Dunoon Park Technical High

School
By. Mr. Davids

Define Milling.
Recognize and explain the purpose of
four milling machines.
Know the purposes of the main parts
of the horizontal and vertical milling
machines.

Milling is the process of cutting

away material by feeding a
workpiece past a rotating multiple
tooth cutter.
The cutting action of the many
teeth around the milling cutter
provides a fast method of
machining. The machined surface
may be flat,angular, or curved.
The surface may also be milled to
any combination of shapes.

The machine for holding the

workpiece, rotating the cutter,
and feeding it is known as the
Milling machine.
Milling machines are among the
most versatile and useful
machine tools due to their
capabilities to perform a variety
of operations.

Milling Machines are made in a wide

variety of types and sizes. They may
be classified as:
1. Manufacturing type
2. Special Type
3. Knee-and-column type

64-6

Copyright The McGraw-Hill Companies, Inc.

Permission required for reproduction or display.

The four most common types of

manually controlled milling machines
are listed below in order of increasing
power (and therefore metal removal
capability):

1. Ram-type milling machines

2. Column-and-knee-type milling machines
a. Horizontal spindle
b. Vertical spindle
3. Fixed-bed-type milling machines
4. Planer-type milling machines

Milling machines whose motions are

electronically controlled are listed in order of
increasing production capacity and
decreasing flexibility:
1. Manual data input milling machines
2. Programmable CNC (Computer Numerical

Controlled) milling machines

3. Machining centers (tool changer and pallet
exchange capability)
4. Flexible Manufacturing Cell and Flexible
Manufacturing System
5. Transfer lines

Most mills consist of column-and-knee

designs
The column is mounted on a base and the Table

mounted on a knee extending from the column.

The knee has vertical movement
The material in mounted on a table with longitudinal
movement, and the table is mounted on a saddle
with transverse movement

Most common of this type mill is the Ram mill

which has a motor and pulley system mounted
on the top of the column.

The ram-type
knee-andcolumn milling
machine is one
of the most
versatile and
popular milling
machine tools
ever designed.

59-10

Major components of a plain column-and-knee-type milling machine, which can have horizontal
spindle shown on the left, or a turret type machine with a vertical spindle, shown on the right. The
workpiece and workholder on the table can be translated in X, Y, and Z directions with respect to
the tool.

Used for general purpose milling

operations, column and knee type
milling machines are the most
common milling machines. The
spindle to which the milling cutter is
mounted may be horizontal (slab
milling) or vertical (face and end
milling).

Work table, on which the workpiece

is clamped using the T-slots. The
table moves longitudinally with
respect to the saddle.
Saddle, which supports the table
and can move transversely.
Knee, which supports the saddle and
gives the table vertical movements
for adjusting the depth of cut.

Overarmin horizontal machines,

which is adjustable to
accomadate different arbor
lengths.
Head, which contains the spindle
and cutter holders. In vertical
machines the head may be fixed
or vertically adjustable.

Made for deep cuts and heavy

material removal, the bed only had
horizontal movement
Once the bed is set up, the spindle
height is not changed during
operation.
These machines are very common
due to their ease of use.

Bed-type
vertical-spindle
heavy-duty
production
machine tools for
milling usually
have three axes
of motion.

Planer type mills can have several

heads to remove large amounts
of material while the material is fed
slowly into the machine.
Systems are setup typically for
single pass operations.
These are advantageous for large
work pieces requiring heavy
material removal.

FIGURE 24-17 Large

planertype milling
machine. Inset shows 90
head being used.
(Courtesy of Cosa
Corporation.)

When purchasing or using a milling

machine, consider the following issues:
1. Spindle orientation and rpm
2. Machine capability (accuracy and

precision)
3. Machine capacity (size of workpieces)
4. Horsepower available at spindle
(usually 70% of machine horsepower)
5. Automatic tool changing

When purchasing or using a milling

machine, consider the following issues:
1. The Table Length And Width.
2. Maximum Longitudinal Cross And
Vertical Travel Of The Table.
3. Number Of Spindle Speeds And Feeds.
4. Power Of Driving Motor.
5. Floor Space And Net Weight.

Peripheral Milling
End milling

Peripheral Milling
In peripheral (or slab) milling, the

milled surface is generated by teeth

located on the periphery of the cutter
body. The axis of cutter rotation is
generally in a plane parallel to the
workpiece surface to be machined.

Face Milling
In face milling, the cutter is mounted

on a spindle having an axis of rotation

perpendicular to the workpiece
surface. The milled surface results
from the action of cutting edges
located on the periphery and face of
the cutter.

End Milling
The cutter in end milling generally

rotates on an axis vertical to the

workpiece. It can be tilted to machine
tapered surfaces. Cutting teeth are
located on both the end face of the
cutter and the periphery of the cutter
body.

There are two methods that may

be used in milling operations.
These are:

Up milling or Conventional milling

Down milling or Climb milling

Up Milling
Up milling is also referred to as

conventional milling. The direction of

the cutter rotation opposes the feed
motion. For example, if the cutter
rotates clockwise , the workpiece is fed
to the right in up milling.

This is the most common

method used. The work
is fed against the
rotational direction of
the cutter.

60-31

Can be used on milling machine

without backlash eliminator.
Good for milling hot rolled steel,
surface hardened and steels with a
surface scale.
Good for milling castings or forgings
where there is a hard abrasive
surface due to scale and sand.
Causes less stress on the machine.

Reduces tool life.

The cutter tends to push the
work along and lift it upwards
from the table. This action
tends to loosen the workpiece
from the fixture.
In up milling, chips can be carried
into the newly machined surface,
causing the surface finish to be
poorer than in down milling.

Down Milling
Down milling is also

referred to as climb
milling. The direction of
cutter rotation is same
as the feed motion. For
example, if the cutter
rotates counterclockwise
, the workpiece is fed to
the right in down milling.

When cutter and

workpiece going
in same direction
The machine must
be equipped with
backlash eliminator
Can increase cutter
life up to 50%

60-35

Increased tool life (up to 50%)

Chips pile up behind or to left of cutter

Less costly fixtures required

Forces workpiece down so simpler holding

devices required

Improved surface finishes

Chips less likely to be carried into

workpiece
60-36

Less edge breakout

Thickness of chip tends to get smaller as

nears edge of workpiece, less chance of

breaking

Easier chip removal

Chips fall behind cutter

Lower power requirements

Cutter with higher rake angle can be used

so approximately 20% less power required

60-37

Method cannot be used unless machine has

backlash eliminator and table gibs tightened
Cannot be used for machining castings or
hot-rolled steel
Hard outer scale will damage cutter

The maximum chip thickness is at the

point of tooth contact with the work
piece. Dulling the teeth more quickly,
especially for workpiece with a hard surface.

60-38

(1)
(2)
(3)
(4)
(5)
(7)
(8)
(9)

Plain milling cutters,

Side milling cutters,
Face milling cutter,
Angle milling cutters,
End milling cutter,
T-slot milling cutter,
Formed cutters,
Metal slitting saw,

Milling cutters are made from the

following metals
1. Tool steel, carbon tool steel, and
high-speed steel

Milling Cutters must be:

1. Harder than metal being machined
2. Strong enough to withstand cutting

pressures
3. Tough to resist shock resulting from contact
4. Resist heat and abrasion of cutting
5. Available in various sizes and shapes

45

Iron with additives

Carbon: hardening agent
Tungsten and Molybdenum: enable steel to

retain hardness up to red heat

Chromium: increases toughness and wear
resistance
Vanadium: increases tensile strength

Used for most solid milling cutters

46

Higher rates of production (3-10 times

faster)
Must select proper type of carbide
Straight tungsten carbide: cast iron, plastics
Tantalum carbide: low/medium-carbon steel
Tungsten-titanium carbide: high-carbon steel

47

Performed with HSS, cobalt, solid carbide, or indexable insert type

end mill

Open and closed

pockets
Facing operations for
small areas
Counterboring and
spotfacing

Peripheral end milling

Milling of slots and
keyways
Channel groves, face
grooves and recesses
Chamfering

Most widely used

Cylinder of high-speed steel with
teeth cut on periphery
Used to produce flat surface
Several types
Light-duty
Light-duty helical
Heavy-duty
High-helix

Less than in. wide, straight teeth

Used for light milling operations
Those over in have helix angle of
25
Too many teeth to permit chip clearance

Have fewer teeth than light-duty

type
Provide for better chip clearance

Helix angle varies up to 45

Produces smoother surface because of

shearing action and reduced chatter

Less power required

Have helix angles from 45 to over 60

Suited to milling of wide and
intermittent surfaces on contour and
profile milling
Usually mounted on milling machine
arbor
Sometimes shank-mounted

with pilot on end and used

for milling elongated slots

Called arbor-type cutters

Used for
Milling forms from solid metal
Removing inner sections from solids

Inserted through previously drilled

hole and supported at outer end
with type A arbor support

Comparatively narrow
cylindrical milling cutters with
teeth on each side and on
periphery
Used for cutting slots and
for face and straddle milling
operations
Free cutting action at high
speeds and feeds
Suited for milling deep, narrow
slots

Straight

Staggered

Used when only one side of cutter

required
Also make with interlocking faces so
two cutter may be placed side by
side for slot milling
Have considerable rake
Able to take heavy cuts

Generally over 6 in. in diameter

Have inserted teeth made of high-speed

steel held in place by wedging device

Most cutting action occurs

at beveled corners and
periphery of cutter
Makes roughing and
finishing cuts in one pass

Face milling cutters under

6 in.
Solid, multiple-tooth
cutters with teeth on face
and periphery
Held on stub arbor
May be threaded or use

key in shank to drive cutter

Single-angle
Teeth on angular surface
May or may not have teeth on flat
45 or 60

Double-angle

Two intersecting angular surfaces

with cutting teeth on both

Equal angles on both side of line
at right angle to axis

Concave

Convex

Gear Tooth

Used to cut wide horizontal groove

at bottom of T-slot
After narrow vertical groove machined

with end mill or side milling cutter

65-70

Consists of small side milling

cutter with teeth on both sides and
integral shank for mounting

Copyright The McGraw-Hill Companies, Inc.

Permission required for reproduction or display.

65-71

Similar to single-angle milling

cutter with integral shank
Used to form sides of dovetail after
tongue or groove machined
Obtained with 45, 50, 55, or 60
angles

Copyright The McGraw-Hill Companies, Inc.

Permission required for reproduction or display.

Similar in design to plain and side

milling cutters
Small (up to 2 in) solid shank, straight

teeth
Large mounted on arbor with staggered
teeth

65-72

Used for milling semicylindrical

keyseats in shafts
Designated by number
system

Copyright The McGraw-Hill Companies, Inc.

Permission required for reproduction or display.

T-slot cutting with a milling cutter.

Cutters for (a) straddle milling, (b) form milling, (c)

slotting, and (d) slitting with a milling cutter.