Milling Machine
Workshop Technology II- ME142
Milling Machine:Introduction
• A milling machine is a machine tool that uses a rotating cutter to
remove material from a workpiece..
• The cutter is mounted on a spindle that can move along multiple
axes to create different shapes and cuts.
• Milling machines are typically used to produce parts with
complex shapes or profiles, and they can be used to create a
variety of products, including metal parts, plastic components,
and even woodworking products.
Milling Machine:Introduction
Bas
e
Milling Machine: Parts
Base: The base is the foundation of the machine and is
responsible for providing support and rigidity to all the other
components of the machine. The bed is usually made of cast
iron and provides a stable base for the other components to
be mounted on.
Knee: The knee is attached to the column by dovetail
ways and is supported and adjusted up and down by an
elevating screw, The vertical movement can be achieved by
either a hand crank or power feed.
Power Feed Mechanism: The power feed
mechanism is contained in the knee. The power feed
mechanism is used to control longitudinal, transverse , and
vertical feeds
Overarm: The overarm is a movable overhanging arm
on a milling machine. The ram is mounted on top of the
column, and the milling head is attached to it on one end.
Milling Machine: Parts
Milling Cutter: It is the very most important part of a
milling machine because through milling cutters different types
of milling operations are performed.
Arbor: It is the extension parts of spindles on which milling
cutters are held or rotated.
Work Table: A work table is the most important part of a
milling machine on which the workpiece or a job holds tightly
and performs many operations.
Milling Machine: Cutting Methods
Two basic methods of milling
1. Up-milling or conventional milling
2.Down-milling or climb milling
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.
Disadvantage- tendency to lift work from the
fixtures and poor surface finish.
Milling Machine: Cutting Methods
Down-milling or climb milling
Metal is removedby cutter rotating
in the same direction of travel of the
workpiece.
Less friction involved
Better surface finish.
Less power consumption.
Milling Machine: Types
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
2. Planer milling machine
3. Fixed-bed type milling machine
4. Special types of milling machines
Column and knee type milling machines
Itis the most commonly used milling
machine used for general shop work.
The table is mounted on the knee
which in turn 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.
Column and knee type milling machines
CLASSIFIACTION OF COLUMN & KNEE TYPE MILLING
MACHINE
(a) Horizontal milling m/c.
(b)Vertical milling m/c.
Horizontal vs Vertical Milling
Machine
Horizontal vs Vertical Milling
Machine
• The main difference between a horizontal milling machine and a vertical milling
machine is the orientation of the spindle, which is the part that holds and
rotates the cutting tool. In a horizontal milling machine, the spindle is
positioned horizontally, while in a vertical milling machine, the spindle is
positioned vertically.
• Here are some other differences between the two types of milling machines:
Cutting direction: In a horizontal milling machine, the cutting tool is positioned
horizontally, which means that the chips fall downwards and away from the workpiece. In
a vertical milling machine, the cutting tool is positioned vertically, which means that the
chips are carried upwards and away from the workpiece.
Workpiece size: A horizontal milling machine is typically used for larger workpieces, while
a vertical milling machine is better suited for smaller workpieces.
Workpiece visibility: With a horizontal milling machine, the workpiece is visible during the
entire milling process, which can be helpful for making adjustments and ensuring
accuracy. With a vertical milling machine, the workpiece may be less visible during
certain parts of the milling process.
Tooling costs: In general, tooling for a horizontal milling machine tends to be less
expensive than tooling for a vertical milling machine.
Versatility: A vertical milling machine can be used for a wider range of operations,
including drilling, tapping, and boring, as well as milling. A horizontal milling machine is
generally used for milling operations only
Horizontal Milling machine
• The horizontal milling machine has
a spindle that is parallel to the
shop floor and an overarm that
extends over the work piece.
• The overarm supports the arbor,
which holds the milling cutter.
• On the horizontal mill, the arbor is
the component that rotates the
milling cutter.
Milling Operations:
Slittingor saw milling
Plain or slab milling
Gear cutting
Face milling
Key way milling
End milling
String milling
Side milling
Profile milling
Slot milling
Thread milling
Angular milling
Helical milling
Form milling
Cam milling
Straddle milling
Parts of Milling Machine and Their Types,Operation (mechical.com)
PLAIN/SURFACE/ SLAB MILLING
Plain milling is a machining process where a
rotating cylindrical cutter with multiple cutting
edges removes material from the surface of a
workpiece in a horizontal direction. It is typically
performed using a horizontal milling machine
with the axis of the cutter parallel to the
workpiece surface. It is used to create flat
surfaces on large workpieces.
FACE MILLING
Face milling is a milling process
where the cutter’s face (end)
engages with the workpiece,
rather than the periphery. The
cutter has multiple cutting edges
and is mounted perpendicular to
the workpiece. It is commonly
used for creating flat, smooth
surfaces and is done using face
mills or shell mills on vertical
or horizontal milling machines.
FACE MILLING
END MILLING
End milling involves using a cylindrical
cutter with cutting edges on the
periphery and the bottom (end face).
The cutter is used for machining
pockets, slots, contours, and
intricate shapes. It is typically
performed on a vertical milling
machine. End mills come in different
shapes, such as flat, ball-nose, and
corner-radius.
SIDE MILLING
Side milling is a process where a side
milling cutter is used to cut along
the side of a workpiece. The cutter
has teeth on the periphery and
sometimes on one or both sides,
allowing it to create slots, steps, or
grooves. This method is commonly
used in keyway cutting and
contour machining.
SLOT MILLING
Slot milling is the process of cutting a
narrow groove or slot into a
workpiece using a slot cutter or end
mill. It can be done using both
horizontal and vertical milling
machines. This method is widely used
for making T-slots, keyways, and
grooves.
FIG. T-SLOT
MILLING
ANGULAR MILLING
Angular milling is a machining process
where a cutter is positioned at an
angle to the workpiece surface,
rather than perpendicular or parallel. It
is used to produce angled surfaces,
chamfers, grooves, and dovetails.
The process is typically performed
using single-angle or double-angle
milling cutters on horizontal or
vertical milling machines.
ANGULAR MILLING
STRADDLE MILLING
Straddle milling is a machining
process where two side milling
cutters are mounted on the same
arbor and spaced apart to
machine two parallel surfaces
on a workpiece simultaneously.
It is performed on a horizontal
milling machine and is
commonly used for creating
slots, steps, or keyways with
precise spacing.
