Milling Machine

MNIT MET-101

Ask yourself these questions before study

 What is a milling m/c?

 What is the need of a milling m/c?

 What are different operations that can be performed

on a milling m/c?
 What are main parts of a milling m/c?

 Make a neat labeled sketch of a milling m/c?

2
MNIT MET-101

Few more questions before study

 Write complete specifications of a milling m/c?

 Enumerate different types of milling m/c’s.

 What are the main specifications of a milling m/c tool?

 Where milling m/c is used?

 Guess approximate cost of small and medium size milling m/c.

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CONTENT of milling machine

 Introduction
 Principle of working
 Types of milling machine
 Main parts of milling m/c
 Milling machine operations
Pic of a Milling
 Milling machine

 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.
 A milling machine is a machine tool that removes metal as
the work piece moves against a rotating multipoint cutter.
 The milling cutter rotates at high speed and it removes metal
at a very fast rate with the help of multiple cutting edges.
 One or more number of cutters can be mounted
simultaneously on the milling machine.
 Milling machine
 This is the reason that a milling machine finds wide application
in production work.

 Used for machining flat surfaces, contoured surfaces, external

and internal threads.

 Machined surface is formed in one or more passes of

the work.
 Feed and Depth of cut
 Cutting feed focuses on how far the cutting spindle travels
across the metal part during one full rotation of the tool.
 As the cutting tool moves into the metal part, the distance
(depth) that tool moves is the depth of cut.
 The depth of cut parameter focuses on the tertiary cutting
motion of the tool as the tool is pushed deeper into the
workpiece to the specified depth.
 The depth of cut will usually vary between 0.1 to 1.0 mm.
 These three parameters (speed, feed and depth of cut) ensure
accuracy of the finished work piece and the surface finish
 Milling machine
 The work to be machined is held in
 a vice,
 a rotary table,
 a three jaw chuck,
 an index head,
 in a special fixture or bolted to machine table.
 In many applications, due to its higher production
rate and accuracy, milling machine has even
replaced shapers.
 Milling machine applications

 Groove milling
 Plain or slab milling  Slot milling

 Plain milling in steps  Angular milling  Vertical, angular

and groove
milling
Main Parts
 Base
 Column
 Swivelling head
 Spindle (rotates)
 Milling Cutter (tool)
 Table (for resting of w/p)
 Knee (support the table)
 Saddle
Spacer
VERTICAL MILLING MACHINE

MAJOR PARTS :
1. BASE
2. COLUMN
3. SPINDLE
HEAD
4. SPINDLE
5. Cutter
6. KNEE
7. SADDLE
8. WORKTA
ACTUAL HORIZONTAL MILLING MACHINE

Arbor ARM

Table with slots

ARBORS

Fig : Mounting a milling cutter on an arbor for use on a horizontal milling machine.
 MILLING METHODS
Two basic methods of milling
1. Up-milling or conventional milling
2. Down-milling or climb milling
1.Up-milling or conventional milling
 Metal is removed by cutter rotating against the
direction of travel of the workpiece.
 Needs stronger holding of the job.

 Cutter teeth cut metal upwards

 Chip thickness is minimum at the start of cut and

maximum at the end of the cut.
 Disadvantage – There is tendency to lift work from the
fixtures and poor surface finish.
 1.Up-milling MILLING

Cutter rotating
against the
direction of travel
of the w/p

Poor surface finish

 MILLING METHODS
2. Down-milling or climb milling
 Metal is removed by cutter rotating in the
same direction of travel of the workpiece.
 Cutter teeth cut metal downward instead of
upwards.
 Chip thickness is maximum at the start of cut
and minimum at the end of cut.
 Less friction is involved

 Better surface finish is obtained.

 Less power consumption.

 2. Down-milling Cutter rotating in the direction of
travel of the w/p
Better surface finish
 PRINCIPLE OF MILLING

Cutter rotating against Cutter rotating in the direction of

the travel of the w/p w/p
 TYPES OF MILLING MACHINE

 The milling machine may be classified in several

forms, but the choice of any particular machine is
determined primarily by the size of the workpiece.
 According to general design, the distinctive types of
milling machines are:

1. Column and knee type milling machines-most common

2. Planer milling machine

3. Fixed-bed type milling machine

4. Special types of milling machines

 COLUMN AND KNEE TYPE

 Itis the most commonly used

milling machine in general
shop work.
 The table is mounted on the
knee and knee is mounted on
the vertical slides of the main
column.
 The knee is vertically
adjustable on the column so
that the table can be moved
up and down to
accommodate work of various
heights.
CLASSIFIACTION OF COLUMN & KNEE
TYPE MILLING MACHINE

(a) Hand milling m/c.

(b) Horizontal milling m/c.

(c) Vertical milling m/c.

(d) Universal milling m/c.

a
( ) Horizontal Milling machine
 Spindle is horizontal to work rable
ACTUAL HORIZONTAL MILLING MACHINE
Cutter cannot be moved up &
ARM
Arbor down.
• Spindle is
parallel to the
shop floor
Table • Overarm
extends over
the work
piece.
• The overarm
supports the
arbor,
• Arbor holds
the milling
cutter.
• Arbor rotates
ARBORS
Operations such as
• plain milling,
• gear cutting,
• form milling
can be performed.

Fig : Mounting a milling cutter on an arbor for use on a horizontal milling machine.
VERTICAL MILLING

 Spindle is vertical to
the work table.
 M/c has all the
movements of the
table
 Spindle head may be
swiveled at an angle
 Cutter can be moved
up & down and
mounted on spindle
 Used for machining
grooves, T-slots and
flat surfaces,
angular milling, and
also drilling, boring
and reaming
operations
(C) UNIVERSAL MILLING MACHINE

Used for milling of

• helical grooves in
twist drills,
• milling cutters, and

• gears
FIXED BED MILLING MACHINE
•Comparatively large,
heavy and rigid Table is
directly mounted on fixed
bed.
•No provision is provided
for cross or vertical
adjustment of the table.
•The cutter is mounted on
the spindle head
MILLING OPERATIONS
 Plain or slab milling
 Face milling

 End milling

 Side milling

 Slot milling

 Angular milling

 Form milling

 Straddle milling
MILLING OPERATIONS
 Slittingor saw milling
 Gear cutting

 Key way milling

 String milling

 Profile milling

 Thread milling

 Helical milling

 Cam milling
PLAIN/SURFACE/ SLAB MILLING
Plain Milling:
 Process is to get the flat
surface on the work piece
 In plain milling cutter
axis and work piece axis
are parallel.
 In plain milling the
primary motion is the
rotation of the cutter.
 The feed is imparted to
the work piece.
Machine used is Horizontal Milling m/c.
PLAIN/SURFACE/ SLAB MILLING

• Process is to get the flat surface

Plain mill on the work piece
cutter • Side of rotating cutter is
making flat surface

Work piece
FACE MILLING OPERATION
 Operation is
carried out to
produce a flat
surface
 Flat surface is
perpendicular to
the axis of rotating
cutter
 Face of rotating
cutter is making
flat surface

Cutter used: Face

milling cutter.
Machine used: Vertical Milling Machine
FACE MILLING
END/ SIDE MILLING
In End Milling: Operations are
performed for producing
• flat surfaces,
• key slots,
• grooves
• or finishing edges of the w/p

Cutter: End milling cutter.

Machine Used: Vertical Milling

Machine
SLOT MILLING

Slot Milling:
Operation of
producing slots like
T-slots, plain
slots etc.,

Cutter: End milling

cutter, T-slot
cutter, side milling
cutter
FIG. T-SLOT MILLING Machine: Vertical
Milling Machine
SLOT MILLING
ANGULAR MILLING

Angular Milling:
Operation for
• producing all types of
angular cuts
• like V-notches and grooves,
• and angular surfaces
Cutter: Double angle cutter.

Machine used: Horizontal

FIG. ANGULAR MILLING
Milling Machine
FORM MILLING

For producing
Grooves, serrations
and angular surfaces.

Cutter: Double angle

cutter.
Machine: Horizontal
Milling Machine
FORM MILLING
 STRADDLE MILLING

Straddle Milling:
Operation for
machining two parallel
surfaces
Simultaneously on a
work piece.
Cutter: 2 or more side
& face milling cutters

FIG. STRADDLE MILLING Machine: Horizontal

Milling Machine
Pocket Milling

Pocket
milling is a
type of end
milling
used to mill
shallow
pockets into
flat parts
SURFACE CONTOURING
Ball - nose cutter is
fed back and
forth across the
work along a
curvilinear path at
close intervals
to create a three
dimensional
surface.
 Universal Milling Machine ( Longitudinal Feed Auto )
SPECIFICATIONS
Number of Spindle Speed 6
Range of Spindle Speed 50, 85, 110, 240, 350,525
RPM
3 Feeds (0.9, 1.4, 2.25 mm
Number of Feeds per Minute )
Shaper Machine
MNIT MET-101

Guess answer to these questions before study

 What is a shaper m/c?

 What is the need of a shaper m/c?

 What are different operations that can be performed

on a shaper m/c?
 What are main parts of a shaper m/c?

 Make a neat labeled sketch of a shaper m/c and

write its important specifications?

 Compare a shaper m/c with a milling m/c.
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 About a Shaper machine

• PRINCIPLE

• HORIZONTAL SHAPER – PARTS AND SKETCH

• SHAPER MECHANISMS

• OPERTIONS DONE ON SHAPER

• CLASSIFICATION OF SHAPER

• SPECIFICATIONS OF SHAPER

• MACHINING TIME CALCULATIONS

• COMPARISON BETWEEN SHAPER AND Milling m/c

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 SHAPER
Shaper is Machine tool which produces
flat surfaces in
• horizontal, tool post
• vertical or
• inclined planes
depending upon the orientation of the cutting
tool.
Features:
• Single point cutting tool is used for
machining.
vice
• Tool is clamped in the tool post mounted on
the ram of the machine.
• The ram reciprocates to and fro,
• Tool cuts the material in the forward
stroke,
• No cutting during return stroke.
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• Job is held rigidly in a vice.
 Major PARTS Of Shaper
RAM

Major PARTS
1. BASE
2. COLUMN CROSS RAIL
3. RAM
4. TOOL HEAD
5. CLAPPER BOX
6. TABLE
7. SADDLE
8. VICE

Saddle: It as an “H” shaped part – mounted on the top of the lathe-ways. It is the
base part of the carriage assembly and provides support to cross-slide, compound
rest, and tool post. By using a big sized hand wheel, you can slide the saddle in left
or right direction – across the bed-ways.
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Labeled SKETCH OF SHAPER

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 Main parts of a shaper machine

Crank and
Slotter
Mechanism
Forward stroke is the cutting stroke i.e. tool cuts the metal.
Return stroke is the Idle stroke i.e. tool does not cut metal
Double stroke = cutting stroke + return stroke

Stroke starts slightly before the work piece (a) and ends after the work piece
(b)
Total stroke length = l + a + b
L = length of work piece, a = length of start before w/p, b = length after w/p
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 PARTS OF SHAPER
BASE made of cast iron. Provides
support for other parts of
machine

COLUMN-
box type of
casting
Vertically mounted
on the top of
base.
•
It has 2 guide ways.
One vertical guide way in the front over which a cross
slide moves up and down.
2
nd
horizontal guideways on the top over which ram
reciprocate.
• The reciprocating mechanism is housed inside the 54
OTHER PARTS OF SHAPER TOOL HEAD fitted on the
CROSS RAIL IT IS MOUNTED face of ram. Holds the
ON THE FRONT VERTICAL
GUIDE WAYS. tool rigidly.
• THE TABLE CAN BE • Provide vertical and angular
LOWERED OR RAISED BY feeds for the tool
ADJUSTING THE CROSS RAIL
• Tool head can be
TABLE- mounted on a saddle positioned at any angle
which is located above the
cross rail. Top and sides are
accurately machined and
have T slots.

RAM- supports tool head on its

front. It reciprocates on
accurately machined
horizontal guide ways on
top of column
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Sketch of Tool head showing components in two different views
 Classification of shapers
1 Position of ram travel
 Horizontal Shaper- Ram holding the cutting tool moves
in horizontal plane
• Vertical Shaper-The cutting tool moves in vertical plane
• Traveling head Shaper-Cutting tool reciprocates & moves
cross wise simultaneously

2 Acc. to Cutting Stroke action

a)Push Type Shaper- Standard Shaper.
• Metal is removed when the ram moves away from
column
• Most common type used in practice
• Unless otherwise specified, the term shaper refers to
Push type Shaper
b) Draw Type Shaper
• Metal is removed when the tool is drawn towards the 57
column
 3 Acc. to Driving Mechanism:
a)Crank type - Driving mechanism is by crank & gear
b)Geared type - Driven by Rack & Pinion mechanism
c)Hydraulic Shaper - Driven by oil pressure developed by a
pump, which is run by an electric motor

4 Acc. to the Table Design:

Rack & Pinion mechanism
d) Standard shaper- Work Table
can be moved 1. Vertically & 2.
Horizontally
e) Universal Shaper- Table can be
moved
1.Horizontally 2. Vertically 3. Swivelled
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and 4. Tilted - This is mostly used in Tool
SHAPER - Showing crank and slotter mechanism parts

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Specifications of Shaper Machine

• Max. Stroke length of Ram

• Type of Drive
• Power input, kW
• Floor Space required, sq ft
• Weight of the Machine, kg
• Cutting to Return Stroke ratio
• Feed, depth of cut and speed 60
Some more Specifications
• Make- Local or standard
• Guarantee and warrantee
• Size of table
• Special features, if any
• First Cost and maintenance cost

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WORKING OF HYDRAULIC SHAPER

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Cutting Horizontal & Vertical Surface on Shaper

Tool cutting Horizontal Surface Tool cutting Vertical Surface

Operations done using a shaper

• Machining Horizontal Surfaces

• Machining Vertical Surfaces
• Machining Angular Surfaces
• Cutting Slots, Grooves & Key ways
• Machining irregular surfaces
• Machining Splines/ Cutting Gears

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 Making Chuck key

Tool producing
flat surface

Tool

Chuck key
 Making V Block

Tool slide is tilted for V

block angle

V Block
Making an external key way
 Making of Dovetail

Dovetail
 Making of rack

Rack
(teeth on flat surface)
 Making of an internal keyway

Internal keyway
Machining a contour surface

contour surface
Milling m/c

Can produce gears, different slots

and plain surfaces
Can handle small and medium
size jobs

Work is help in vise

Cutter is mounted on arbor

Uses multi point cutting tool

It is a multi purpose mc

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What people But, what you

 Think about you Think about

yourself

 Feel about you Feel about yourself

 Dream about you Dream about

yourself

 Talk about you Talk

Dr. Anup Malik, School
Engg., LPU
about yourself
of Mech. 73