x 30mm.
2. Longitudinal movement: Total movement of
table in mm(X-direction). Eg:800mm
3. Transverse movement: Total movement of
saddle along with table in mm(Y-direction).
Eg:200mm
4. Vertical movement: Total movement of table,
saddle & knee in mm mm(Z-direction).
Eg:380mm
5. Range of the speed: Speed variation in the
gear box in RPM. Eg: 45 to 200 rpm.
6. Power capacity of the motor in HP. Eg: 2 HP
Thank You….!!!!!!!!!!!

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Milling machine-types-operations..etc..from L.NARAYANAN,M.E.,AP.MECH

  • 1. MAHA BARATHIO ENGINEERING COLLEGE, CHINASALEM TK.,VILLUPURAM DT., Pre pared by:- l.NARAYANAN,M.E., ASST. PROFESSOR Dept. of mechanical Engg
  • 3. CONTENTS Milling Milling Machines Milling Operations Specifications of Milling Machine Grinding Abrasives & Bonding Materials Grinding Machines
  • 4. MILLING Milling: is a metal cutting operation in which the excess material from the work piece is removed by rotating multipoint cutting tool called milling cutter. Milling machine: is a power operated machine tool in which work piece mounted on a moving table is machined to various shapes when moved under a slow revolving serrated cutter.
  • 5. CLASSIFICATION OF MILLING MACHINES 1. Column and knee milling machines a. Plain column & knee type milling machine - Horizontal spindle type - Vertical spindle type 2. Bed type milling machine 3. Planer type milling machine 4. Special purpose milling machine a. Tracer controlled milling machine b. Thread milling machine c. CNC milling machine
  • 6. HORIZONTAL MILLING MACHINE FIG. HORIZONTAL MILLING MACHINE MAJOR PARTS : 1.BASE 2.COLUMN 3.SPINDLE 4.OVERARM 5.KNEE 6.SADDLE 7.WORKTABLE Collar
  • 7.
  • 8.
  • 9. VERTICAL MILLING MACHINE MAJOR PARTS : 1.BASE 2.COLUMN 3.SPINDLE 4.SPINDLE HEAD 5.KNEE 6.SADDLE 7.WORKTABLE
  • 10.
  • 11. DIFFERENCES BETWEEN HORIZONTAL & VERTICAL MILLING MACHINES SL. NO. HORIZONTAL MILLING MACHINE VERTICAL MILLING MACHINE 01 Spindle is horizontal & parallel to the worktable. Spindle is vertical & perpendicular to the worktable. 02 Cutter cannot be moved up & down. Cutter can be moved up & down. 03 Cutter is mounted on the arbor. Cutter is directly mounted on the spindle. 04 Spindle cannot be tilted. Spindle can be tilted for angular cutting. 05 Operations such as plain milling, gear cutting, form milling, straddle milling, gang milling etc., can be performed. Operations such as slot milling, T-slot milling, angular milling, flat milling etc., can be performed and also drilling, boring and reaming can be carried out.
  • 13. COMPARISON BETWEEN UP MILLING & DOWN MILLING SL. NO. UP MILLING (CONVENTIONAL MILLING) DOWN MILLING (CLIMB MILLING) 01 Work piece fed in the opposite direction that of the cutter. Work piece fed in the same direction that of the cutter. 02 Chips are progressively thicker. Chips are progressively thinner. 03 Strong clamping is required since the cutting force is directed upwards & tends to lift the work piece. Strong clamping is not required since the cutting force is directed downwards & keep the work piece pressed to the table. 04 Gives poor surface finish, since chips gets accumulated at the cutting zone. Gives good surface finish, since the chips are thrown away during cutting. 05 Used for hard materials. Used for soft materials and finishing operations.
  • 14. MILLING OPERATIONS Plain or slab milling Face milling End milling Side milling Slot milling Angular milling Form milling Straddle milling Gang milling Slitting or saw milling Gear cutting
  • 15. PLAIN/SURFACE/ SLAB MILLING FIG. PLAIN MILLING Plain Milling: Process to get the flat surface on the work piece in which the cutter axis and work piece axis are parallel. Cutter: Plain/ Slab milling cutter. Machine: Horizontal Milling m/c.
  • 16. PLAIN/SURFACE/ SLAB MILLING FIG. PLAIN MILLING Work piece Plain mill cutter
  • 17. FACE MILLING FIG. FACE MILLING Face Milling: Operation carried out for producing a flat surface, which is perpendicular to the axis of rotating cutter. Cutter: Face milling cutter. Machine: Vertical Milling Machine
  • 18. END MILLING FIG. END MILLING End Milling: Operation performed for producing flat surfaces, slots, grooves or finishing the edges of the work piece. Cutter: End milling cutter. Machine: Vertical Milling Machine
  • 19. SIDE MILLING FIG. END MILLING SIDE MILLING : Operation performed for producing flat surfaces, slots, grooves or finishing the edges of the work piece. Cutter: End milling cutter. Machine: Horizontal Milling Machine
  • 20. SLOT MILLING FIG. T-SLOT MILLING SLOT Milling: Operation of producing slots like T- slots, plain slots, dovetail slots etc., Cutter: End milling cutter, T-slot cutter, dovetail cutter or side milling cutter Machine: Vertical Milling Machine
  • 21.
  • 22.
  • 23. ANGULAR MILLING FIG. ANGULAR MILLING Angular Milling: Operation of producing all types of angular cuts like V- notches and grooves, serrations and angular surfaces. Cutter: Double angle cutter. Machine: Horizontal Milling Machine
  • 24. FORM MILLING End Milling: Operation of producing all types of angular cuts like V-notches and grooves, serrations and angular surfaces. Cutter: Double angle cutter. Machine: Horizontal Milling Machine
  • 25.
  • 27. STRADDLE MILLING FIG. STRADDLE MILLING Straddle Milling: Operation of machining two parallel surfaces simultaneously on a work piece. Cutter: 2 or more side & face milling cutters Machine: Horizontal Milling Machine
  • 29. GANG MILLING FIG. GANG MILLING Gang Milling: Process to get different profiles on the work piece simultaneously with two or more cutters at one stretch. Cutter: Different cutters as required. Machine: Horizontal Milling Machine
  • 31.
  • 32.
  • 33. CLASSIFICATION OF MILLING CUTTERS 1.Plain milling cutter 2.Face milling cutter 3. End milling cutter 4.Angle milling cutter 5.T-slot milling cutter 6.Slitting milling cutter 7.Form milling cutter 8.Fly cutter 9.Woodruff key slot milling cutter
  • 34. 1.Plain milling cutter The most common milling cutter is known as a plain milling cutter. It is merely a metal cylinder having teeth cut on its periphery for producing a flat horizontal surface
  • 35. 1(a).SLAB MILLING CUTTER • Cutter width extends beyond the work piece on both sides • Process where axis of cutting tool is parallel to the work piece surface to be machined • Used to create flat surfaces or slots • Cutter may have either straight or helical teeth
  • 38. 2.SIDE MILLING CUTTER Side milling cutters have teeth on its periphery and also on one or both of its sides. They are intended for removing metal from the sides of the work piece. There are different types of side milling cutters namely face and side milling cutter, half side milling cutter.
  • 40. 3.END MILLING CUTTERS These cutters have cutting teeth on the end as well as on the periphery of the cutter. It is made of two parts – body and shank. The shanks of the cutter may be straight or taper.
  • 42. 4.Metal slitting saw • It is intended for cutting narrow, deep slots and for parting off operation. The teeth are cut on the circumference of the cutter. The width of the cutter is limited. The outside diameter of the cutter will be up to 200mm and width of the cutter ranges from 0.75mm to 7mm.
  • 44. 5.Angle milling cutter The teeth of the angle milling cutter are not parallel to the axis but are at an angle to it. By using angle milling cutter, inclined surfaces, bevels and helical grooves are machined. There are two types of angle milling cutter 1. Single angle milling cutter and 2.double angle milling cutter.
  • 46. 6. ‘T’ – Slot milling cutter. It is a special form of end mills intended for machining ‘T’- slots. It looks like a side milling cutter with a shank. The cutters have cutting teeth on the periphery as well as on both sides of the cutter.
  • 47. 6. ‘T’ – Slot milling cutter.
  • 48. 7. Fly cutter Fly cutter is the simplest form of cutter. It consists of a single point cutting tool attached to the end of the arbor. The cutting edge may be formed to reproduce a contoured surface. They are used when standard cutters are not available. The work is done very slowly because of a single cutting edge.
  • 50. 8.Formed cutter Formed cutters have irregular profiles on their cutting edges to produce required outlines on the work. Concave and convex milling cutters are used to produce convex and concave surfaces respectively.
  • 51. SPECIFICATIONS OF MILLING MACHINE 1. Size of the work table: expressed in length x width Eg: 1500 x 30mm. 2. Longitudinal movement: Total movement of table in mm(X-direction). Eg:800mm 3. Transverse movement: Total movement of saddle along with table in mm(Y-direction). Eg:200mm 4. Vertical movement: Total movement of table, saddle & knee in mm mm(Z-direction). Eg:380mm 5. Range of the speed: Speed variation in the gear box in RPM. Eg: 45 to 200 rpm. 6. Power capacity of the motor in HP. Eg: 2 HP