MILLING

Milling is the process of removing excess stock by relative motion between a

workpiece and a rotating cutter having a single cutting edge or multiple cutting edges.
The machine on which this process is done is called as the Milling Machine.

HISTORY OF THE MILLING MACHINE:

In 1772, a French mechanic Vaucanson was the first person who worked with a
rotating multi point toothed cutter on a machine. The remodified version of first plain
milling machine was designed by Eli Whitney in the year 1818. The first Universal
milling machine was invented by Joseph R Brown in the year 1886.

PURPOSE OF THE MILLILNG MACHINE:

Milling machines are used for machining of flat surfaces, formed surfaces, to
cut splines, milling of threads, gear teeth etc.

TYPES OF MILLILNG MACHINES:

Milling machines may be classified according to their general design as

follows:
01. Column and knee type
a. Hand milling machine
b. Plain milling machine
c. Universal milling machine
d. Omniversal milling machine
e. Vertical milling machine
f. Horizontal milling machine
g. Ram type milling machine

02. Manufacturing or Fixed bed type

a. Simples
b. Duplex
c. Triplex

03. Planer type

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 04. Special type
a. Rotary table milling machine
b. Drum milling machine
c. Planetary milling machine
d. Pantograph, Profiling and Tracer control milling machines

01. COLUMN AND KNEE TYPE MILLING MACHINES:

a. Hand type Milling machines:

These are the simplest types of milling machines. The feed movement of the table
is supplied by hand. These machines are relatively smaller in size than that of other
types and are suitable for light and simple milling operations like milling of slots,
grooves and keyways.

b. Plain Milling Machines

1.Base
2. Knee
3. Table
4. Long Arbor
5.Ram
6. Column

Plain milling machines are much more rigid and sturdy than hand milling
machines. They can accommodate heavy workpieces. The table may be fed by
hand or power against a rotating cutter mounted on a horizontal arbor. In a Plain
milling machine, the table may be fed in longitudinal, cross or vertical directions.
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c. Universal Milling
Machines:

These machines are

so named because they may
be adapted to a very wide
range of milling operations.
The table of a Universal
milling machine is mounted
on a swivel base, which can
be swiveled to 45 degrees
on either side of the normal
position. The table can also
be swiveled about a vertical
axis and set at an angle
other than right angles to
the spindles. Thus in an Universal milling machine, in addition to the three movements
as incorporated in a Plain milling machine, the table may have a fourth movement when
it is fed at an angle to the milling cutter. This addition feature enables it to perform
helical milling operations, which cannot be done on a Plain milling machine unless a
spiral milling attachment is used. The capacity of a Universal milling machine is
considerably increased by the use of special attachments such as Dividing Head,
vertical milling attachment, Rotary attachment, Slotting attachment etc., The machine
can produce spur, spiral, Bevel gears, twist drills, reamers, milling cutters, etc. besides
doing all conventional milling operations.

d. Omniversal Milling Machines:

In this type of machine, the table in addition to having the movements of a

Universal milling Machine; can be tilted in a vertical plane. To achieve this, a swivel
arrangement I provided at the knee. The additional swiveling arrangement of the table
enables it to machine taper spiral grooves in Reamers, Bevel gears, etc.

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e. Vertical Milling Machines:

A vertical milling machine has its

spindle perpendicular to the worktable. The
machine may be of Plain or Universal type
and has all the movements of the table for
proper setting and feeding the work. The
spindle head, which is clamped, to the
vertical column can be swiveled at an angled,
permitting the milling cutter mounted on the
spindle to work on angular surfaces. In some
machines, the spindle can also be adjusted up
or down in relation to the work. The machine
is adapted for machining grooves, slots and
flat surfaces.

1.BASE
2.SADDLE
3.TABLE
4.SPINDLE HAED
5.COLOUMN.

f. Horizontal Milling
Machines:

The horizontal milling

machine consists basically of
a Headstock or a Column
bolted to or integral with a
fixed bed. On this member, a
spindle carries, head, or a
block is mounted, and
carrying a spindle that is horizontally positioned. The axis of this spindle is parallel to
the table surface and at right angles to the axis of the Table movement. The surface
carrier usually moves (manually or auto automatically) in a vertical direction on the
Headstock, and the spindle is adjusted axially (in and out) through a Spindle quill or
Ram.

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g. Ram Type Milling Machines:

In place of the ordinary type, over-

arm can slide forward and backward for
the adjustment of tool position of for
shifting the cutter position quickly. The
cutter head is pivoted to the face or the
arm and is capable of any angle
adjustments between vertical and
horizontal position. This range of
adjustment often makes it possible to
complete the job with one setup without
having to change the job to some other
machine. Thus the movable ram
enables the throat distance to be
adjusted in or out, bringing the spindle
in each case as close to the column as
possible.

2. MANUFACTURING TYPE MILLING MACHINES:

1. BED 2. LARGE CUTTER 3. COLOUMN. 4. MOTOR 5. SPINDLE

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 DUPLEX
These milling machines are comparatively large, heavy and sturdily built. They
differ from the Column and knee type machines in the mounting of the table. The table
is mounted on the ways of the fixed bed. The table movement is restricted to a right
angle movement with respect to the vertical spindle axis with no provision for cross or
vertical adjustment. The cutter mounted on the spindle head may be moved vertically
on the column and the spindle may be adjusted horizontally to prove usual feature of
these machines is the automatic cycle of operation for feeding the table that is repeated
in a regular sequence. This automatic control of the machine enables it to be used with
advantage in repetitive type of work.

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 2. PLANER TYPE MACHINES:

Planer type machines are sturdily built machines used for milling of heavier jobs
having spindle heads adjustable in vertical and in traverse direction. It resembles a
planer and like a planing machine, it has a cross rail capable of being raised or lowered
carrying the cutters, their heads, and the saddles, all supported by rigid upright
supports. There may be a number of independent spindles carrying cutters on the rail
as well as two heads on the uprights. This arrangement of independently driving
multiple cutter spindles enables number of work surfaces to be machined
simultaneously, thereby obtaining great reduction in production time. The essential
difference between a planer and a plano-miller lies in the table movement. In a planer,
the table moves to give the cutting speed, but in a plano-milling machine is much
slower than that of a planing machine.

4. SPECIAL TYPE:

Milling machines of non-conventional design have been developed to suit special

purposes. The features that they have in common are the spindle for rotating the cutter
and provision for moving the tool or the work in different directions. The following
special types of machines of interest are described below:

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Rotary table machine:
This machine is a modification to a vertical milling machine and is adapted for
machining flat surfaces at a faster production rate. The face milling cutters are
mounted on two or more vertical spindles and a number of workpieces are clamped on
the horizontal surface and a number of workpieces are clamped on the horizontal
surface of a circular table which rotates about a vertical axis. The cutters may be set at
different heights relative to the work so that when one of the cutters is roughing the
pieces, the other is finishing them. The operator may carry out a continuous loading
and unloading of work, when milling is in progress.

Drum milling machine:

The drum milling machine is similar to a
rotary table-milling machine in that its work-
supporting table, which is called a drum,
rotates in a horizontal axis. The faces milling
cutters mounted on three of four spindles
heads rotates in a horizontal axis and remove
metal from workpieces supported on both the
faces of the drum. The finished - machined
parts are removed after one complete turn of
the drum, and then the new ones are clamped
to it.

Planetary milling Machine:

In a planetary milling machine, the work
is held stationary while the revolving cutter or
cutters move in a planetary path to finish a cylindrical surface on the work either
internally or externally or externally or simultaneously. The machine is particularly
adapted for milling internal or external threads of different pitches.

Pantograph milling machine:

A Pantograph machine can duplicate a job by using a Pantograph mechanism,
which permits the size of the work piece reproduced to be smaller than, equal to or
greater than the size of a template or model used for the purpose. A Pantograph is a
mechanism that is generally constructed of four bars or links, which are joined in the
form of a parallelogram. Pantograph machines are available in two dimensional
models are employed for copying any shape and contour of the workpiece. The tracing
stylus is moved manually on the contour of the model to be duplicated and the milling
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cutter mounted on the model to be duplicated and the milling cutter mounted on the
spindle moves in a similar path on the workpieces, reproducing the shape of the model.

Profiling machine:
A profiling machine duplicates the full size of the template attached to the
machine. This is practically a vertical milling machine of bed type in which the spindle
can be adjusted vertically and the cutter head horizontally across the table. A hardened
guide pin regulates the movement of the cutter. The pin is held against and follows the
outline or profile of a template mounted on the table at the side of the job.

PARTS OF A COLUMN AND KNEE TYPE MILLING MACHINE:

The following are the parts of a Column and knee type-milling machine:

COLUMN:

It is the main part of the machine that provides support for other parts of the
machine such as Knee, Saddle, and Table etc. It is a heavy hollow casting made up of
high quality Grey Cast Iron. The inner space in the column accommodates the motor,
controls for the driving mechanism and electrical fittings. The topside of the column
accommodates the Spindle. The front of the column face has a dovetail slide for the
movement of the Knee.

BASE:

The Base is usually box in construction and accommodates the coolant fluid.
The Base is mounted on the shop floor with foundation bolts. The column and the
elevating screw for the knee rest on the Base.

KNEE:

The Knee carries the Saddle, Table and workpiece. It is sturdily built to
withstand heavy cutting pressure. The surface of the Knee is accurately machined at
right angles to the column. The bottom face forms a slide for the Saddle. The Knee is
supported at its rear side by an elevating screw. It has a vertical movement, which is
obtained with the help of an elevating crank.

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SADDLE:

The Saddle has a dovetail machined on its bottom side, which receives the Knee.
The Saddle provides bearing surfaces for guiding the Table in its crosswise movement
in relation to the column. The second longitudinal dove tailed slide on top of the
saddle, which is machined at right angles to the lower dove tailed slide on top of the
saddle, which is machined at right angles to the lower dove tailed Slide, provides the
bearing surfaces which support and guide the table in its longitudinal movements
parallel to the column face. The Saddle in the Universal type of milling machine is
made into two parts. The upper part receives the Knee. The lower part has circular
ways machined in it to form a swiveling joint and set the table at an angle of 45 degree
on either side of the centerline.

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TABLE:
Table is the working surface of the machine. It holds workpieces, fixtures,
attachments etc. The underside of the Table has male dovetail ways, which slide in the
female guide of the Saddle. The upper face is scraped accurately for parallality and
flatness. T-slots of standard sizes are machined to accommodating the stops. The
Table is made of Cast iron.

FEED SCREW OR LEAD SCREW:

It is attached longitudinally to the bottom of the Table. It can be operated
either by hand or automatic feed:

SPINDLE:
Spindle is a hollow shaft made up of alloy steel. It is hardened and ground for
perfect concentricity and a high finish to ensure accurate alignment with the top of the
column. The spindle is mounted on bearings supported by the column. The Spindle is
driven by an electric motor through a gear train mounted within the column. The front
end of the Spindle has a tapered hole and driving keys for locating and driving various
cutting tools, chucks and arbors.

OVERARM:
It is a part of the unit to support and drive the cutter arbor. It is mounted on top
of the Column and is guided in perfect alignment by the machined dovetail surfaces.
The Overarm is at right angle to the column face. It is used to carry the Yoke and
Arbor support, which provides a bearing, or support to the outer end of the cutter
arbor. Overarm may be of the Double cylindrical type for heavy duty or the
rectangular dovetail type used for medium duty operations.

OVERARM SUPPORTING BRACES OR YOKE:

These are provided with all Universal-milling machines to tie the Knee and
the Overarm for greater rigidity and support when applying heavy cuts. The Braces
have a base, which is attached to the Knee, and the slotted arms extend upwards
and are clamped to the arbor support.

ARBOR SUPPORT:
It is a separate part which slides and can be clamped to the ways of the
Overarm and extends downward to the cutting arbor. Its lower end contains a
bearing to support the arbor. It is made up of Grey Cast Iron.

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