BY : L M LIKANDAWE

OBJECTIVES
By the end of this lecture students should be able to:
•Practice general safety and safety related to particular machine tools
•Draw and name parts of machine tools
•Explain the drive mechanism on a milling machine .
•Select correct cutting speed.
•Differentiate between forming and generation of surface
•Calculate using different indexing methods the indexing required for
particular jobs.
Select proper milling cutters tools for various applications
Discriminate different milling processes.
 SAFETY
The main danger associated with milling machines is the cutter.
• Make sure the cutter guard is in place before starting the
machine.
• Do not remove swarf with a brush whilst the cutter is revolving.
• Do not wipe away coolant from the cutting zone with a rag
whilst the cutter is revolving.
• Do not take measurements whilst the cutter is revolving.
• Do not load or unload work whilst the cutter is revolving.
• Do not put your hands anywhere near the cutter whilst it is
Revolving.
 SAFETY GUARDS

(a) Toolroom Type Cutter Guard

(b) Production Type Cutter Guard

Adapted from Figure 11.1 Timings

 MILLING
•The milling machine is one of the most important machine tools
in the workshop.
•Milling is the machining process in which the removal of metal is
due to the cutting action of a rotating milling cutter.
•The workpiece is fed against the cutter.
•In some cases it holds more than one tool at a time. The cutter
rotates at high speed.
•Metal removal is very fast rate.
•All operations can be performed with high accuracy.
THE MILLING MACHINE AND
MILLING PROCESS

PROCESS

MACHINE
 COLUMN AND KNEE TYPE
Column and Knee Type
For general shop work column and
knee type is used.
The table is mounted on the knee-
casting which in turn is mounted on the
vertical slides of the main column.

The knee vertical adjustable on the

column.
The table is moved up and down to
accommodate work of various heights.
Classification of column and knee type
milling machines:
•According to the various methods of
supplying power to the table.
•Different movements of the table. and
•The different axis of rotation of the main
spindle
COLUMN AND KNEE TYPE NOMENCLATURE
HAND MILLING MACHINE
It simplest of all types
of milling machine in which table
feeding is controlled by hand. The
cutter is mounted on a horizontal arbor
and is rotated by power. This type of
milling machine is of small in size and
suitable for light and simple milling
operations. For Example, machining
slots, grooves, and keyway.
 PLAIN MILLING MACHINE
These are much stronger than hand millers.
The table feeding is done either by hand or
power. The plain milling machine having a
horizontal spindle is also called as a
horizontal spindle milling machine. The
table may be fed in a longitudinal, cross,
or vertical directions.

The feed is:

Longitudinal – when the table is moved at right angles to the spindle.
Cross – when the table is moved parallel to the spindle.
Vertical – when the table is adjusted in the vertical plane
 UNIVERSAL MILLING MACHINE
It can be adapted to a wide range of milling
operations.
Table can be swiveled to any angle up to 45-
degrees on either side.
The table may fed at an angle to the milling
cutter.
Helical milling operation can also be performed.
Capacity increased by using special
attachments:
•Dividing head or index head.
•Vertical milling attachment.
•Rotary attachment.
•Slotting attachment.

Parts produced eg: spur, bevel, spiral, twist drill, reamer, milling cutter.
All operations that are performed on a shaper can be done using a universal
milling machine.
 FIXED BED TYPE MILLING
MACHINE
These machines are large, heavy and rigid in
construction.
They differ from column and knee type milling
machines by the construction of its table mounting.
The table is mounted directly on the ways of a
fixed bed.
The table movement is restricted to reciprocating
at a right angle to the spindle axis with no
provisions for cross or vertical adjustment.

It is classified based on spindle heads:

Simplex – single spindle head, Duplex – two-spindle head and Triplex – three spindle
head.
 Vertical Milling Machine
The spindle is vertical or perpendicular to the
table.
This type of machine is adapted for machining
grooves, slots, and flat surfaces.
The machine may be of the plain or universal
type.
It has all the movements of the table for a proper
setting and feeding the work.
The spindle head is clamped to the vertical
column.
It can be swivelled at an angle when angular
surfaces are required.
In some machines, the spindle can also be
adjusted up or down relative to the work.
 PLANNER MILLING MACHINE
•This types of milling machine are also called as
“Plano-Miller”. It is a massive machine used for
heavy-duty work having spindle heads adjustable in
the vertical and transverse direction.
•It relates to a planer and like a planing
machine. This machine has a cross rail capable of
being raised or lowered carrying the cutters. It has
their heads, and the saddles, all supported by rigid
uprights.
•This arrangement of driving multiple cutter spindles enables a number of work surfaces to be
machined. Thereby it obtains the 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, the table
movement gives the feed
SPECIAL MILLING MACHINES
Rotary milling machine
The table is circular in nature and
rotates about a vertical axis. Cutters are
set at different heights.
One cutter roughs the workpiece and
other one cutter finishes them.
The advantage of this machine is that
continuous loading and unloading of
workpieces can be done by the operator,
while is in progress.
PROFILING MACHINE
A profiling machine duplicated the full
size of the template attached to the
machine. Here the spindle can be adjusted
vertically and the cutter horizontally across
the table.
A hardened guide pin regulates the
movement of the cutter. The longitudinal
movement of the table and
the crosswise movement of the cutter head
follows the movement of the guide pin on
the template
THE TRACER CONTROLLED MILLING MACHINE

The tracer controlled milling

machine reproduces irregular or
complex shapes of dies, moulds
by synchronized (matched)
movements of the cutter and
tracing elements.
The movement of the stylus
energized an oil relay system
which in turn operates the main
hydraulic system for the table.
This arrangement is termed as a
servomechanism.
DISCLAIMER
Despite the vast list of milling machines available, our study will
be concentrated at the basic types namely:
•Vertical milling,
•Horizontal milling and
•Universal milling machines.
 TOOL TYPES
Named According To The Constructional Feature of The Cutter
Solid Cutter
A solid cutter has teeth with the cutter body. The cutters are of smaller diameter and made
of one piece material usually of (HSS) high-speed steel.

Tipped Solid Cutter

A tipped solid cutter is similar to a solid cutter, except that the cutter teeth are made of
cemented carbide or stellite tips which are brazed on the tool shanks of an ordinary tool
steel cutter body to lower the cost of the cutter.

Inserted Teeth Cutter

In large milling cutters, the teeth or blades are inserted or secured in a body of less
expensive materials. The blades are held in the cutter body by mechanical means. This
arrangement reduces the cost of the cutter and enables economy in maintenance, as a
single tooth if broken can be readily replaced.
Named According To The Relief
Characteristics of The Cutter Teeth
Profile Relieved Cutter
In this category of milling cutters, a relief to the cutting edges is provided
by grinding a narrow land at the back of the cutting edges. The profile
relieved cutters generate flat, curved or irregular surfaces.
Form Relieved Cutter
Form relived cutter also known as surface milling. These cutters have
curved relief provided at the backside of the cutting edges. These cutters
are sharpened by grinding the faces of the teeth. The form relieved cutters
are used for generating formed or contoured surfaces
Named According To Methods of Mounting
Cutter
Arbor Type Cutter
The arbor type cutters are provided with a central hole having a keyway for mounting them
directly on the milling machine arbor. Also available are those tapered or with threaded holes
They are mounted on arbors of different designs.
Shank Type Cutter
The shank type cutters are provided with straight or tapered shank integral with cutter body.
The straight or tapered shanks are inserted into the spindle nose and are fixed to it by a draw
bolt.
Facing Type Cutter
The facing type cutters are either bolted or attached directly to the spindle nose, or secured on
the face of a short arbor called stub arbor. The facing type cutters are mainly used to produce
flat surfaces
Named According To The direction of
Rotation of The Cutter Teeth

Right Hand Cutter

A milling cutter is designated as a right-hand cutter which rotates in an
anticlockwise direction when viewed from the end of the spindle.
Left Hand Cutter
A milling cutter is designated as a left-hand cutter which rotates in a
clockwise direction when viewed from the end of the spindle.
Named According To The Direction of The Helix
of The Cutter Teeth
Parallel or Straight Teeth Cutter
The parallel or straight teeth cutters have their straight or parallel to the axis of rotation of
the cutter. The helix angle of parallel teeth cutters is equal to zero.
Right Hand Helical Teeth Cutter
These cutters have their teeth cut at an angle to the axis of rotation of the cutter. The cutters
may be distinguished by viewing it from one of its end faces when the helical groove or
flute will be found to lead from left to right-hand direction of the cutter body.
Left Hand Helical Teeth Cutter
These cutters have their teeth cut at an angle to the axis of rotation of the cutter. The cutter
may be distinguished by viewing it from one of its end faces when the helical groove or
flute will be found to lead from right to left-hand direction of the cutter body.
Alternate Helical Teeth Cutter
In some cutters, the alternate teeth are provided with right and left and helical angles.
Named According To The Purpose or Use of
The Cutter
Standard Helical Teeth Cutter
These cutters are a conventional type of milling cutters whose dimensions such
as cutter diameter and width, the diameter of the centre hole, width and depth of
keyways, etc. are standardized.
Special Milling Cutter
Special milling cutters are designed to perform special operations which may be
the combination of several standard operations. The cutters may have standard or
non-standard dimensions.
 MILLING MACHINE CUTTERS

Horizontal milling machine cutters and the surfaces they produce: (a) slab
milling cutter (cylinder mill); (b) side and face cutter; (c) single-angle cutter; (d)
double equal-angle cutter; (e) cutting a V-slot with a side and face mill; (f)
double unequal-angle cutter; (g) concave cutter; (h) convex cutter; (i) single and
double corner rounding cutters; (j) involute gear tooth cutter.
 CHOICE OF MILLING CUTTERS
When choosing a milling cutter you will have to specify:
• The bore of this must suit the arbor on which the cutter is to be
mounted. In many workshops one size of arbor will be standard
on all machines and all the cutters will have the appropriate
bores.
• The diameter of the cutter.
• The width of the cutter to suit the work in hand.
• The shape of the cutter.
• The tooth formation.
MILLING CUTTERS FOR VERTICAL
MILLING MACHINES
EXAMPLES OF VERTICAL MILLING OPERATIONS
VERTICAL MILLING MACHINE CUTTERS
ONLY slot drills can be used for making pocket cuts. All the other cutters have to
be fed into the workpiece from its side as they cannot be fed vertically downwards
into the work.
When choosing a cutter you will need to specify:
• The diameter of the cutter.
• The length of the cutter.
• The type of cutter.
• The type of shank. Some cutters have solid shanks integral with the cutter for
holding in a chuck, whilst other cutters are made for mounting on a separate stub
arbor. Some large face milling cutters are designed to bolt directly onto the spindle
nose of the machine.
 THE SIDE MILLING CUTTER

The side milling cutter has teeth on its periphery and also on one or both of its sides.
This types of milling cutters are intended for removing metals from the side of a work a
side milling cutter.
Types: Plain, staggered teeth, half side milling, interlocking.
MILLING CUTTERS
MILLING CUTTERS

End Mill
MILLING CUTTER

Side And Face Cutter

Woodruff Cutter
MILLING CUTTERS
RELIEVED MILLING CUTTERS
THREAD MILLING CUTTERS
 MILLING OPERATIONS

•The face milling is the simplest

•Plain milling is the most common operation. milling machine operations.
•Aims to produce a plain, flat, horizontal •This operation is performed by a face
surface parallel to the axis of rotation of a plain milling cutter rotated about an axis
milling cutter. perpendicular to the work surface.
•Operation is also known as slab milling. •The operation is carried in plain
•To perform the operation, the work and the milling, and the cutter is mounted on a
cutter are secured properly on the machine. stub arbor to produce a flat surface.
•The depth of cut is set by rotating the vertical •The depth of cut is adjusted by
feed screw of the table. And the machine is rotating the cross feed screw of the
started after selecting the right speed and feed. table.
 MILLING CUTTER

Corner-rounding cutter
Designed to produce a radius along
the edge of the workpiece, this
cutter has a quarter circle cut in
the outer edge, Fig. 11.8(m). It is
available in a variety of sizes with
corresponding radii up to a
maximum radius of 12 mm.
 MILLING OPERATIONS

•The straddle milling is the operation of

producing a flat vertical surface on both •The angular milling is the operation of
sides of a workpiece by using two side producing an angular surface on a
milling cutters mounted on the workpiece other than at right angles of the
same arbor. axis of the milling machine spindle.
•The angular groove may be single or
•Distance between the two cutters is double angle and may be of varying
adjusted by using suitable spacing collars. included angle according to the type and
contour of the angular cutter used.
•The straddle milling is commonly used to •One simple example of angular milling is
design a square or hexagonal surfaces. the production of V-blocks.
 MILLING OPERATIONS CONTD

•The gang milling is the operation of

machining several surfaces of a workpiece •The form milling is the operation of
simultaneously by feeding the table against a producing the irregular contour by
using form cutters.
number of cutters having the same or different •The irregular shape may be convex,
diameters mounted on the arbor of the machine. concave, or of any other shape. After
machining, the formed surface is
•The method saves much of machining time inspected by a template gauge.
and is widely used in repetitive work. •Cutting rate for form milling is 20%
to 30% less than that of the plain
•Cutting speed of a gang of cutters is calculated milling.
from the cutter of the largest diameter.
 MILLING OPERATIONS
•Profile milling is the operation of reproduction an outline of a
template or complex shape of a master die on a workpiece.
•Different cutters are used for profile milling. An end mill is one
of the widely used milling cutters in profile milling work.
END MILLING

•The end milling is the operation of

producing a flat surface which may be
vertical, horizontal or at an angle in
reference to the table surface.
•The cutter used is an end mill. The
end milling cutters are also used for
the production of slots, grooves or
keyways.
•A vertical milling machine is more
suitable for end milling operation.
 SLOT MILLING

Setting Tool on edge

Tool brought to centre line
SAW MILLING
•Saw-milling is the operation of
producing narrow slots or grooves on a
workpiece by using a saw-milling
cutter.
•The saw-milling also performed for
complete parting-off operation.
•The cutter and the workpiece are set in
a manner so that the cutter is directly
placed over one of the T-slots of the
table.
MILLING KEYWAYS, GROOVES AND SLOTS

•The operation of producing of keyways,

grooves and slots of varying shapes and
sizes can be performed in a milling
machine.
•It is done by using a plain milling cutter,
a metal slitting saw, an end mill or by a
side milling cutter.
•The open slots can be cut by a plain
milling cutter, a metal slitting saw, or by
a side milling cutter. The closed slots are
produced by using slot drills.
MILLING PROCESSES CONTD
•A dovetail slot or T-slot is manufactured by
using special types of cutters designed to
give the required shape on the workpiece.
•The second slot is cut at right angles to the
first slot by feeding the work past the cutter.
•A woodruff key is designed by using a
woodruff key slot cutter.
•Standard keyways are cut on the shaft by
using side milling cutters or end mills.
•The cutter is set exactly at the centre line of
the workpiece and then the cut is taken
 MILLING OPERATION CONTD

•The helical milling is the operation of

producing helical flutes or grooves around
the periphery of a cylindrical or conical
•The gear cutting operation is performed by workpiece.
using a form-relieved cutter. •The operation is performed by rotating
•The cutter may be a cylindrical type or end the table to the required helix angle. And
mill type. then by rotating and feeding the workpiece
•The cutter profile fits exactly with the tooth against rotary cutting edges of a milling
space of the gear. cutter.
•Equally spaced gear teeth are cut on a gear •Production of the helical milling cutter,
blank by holding the work on a universal helical gears, cutting helical grooves or
diving head and then indexing it. flutes on a drill blank or a reamer.
 THREAD MILLING

It is a method of milling threads on dies, screws, worms, etc.

both internally and externally. As an alternative to the screw

cutting in a lathe, this method is being more extensively

introduced nowadays in modern machine shops.

Cam Milling
The cam milling is the operation of producing cams in a milling
machine by the use of universal dividing head and a vertical milling
attachment. The cam blank is mounted at the end of the dividing
head spindle and an end mill is held in the vertical milling
attachment.
The axis of the cam blank and the end mill spindle should always
remain parallel to each other when setting for cam milling. The
dividing head is geared to the table feed screw so that the cam is
rotated about its axis while it is fed against the end mill. The axis of
the cam can be set from 0 to 90° in reference to the surface of the
table for obtaining a different rise of the cam.
 MILLING OPERATIONS CONTD
Up-cut or conventional milling
The work is fed towards the cutter against the
direction of rotation.
• This prevents the work being dragged into the
cutter if there is any backlash in the feed
mechanism.
• Unfortunately this technique causes the cutting
edges to rub as each tooth starts to cut and this
can lead to chatter and blunting of the cutting
edge.
• The cutting action tends to lift the work off the
UPCUT MILLING
machine table.
• For safety this is the technique you should
always adopt unless your instructor advises you
to the contrary
 MILLING OPERATIONS CONTD
Down-cut or climb milling
The work is fed into the cutter in the same direction
as the cutter is rotating.
Safety: The climb milling technique can be used
only on machines fitted with a ‘backlash eliminator’
and which are designed for this technique. If it can
be used safely this technique has a number of
advantages, particularly for heavy cutting
operations.
• The cutter does not rub as each tooth starts to cut.
Down-cut milling
This reduces the risk of chatter and prolongs the
cutter life.
• The cutting forces keep the workpiece pressed
down against the machine table.
• The action of the cutter helps to feed to the work.
 WORKHOLDING DEVICES
The work to be machined on a milling machine may be held:
• In a machine vice.
• Clamped directly onto the machine table.
• Clamped to an angle plate that is itself clamped to the machine table.
• In a milling fixture for production work. To save time pneumatic
clamping is often employed.

To maintain positional accuracy of the vice:

• Check the tenons are a close slide fit in the tenon slots in the vice
body and also in the T-slots of the machine table.
• Check that the tenons are clean and free from burrs and bruises.
• Clean the tenon slots and insert the tenon blocks, securing them with
socket head cap screws.
 Types of Machine vices

Dividing Head
 INDEX PLATE
Hole circles

Adjusting the sector arm

 CLAMPS

CLAMPING PRINCIPLES Clamps

Clamps
 ROTARY TABLE WORK EXAMPLE
consider the workpiece shown which
requires the 40 mm radius to be
machined in a vertical milling machine.
•A bung is produced with one end to suit the
hole in the rotary table and the other to suit
the diameter of hole in the workpiece.
•The workpiece is set on a pair of thin parallels, to
raise the workpiece and avoid machining the table
surface.
•Clamp the workpiece in position and
mount the required size of end-mill cutter
in the machine.
•Lock the saddle movement in the
already established central position.
•Move the machine table a distance equal
to the radius to be machined plus half
the cutter diameter.
•This distance is moved accurately by
referring to the micrometer dial on the
machine-table traverse.
WORKHOLDING DEVICES

Examples of various vices

Dividing head and accessories

WORK HOLDING
 SPEEDS AND FEEDS
Speeds and feeds choice depends upon:
• The surface finish required.
• The rate of metal removal required.
• The power of the machine.
• The rigidity of the machine.
• The rigidity of the work.
• The security of the workholding device.
• The material from which the work is made.