MILLING MACHINE

Milling (machining)
Milling is the machining process of using rotary cutters to remove
material] from a work piece by advancing (or feeding) in a direction at an
angle with the axis of the tool. It covers a wide variety of different
operations and machines, on scales from small individual parts to large,
heavy-duty gang milling operations. It is one of the most commonly used
processes in industry and machine shops today for machining parts to
precise sizes and shapes.
Milling can be done with a wide range of machine tools. The original
class of machine tools for milling was the milling machine (often called a
mill). After the advent of computer numerical control (CNC), milling
machines evolved into machining centers (milling machines with
automatic tool changers, tool magazines or carousels, CNC control,
coolant systems, and enclosures), generally classified as vertical
machining centers (VMCs) and horizontal machining centers (HMCs).
The integration of milling into turning environments and of turning into
milling environments, begun with live tooling for lathes and the
occasional use of mills for turning operations, led to a new class of
machine tools, multitasking machines (MTMs), which are purpose-built to
provide for a default machining strategy of using any combination of
milling and turning within the same work envelope.
History of Milling Machine (1810s1830s)

Milling machines evolved from the practice of rotary

filingthat is, running a circular cutter with file-like
teeth in the headstock of a lathe. Rotary filing and,
later, true milling were developed to reduce time
and effort spent hand-filing.
However, the broad outlines are known, as
summarized below. From a history-of-technology
viewpoint, it is clear that the naming of this new
type of machining with the term "milling" was an
extension from that word's earlier senses of
processing materials by abrading them in some way
(cutting, grinding, crushing, etc.).
 This milling machine was
long credited to Eli
Whitney and dated to circa
1818. From the 1910s
through the 1940s, this
version of its provenance
was widely published. In
the 1950s and 1960s,
various historians of
technology mostly
discredited the view of this
machine as the first miller
and possibly even of
Whitney as its builder.
Nonetheless, it is still an
important early milling
machine, regardless of its
exact provenance.
 Line drawing of a milling machine in use
in a firearms factory in Middletown,
Connecticut, USA, by 1818. It was
described by E.G. Parkhurst, who had
seen it in 1851 and gathered information
about it then from Robert Johnson, who
dated it to 1818. Another of the people
associated with its development is
Simeon North. It has often been
described as "the first milling machine",
as has
another contemporary machine long credi
ted to Eli Whitney and dated circa 1818
, although today's scholarship in the
history of technology makes clear that
milling practice and equipment evolved
from rotary filing gradually enough, and
among enough builders, that it cannot
be said with accuracy that the builders
of this machine "invented" the milling
machine.
 The milling machine built by
James Nasmyth between
1829 and 1831 for milling
the six sides of a hex nut
using an indexing fixture.
 A typical example of
the class of milling
machines known as
the Lincoln miller.
This example was
made by Pratt &
Whitney of Hartford,
Connecticut, USA. It
probably dates to
sometime in the
1870s or 1880s.
 Brown & Sharpe's
groundbreaking universal
milling machine, 1861.
Displayed at the foot of the
machine are the countershaft
for the belt drive (which in
operation would be above or
behind the machine); a 3-jaw
chuck and a vise (for mounting
on the indexing head or on the
table); and other miscellaneous
tooling. Drawing reproduced in
Woodbury 1972 [1960] from the
original in the journal Scientific
American, 1862-12-27. Public
domain in U.S. (age).
 A typical milling
machine of the
1900-1920 era. This
is a horizontal
-spindle universal
miller built by the
Cincinnati Milling
Machine Company
of Cincinnati, Ohio,
USA.
 History of Milling Machine (1980spresent)

Computers and CNC machine tools continue to

develop rapidly. The personal computer revolution
has a great impact on this development. By the late
1980s small machine shops had desktop computers
and CNC machine tools. Soon after, hobbyists,
artists, and designers began obtaining CNC mills
and lathes. Manufacturers have started producing
economically priced CNCs machines small enough
to sit on a desktop which can cut at high resolution
materials softer than stainless steel. They can be
used to make anything from jewelry to printed
circuit boards to gun parts, even fine art.
MILLING APPLICATION &
SELECTION
When milling with an indexable face mill,
the workpiece, machine, and fixturing
must all be as rigid as possible. This will
help ensure efficient use of this type of
tool and produce the results required.
Only cutters using indexable carbide
inserts will be discussed here.
Proper cutter diameter
For maximum efficiency, two-thirds of the cutter
diameter should engage the work piece. In other
words, the cutter diameter should be 1-1/2 times
the width of cut desired. Climb milling using this
cutter diameter to width of cut ratio will ensure a
favorable entry angle into the work piece (Fig. 1).If
uncertain as to whether the machine has enough
horsepower to operate the cutter under this ratio, it
may be best to divide the axial depth of cut into
two passes (or more) to maintain as closely as
possible this cutter diameter to width of cut ratio.
Figure 1
Applying cutter geometry
Insert cutting edges may be positioned relative to
both radial and axial planes in positive, neutral,
or negative rakes. Neutral rake is generally not
used due to the shock of the entire cutting edge
impacting the work piece simultaneously.
The combination of radial and axial rakes
determines the shear angle. Three basic
combinations are available: negative radial and
axial, positive radial and axial, negative
radial/positive axial, and positive radial/negative
axial.
 Double negative geometry is
the traditional starting point
for rough milling cast iron and
steels when horsepower and
rigidity are adequate. The
double negative insert design
provides the strongest
possible cutting edge and can
withstand heavier chip loads
and considerable cutting
forces (Fig. 2).
Figure 2
 The increased cutting forces generated by
this geometry will consume more
horsepower. Double negative cutters also
require greater machine, work piece, and
fixture rigidity.
Double positive geometry provides the
most efficient cutting action due to its
increased shearing angle. Although not as
strong as double negative, entry impact
and cutting forces are greatly reduced,
making it a good choice for older, less rigid
machines or where horsepower is limited.
 With double positive geometry, the
peripheral edge, in both the radial and
axial planes, leads the insert through the
work piece creating a true shearing
action. This makes it the best choice for
non-ferrous materials and many soft,
gummy stainless steels (Fig. 3).
Negative radial/positive axial geometry
combines some of the advantages of both
double negative and double positive.
Negative radial rake provides strong
cutting edges, while positive axial rake
creates a shearing action. A positive axial
rake directs chips up and away from the
work piece. This prevents chip
recutting and takes heat away from the
work surface and the cutting edge.
Positive radial/negative axial geometry Figure 3
reduces power consumption while still
providing a strong corner cross-section
Effective lead angles

Figure 4
Cutter lead angles also affect performance. A 45
lead tool reduces chip thickness about 30
percent as compared to a 0 lead tool (Fig. 4).
This allows you to maintain a given chip load at a
higher feed rate, increasing the metal removal
rate. A proper lead angle allows a cutter to enter
and exit the cut more smoothly, minimizing shock
to the cutting edges. Work piece edge break-out,
a common problem when machining cast iron,
can be significantly reduced or eliminated by use
of increased lead angle. The lead angle allows
the cutting edge to exit the work piece gradually.
This reduces radial pressure and minimizes
breakout. Remember that increasing the lead
angle to reduce radial pressure does increase
axial pressure. This can cause deflection of the
machined surface when the work piece has a
thin cross-section.
Choosing cutter density
The cutter density must allow chips to form properly and clear the cut.
Inadequate chip space can cause chips to plug the gullet, breaking the
cutting edge and possibly damaging the work piece. However, the cutter
must have sufficient density to keep at least one insert in the cut at all
times. Failure to do this could cause severe pounding which can lead to
chipped cutting edges, a damaged cutter, and excess wear to the machine
(Fig. 5).Coarse pitch tools, with 1 to 1-1/2 inserts per inch of diameter,
allow for greater chip gullet space. These tools are recommended for soft
materials that produce continuous chips, and in wide cuts with a long insert
engagement. It is desirable to have at least one insert in contact with the
work piece at all times. Fine pitch tools, though primarily for cast iron, are
also good for shallow or narrow cuts in high-temperature alloys where light
chip loads are taken. Small chips require less gullet, allowing more inserts
per inch. Although selecting a face mill can be a complicated and
somewhat subjective process, these guidelines can give you a good
starting point. By using and expanding on these principles, you will be able
to select a face mill for any operation in your plant.
Figure 5
GENERAL APPLICATION
INFORMATION
GENERAL APPLICATION INFORMATION
The following information is directed toward
indexable carbide tools but it can be
applied to many other cutting tools, as well.
It provides some basic guidelines designed
to serve as a starting point for safe and
reliable performance. Contact your
Ingersoll Cutting Tool Company sales
engineer for specific application assistance.
Rigidity
Use the most rigid cutter possible. This
usually means the cutter with the largest
diameter and shortest length. Use the
best adaption possible. Integral tapers,
such as a 50 V-flange, are better than
straight shanks. When selecting straight
shank tools, use a cutter with the largest
diameter shank possible and a holder
with the shortest length possible
Effective cutting edges.

When calculating feed rate, use the

effective number of inserts. In extended
flute cutters, the effective number of
inserts is not the number of rows. Use
the effective number listed with the
specifications for each series of tools.
Chip load.
Carbide cutting tools have to take a bite
to cut. Be sure to cut with an adequate
chip load. Light chip loads can contribute
to chatter, causing a cutter to rub instead
of bite. This can also result in poor tool
life. As a general rule, chip loads should
not be less than .004. Also, be sure to
use Radial Chip Thinning Factors (RCTF)
when calculating feed rates
Chip recutting
Unlike HSS, carbide cutting tools cannot
recut chips. Recutting chips will damage
carbide. To evacuate chips, use air or
coolant depending on the material being cut.

Coolant
Generous amounts of coolant are required when
low thermal conductivity, work hardening, and
chip welding tendencies are evident. Use coolant
only when necessary. Some materials cut better
dry. In some applications, coolant causes thermal
cracking of inserts and poor tool life.
Feed rates
Reduce feed rates by 50 percent when entering
or exiting a cut. Since fewer inserts are engaged
in the work, pounding can occur. Reducing feed
rates will reduce the shock of the interrupted cut
and contribute to longer tool life.
When entering a corner during pocket milling, a
larger portion of the cutters diameter is
engaged. Power requirements and tool
deflection increase. To compensate, program a
reduced interpolated feed rate. Alternately, drill
or plunge the corner prior to milling.
Cutter rotation
Climb cut whenever possible. Carbide is
designed for climb milling and will not
generally perform as well when
conventional cutting. Conventional
cutting may be employed on older
machines to minimize backlash. It can
also extend tool life in sandy, scaly, or
torch-cut surfaces as the cutting edge
enters into cleaner, softer material.
Hardness
Generally, harder materials should be
machined at the lowest speed in Surface
Milling Machine: Parts and
Working
Milling is a mechanical machine which is
used to machined unsymmetrical job. It
is widely used in tool and die making
industries. It is a versatile machine. It
can perform all operations like turning,
facing, drilling, shaping, grooving, etc.
Milling Machine Parts:
Base
Column
Knee
Saddle
Table
Overhangingarm
Spindle
Arbor
ArborSupports
Millinghead
Ram
Base
It is the foundation part of a milling
machine. All other parts are jointed on it.
It carries the entire load so it should
have high compressive strength so it is
made by cast iron. It also works as
reservoir of cutting fluid.
Column
Column is another foundation part
of milling machine. It is mountain
vertically on the base. It supports
the knee, table etc. Work as
housing for the all the other driving
member. it is a hollow member
which contains driving gears and
sometimes motor for spindle and
the table.
Knee
Knee is the first moving part of milling
machine. If is mounted on the column
and moves along the sideways situated
over the column. It is made by cast iron
and moves vertically on sideways It
moves up and down on sideways which
change the distance between tool and
work piece It is driven by mechanically
or hydraulically
Saddle
It is placed between table and the knee
and work as intermediate part between
them. It can moves transversally to the
column face. It slides over the guide
ways provided situated on the knee
which is perpendicular to the column
face. The main function of it is to provide
motion in horizontal direction to work
piece. It is also made by cast iron.
Table
Table is situated over the knee. It is the part of
machine which holds the work piece while
machining. It is made by cast iron and have T slot cut
over it. The work piece clamp over it by using
clamping bolts. The one end of clamping bolt fix into
this slot and other is fix to work piece which hold the
work piece. It can provide three degree of freedom to
work piece.
It provides vertical motion by moving the knee up and down.
It provides horizontal motion by the feed screw.
It provides horizontal (transverse) motion by moving the
saddle.
Overhangingarm
It is situated over the column on
horizontal milling machine. It is
overhang over the column surface and
other end supports the arbor. It is made
by cast iron.
Spindle
Spindle is the main part of the machine
which hold tool at right place in vertical
milling machine and hold arbor in
horizontal milling machine. It is a moving
part which is in rotary motion. It is motor
driven and drives the tool. It has a slot
on the front end of it. The cutting tool fix
in that slot.
Arbor
It is a mechanical part on which is used
as extension part of the spindle in
horizontal milling machine. It is fitted on
the spindle whenever required. It holds
the tool and moves it in correct direction.
Arbor Supports
This are used to support arbor at right
place. One end of this support is jointed
at the overhanging arm and another is
jointed with arbor.
 Milling head
It is upper section of vertical milling
machine. It consist spindle, driving
motor and other controlling mechanism.
Ram
Ram is work as overhanging arm in vertical
milling machine. One end of the arm is attached
to the column and other end to the milling head.
Working of Milling
Machine
A milling is a versatile machine which is used to form different shapes
by metal cutting. The working of milling machine is as follow.

1. First the cutting tool is set at the arbor which is connected to

the spindle.
2. The knee is moved downward.
3. Now the work piece is clamped on the table by using clamping
screw.
4. All the controlling points are set to zero like knee position, saddle
position etc
5. Now the spindle starts to rotate which further rotates the cutting tool.
6. As the tool is moving, we move the work piece as required by
moving the knee, saddle and table.
7. The controlling axis move the work piece and cut the desire shape
on it. The tool remains stationary and only in rotary motion.
Indexing head (dividing head or
spiral head)
Is a specialized tool that allows a work piece to
be circularly indexed; that is, easily and precisely
rotated to preset angles or circular divisions.
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. Common jobs for
a dividing head include machining the flutes of a
milling cutter, cutting the teeth of a gear, milling
curved slots, or drilling a bolt hole circle around
the circumference of a part.
Manual indexing heads
ndexing is an operation of dividing a periphery of a
cylindrical workpiece into equal number of
divisions by the help of index crank and index
plate. A manual indexing head includes a hand
crank. Rotating the hand crank in turn rotates the
spindle and therefore the workpiece. The hand
crank uses a worm gear drive to provide precise
control of the rotation of the work. The work may
be rotated and then locked into place before the
cutter is applied, or it may be rotated during cutting
depending on the type of machining being done.
CNC indexing heads
CNC indexing heads are similar in
design to the manual variety except that
they have a servo motor coupled to the
spindle instead of a hand crank and
indexing plates. The servo motor is
electronically controlled to index the
work to the required position.
Types of Milling Machines

HorizontalMill
Vertical Mill
Horizontal Milling
Horizontal milling machines have a spindle or cutters
mounted on a horizontal arbor above an X-Y table.
Some horizontal mills have a table, known as universal
table, that features a rotary function for machining at
different angles. Horizontal mills are optimal for
machining heavier pieces because the cutters have
support from the arbor, as well as a bigger cross-
section area than a vertical mill. The design of the
horizontal milling machine allows for the rapid removal
of material off of the piece one is machining. These
types of milling machines can range in size from
something small enough to fit on a tabletop to room-
sized machines.
Vertical Milling
Vertical milling machines have a spindle that moves in
a vertical orientation over the table, working on the top
and bottom sides of the object being machined.
Vertical milling machines lend themselves to standing
machinists and detailed work. These machines tend to
be taller than they are wide since their operation is
vertical, which works well when dealing with die
sinking. Die sinking is when a cavity of a particular size
and shape is machined into a steel block. The opening
can then be used for molding plastic or for forging,
coining, or die-casting. Below are the two types of
vertical milling machines most commonly used.