MILLING

Introduction
Milling is the process of removing metal by cutting with the help of a rotary
cutting tool provided with one or more cutting edges.
The cutting tool in milling is called milling cutter and the edges are called
teeth.
The milling cutter rotates at high speed and it removes metal at a very fast
rate with the help of multiple cutting edges.
Milling process is more complicated than the turning process.
In milling operation, the workpiece is fixed on the machine table which
provides the feed motions, while the cutting velocity is obtained from the
rotation of the cutter.
Milling operations
There are two basic cutting operations in milling:1. Peripheral milling, and
2. Face milling.
1. Peripheral milling: In peripheral milling, the finished surface is parallel to the axis of the
milling cutter and is generated by teeth located on the periphery of
the cutter.
Fig. 1 shows the peripheral milling operation.

Fig. 1:- Peripheral milling.

Prepared by: Dinbandhu Singh

1|P a ge

 The peripheral milling operation can be done in two ways:1.1. Up-milling or conventional milling, and
1.2. Down milling or climb milling.
1.1

Up-milling: If the metal removal is done by rotating the cutter against the
direction of the travel of the workpiece, then it is known as
conventional or up-milling. (Fig. 2).

Fig. 2:- Up-milling.

In this type of milling, the chip thickness is minimum at the start of
the cut and maximum at the end of cut.
As a result the cutting force also varies from zero to the maximum
value per tooth movement of the milling cutter.
The major disadvantages of up-milling process are the tendency of
cutting force to lift the work from the fixtures and poor surface finish
obtained.
But being a safer process, it is commonly used method of milling.
1.2

Down milling: If the metal removal is done by rotating the cutter with the direction
of the travel of the workpiece, then it is known as climb or down
milling. (Fig. 3).
The effect of this is that the teeth cut downward instead of upwards.
Chip thickness is maximum at the start of the cut and minimum in
the end.

Prepared by: Dinbandhu Singh

2|P a ge

 In this method, it is claimed that there is less friction involved and

consequently less heat is generated on the contact surface of the cutter
and workpiece.

Fig. 3:- Down milling.

Climb milling can be used advantageously on many kinds of work to
increase the number of pieces per sharpening and to produce a
better finish.
With climb milling, saws cut long thin slots more satisfactorily than
with standard milling.
Another advantage is that slightly lower power consumption is
obtainable by climb milling, since there is no need to drive the table
against the cutter.
Differences between UP MILLING & DOWN MILLING
UP MILLING
1. The cutter rotates in a direction
opposite to the table feed.
2. It is also known as conventional
milling.
3. Job-tool motion is in the opposite
direction.
4. Chip thickness varies from
minimum to maximum.
5. Cutting forces vary from zero to
Prepared by: Dinbandhu Singh

DOWN MILLING
1. The cutter rotates in the same
direction to the table feed.
2. It is also known as climb milling.
3. Job-tool motion is in the same
direction.
4. Chip thickness varies from maximum
to minimum.
5. Cutting forces vary from maximum
to zero.
3|P a ge

maximum.

6. Good surface finish.

6. Poor surface finish.

7. There is no such situation arises.

7. There is a tendency of cutting

8. Use of cutting fluid is easy.

forces to lift the work so more

9. It is impracticable.

clamping forces are required to

hold the job on the table.
8. Use of cutting fluid is difficult.
9. It is practicable.

2. Face milling: In face milling, the finished surface is at right angle with the cutter axis
and is generated by teeth located on the periphery and the flat end of
the cutter.
Fig. 4 shows the face milling operation.
In this operation, the bulk of material is removed by the cutting edges
on the periphery of the cutter or at the corner.
The face cutting edges remove only a small volume of metal and make
the surface finish.
The chip thickness varies along the path of the cutting edge. It is
minimum at the start and maximum at the end of the cutting path at the
horizontal axis in the direction of the feed motion.
The variation in chip thickness also depends on the eccentricity of tool
axis with the midline of the workpiece.

Fig. 4:- Face milling.

Prepared by: Dinbandhu Singh

4|P a ge

Types of milling cutters: Milling cutters are made in various forms to perform certain classes of work,
and they may be classified as:
1. Plain milling cutters
1.1 Light duty plain milling cutter
1.2 Heavy duty plain milling cutter
1.3 Helical plain milling cutter
2. Side milling cutters
2.1 Plain side milling cutter
2.2 Staggered teeth side milling cutter
2.3 Half side milling cutter
2.4 Interlocking side milling cutter
3. Metal slitting saw
3.1 Plain metal slitting saw
3.2 Staggered teeth metal slitting saw
4. Angle milling cutters
4.1 Single angle milling cutters
4.2 Double angle milling cutters
5. End mill
5.1 Taper shank end mill
5.2 Straight shank end mill
5.3 Shell end mill
6. Fly cutters
7. T-slot milling cutters
8. Formed cutters
8.1 Convex milling cutter
8.2 Concave milling cutter
8.3 Corner rounding milling cutter
8.4 Gear cutter
8.5 Thread milling cutter
Prepared by: Dinbandhu Singh

5|P a ge

9. Woodruff key slot milling cutter

10. Tap and reamer cutter
11. Face milling cutter
1. Plain milling cutter: Plain milling cutters are cylindrical in shape and have teeth on the
circumferential surfaces only.
The cutters are intended for the production of flat surfaces parallel
to the axis of rotation of spindle.
The cutter teeth may be straight or helical according to the size of
the cutter.
Fig. 5 shows a straight teeth plain milling cutter.

Fig. 5:- Straight teeth plain milling cutter

The plain milling cutters are available in diameters from 16 to 160
mm and the width of the cutters range from 20 to 160 mm.
Fig. 6 illustrates a helical plain milling cutter.
Very wide plain milling cutters are termed as slabbing cutters. These
cutters have nicked teeth.

Fig. 6:- Helical plain milling cutter.

Prepared by: Dinbandhu Singh

6|P a ge

1.1

1.2

1.3

Light duty plain milling cutter:The light duty plain milling cutters have face width less than 20 mm
and are made with straight teeth parallel to the axis.
The wider cutters are made with helical teeth, with helix angle of less
than 25. These are relatively fine tooth cutters.
Heavy duty plain milling cutter:The heavy duty plain milling cutters are wider cutters and are used
for heavy duty works.
The helix angle of the teeth ranges from 25 to 45.
The cutters have fewer teeth on the periphery and that increases
chip space permitting them to take deeper cuts.
They are also sometimes called coarse tooth milling cutters.
Helical plain milling cutter:The helical plain milling cutters have further coarse pitch and the
helix angle of the teeth ranges from 45 to 60.
The cutter is useful in profile milling work due to its smooth cutting
action
It is adapted for taking light cuts on soft steel or brass and where
wide surfaces are to be machined.

2. Side milling cutter: The side milling cutters have teeth on its periphery and also on one
or both of its sides.
The side milling cutters are intended for removing metals from the
side of a workpiece.
Fig. 7 illustrates a side milling cutter.

Fig. 7:- Side milling cutter

Prepared by: Dinbandhu Singh

7|P a ge

 The side milling cutters are available from 50 to 200 mm in diameter

and the width of the cutter ranges from 5 to 32 mm.
2.1 Plain side milling cutter: The plain side milling cutters have straight circumferential teeth and
have side teeth on both of its sides.
Fig. 8 shows a plain side milling cutter.

Fig. 8:- Plain side milling cutter.

Two or more such cutters may be mounted on the arbor and
different faces of the workpiece may be machined simultaneously.
2.2 Staggered teeth side milling cutter: The staggered teeth side milling cutters have alternate teeth with
opposite helix angles.
This design of the cutter teeth increases the chip space to a great
extent.
The cutter is suitable for milling deep, narrow slots or key ways on
workpiece.
Fig. 9 illustrates a staggered teeth side milling cutter.

Fig. 9:- Staggered teeth side milling cutter.

2.3

Half side milling cutter: The half side milling cutters have straight or helical teeth on its
circumferential surface and on one of its sides only.

Prepared by: Dinbandhu Singh

8|P a ge

 The peripheral do the actual cutting, whereas the side teeth size and
finish the work.
Fig. 10 shows a half side milling cutter.

Fig. 10:- Half side milling cutter

2.4

Interlocking side milling cutter: The interlocking side milling cutters are formed out of two half side
milling cutters or two staggered teeth side milling cutters which are
made to interlock to form one unit.
Fig. 11 illustrates an interlocked side milling cutter.

Fig. 11:- Interlocked side milling cutter.

The teeth of the two cutters may be plain or of alternate helix. The
paths of the teeth overlap when the cutters are assembled.
The cutters are used for milling wider slots of accurate width.
The width of the cutter ranges from 10 to 32 mm with a possible
adjustment to the maximum of 4 mm.
The cutters diameter range varies from 50 to 200 mm.
3. Metal slitting saw: The metal slitting saws resemble a plain milling cutter or a side
milling cutter in appearance but they are of very small width.
The cutters are used for parting-off operation or for slotting.
Fig. 12 illustrates a metal slitting saw.
Prepared by: Dinbandhu Singh

9|P a ge

Fig. 12:- Metal slitting saw.

3.1

Plain slitting saw: The plain metal slitting saws are thinner in construction and the
width of the cutter is limited to 5 mm.
The sides of the cutter are relieved in order that the side faces may
not rub against the work.
3.2 Staggered teeth metal slitting saw: The staggered teeth metal slitting saws resemble a staggered teeth
milling cutter, but the width of the cutter is limited to 6.5 to 7 mm.

Fig. 13:- Staggered teeth metal slitting saw.

The cutter is used for heavy sawing in steel.
Fig. 13 illustrates a staggered teeth metal slitting saw.
4. Angle milling cutter: The angle milling cutters are made as single or double angle cutters
and are used to machine angles other than 90.
The cutting edges are formed at the conical surface around the
periphery of the cutter.
4.1 Single angle milling cutter: The single angle milling cutters have teeth on the conical or angular
face of the cutter as shown in the Fig. 14.
Prepared by: Dinbandhu Singh

10 | P a g e

 The angle of the cutter is designated by the included angle between

the conical phase and the large flat face of the cutter.

Fig. 14:- Single angle milling cutter.

The cutter having different included angles of 30, 45, 60, 65, 70,
75, 80 and 85 are available with diameter of 50 mm and width of
12 mm.
4.2 Double angle milling cutter: The double angle milling cutters illustrated in Fig. 15 have V-shaped
teeth with both conical surfaces at an angle to their end faces.

Fig. 15:- Double angle milling cutter.

The angle of teeth may not be symmetrical with respect to a plane at
right angles to the cutter axis.
The unsymmetrical double angle cutters are available in diameters of
50, 63, 80 and 100 mm and their width varies from 12 to 36 mm.
The cutters are available in different included angles of 55, 60, 65,
70, 75, 80, 90 and 100.
The double angle milling cutters are mainly used for cutting spiral
grooves on a piece of blank.
5. End mill:-

Prepared by: Dinbandhu Singh

11 | P a g e

 The end mills have cutting teeth on the end as well as on the
periphery of the cutter.
The peripheral teeth may be straight or helical and the helix may be
right hand or left hand.
The end mills are used for light milling operations like cutting slots,
machining accurate holes, producing narrow flat surfaces and for
profile milling operations.
5.1 Taper shank end mill: The taper shank end mills have a tapered shank or extension on one
end for mounting and driving the cutters.
The cutters may be double fluted or multiple fluted.
The taper shank end mills are available from 10 to 63mm in diameter
and may have tanged end or tapped end for mounting on the arbor.
The taper shanks conform to the Morse taper No. 1 to No. 5.
Fig. 16 illustrates a taper shank end mill.

Fig. 16:- Taper shank end mill.

5.2

Straight shank end mill: The straight shank end mills have round shanks for mounting and
driving the cutters.

Fig. 17:- Straight shank end mill.

The cutter teeth may be straight or helical.
The diameter of the cutter ranges from 2 to 63 mm.
Fig. 17 illustrates a straight shank end mill.
5.3 Shell end mill: The shell end mills are larger and heavier end mills provided with a
central hole for mounting the cutter on a short arbor.
This design of cutter gives economy in tool material as the cutter
having different diameters may be interchanged on a single shank.
The cutting edges are provided at the end and around the periphery
of the cutter.
Prepared by: Dinbandhu Singh

12 | P a g e

 The teeth may be straight or helical and may be left or right handed.
Face milling operations are usually performed with these cutters.
The diameter of the cutter ranges from 40 to 160 mm and width
from 32 to 63 mm.
The bore diameter of the cutters ranges from 16 to 50 mm.
Fig. 18 illustrates a shell end mill.

Fig. 18:- Shell end mill.

6. Fly cutters: The fly cutters are simplest form of cutters and are mainly used in
experimental shops or in tool room works.

Fig. 19:- Fly cutter.

The cutter consists of a single point cutting tool attached to the end of
an arbor.
The cutting edge may be formed to reproduce contoured surface.
The cutter may be considered as an emergency tool when the standard
cutters are not available.
A fly cutter is illustrated in Fig. 19.

7. T-slot milling cutter: The T-slot milling cutters are special form of end mills for producing Tslots.
Prepared by: Dinbandhu Singh

13 | P a g e

 Fig. 20 illustrates a T-slot milling cutter.

Fig. 19:- T-slot milling cutter.

The teeth are provided on the periphery as well as on both sides of the
cutter.
8. Formed cutters: The formed cutters have irregular profiles on the cutting edges in
order to generate an irregular outline of the work.
Fig. 20 illustrates some formed cutters.

Fig. 20:- Formed cutters.

8.1

Convex milling cutter:The convex milling cutters have teeth curved outwards on the
circumferential surface to form the contour of a semicircle.
The cutter produces a concave semicircular surface on a workpiece.
The diameter of the cutter ranges from 50 to 125 mm and the radius
of the semicircle varies from 1.6 to 20 mm.
Fig. 21 illustrates a convex milling cutter.

Prepared by: Dinbandhu Singh

14 | P a g e

Fig. 21:- Convex milling cutter.

8.2

8.3

Concave milling cutter:The concave milling cutters have teeth curved inwards on the
circumferential surface to form the contour of a semicircle.
The concave milling cutters produce a convex semicircle surface on a
workpiece.
The diameter of the cutter ranges from 56 to 110 mm and the radius
of the semicircle varies from 1.5 to 20 mm.
Fig. 22 illustrates a concave milling cutter.

Fig. 22:- Concave milling cutter.

Corner rounding milling cutter:The corner rounding milling cutters have teeth curved inwards on the
circumferential surface to form the contour of a quarter circle.
The cutter produces a convex surface having a contour of a quarter
circle.
The cutters are used for cutting a radius on the corner or edges of
the work.
The diameter of the cutter ranges from 56 to 110 mm and the radius
of the quarter circle varies from 1.5 to 20 mm.
Fig. 23 illustrates a corner rounding milling cutter.

Fig. 23:- Corner rounding milling cutter.

8.4

Gear cutter:-

Prepared by: Dinbandhu Singh

15 | P a g e

 Gear milling cutters are made of HSS and available mostly in disc
form slot milling cutters and also in the form of end mill for
producing teeth of large module gears.
The form of these tools conforms to the shape of the gear tooth-gaps
bounded by two involutes as shown in Fig. 24.
Such form relieved cutters can be used for producing teeth of
straight and helical toothed external spur gears and worm wheels as
well as straight toothed bevel gears.

Fig. 24:- Gear cutter.

8.5

Thread milling cutter: The thread milling cutters are designed to mill threads of specific
form and size on a workpiece.
Generally, worms and acme threads are produced by thread milling
cutters.

Fig. 25:- Short thread milling.

The cutters may have parallel or taper shanks.
These type of cutters are used in large lot production of screws, bolts
etc.
Fig. 25 shows the thread milling cutter and its uses in short thread
milling whereas Fig. 26 shows the thread milling cutter and its uses in
long thread milling.

Prepared by: Dinbandhu Singh

16 | P a g e

Fig. 26:- Short thread milling.

9. Woodruff key slot milling cutter: The woodruff key slot milling cutters are small standard cutters
similar in construction to a thin, small diameter plain milling cutter,
intended for the production of woodruff key slots.
The cutter is provided with a shank and may have straight or
staggered teeth.
Fig. 27 illustrates a woodruff key slot milling cutter.

Fig. 27:- Woodruff key slot milling cutter.

10. Tap and reamer cutter: The tap and reamer cutters are special type double angle cutters
intended for producing grooves or flutes in taps or reamers.
The point end of the tooth is rounded and the tooth profile
corresponds to the type of the groove that it is going to make.
A tap and reamer cutter is illustrated in Fig. 28.

Fig. 28:- Tap and reamer cutter.

Prepared by: Dinbandhu Singh

17 | P a g e

11. Face milling cutter: The shape, geometry and typical use of face milling cutters are
shown in Fig. 29.
These types of cutters are usually large in diameter (80 to 800 mm)
and heavy.
Face milling cutters are used for machining flat surfaces indifferent
orientations.
These cutters are mounted directly in the vertical and/or horizontal
spindles.
Coated or uncoated carbide inserts are clamped at the outer edge of
the carbon steel body.
These cutters are generally used for high production machining of
large jobs.

Fig. 29:- Face milling cutter.

Elements of a Plain Milling Cutter: The principle parts and angles of a plain milling cutter illustrated in Fig. 30 are
described below:1. Body of cutter: - The part of the cutter left after exclusion of the teeth and
the portion to which the teeth are attached.
2. Cutting edge: - The edge formed by the intersection of the face and the
circular land or the surface left by the provision of primary clearance.
3. Face: - The portion of the gash adjacent to the cutting edge on which the
chip impinges as it is cut from the work.
4. Fillet: - The curved surface at the bottom of gash which joins the face of
one tooth to the back of the tooth immediately ahead.
5. Gash: - the chip space between the back of one tooth and the face of the
next tooth.
Prepared by: Dinbandhu Singh

18 | P a g e

6. Lead: - The axial advance of the helix of the cutting edge in one complete
revolution of the cutter.
7. Land: - the part of the back of the tooth adjacent to the cutting edge which
is relieved to avoid interference between the surface being machined and
the cutter.
8. Outside diameter: - The diameter of the circle, passing through the
peripheral cutting edge.
9. Root diameter: - The diameter of the circle, passing through the bottom of
the fillet.

Prepared by: Dinbandhu Singh

19 | P a g e

Fig. 30:- Elements of plain milling cutter.

Cutter angles: - Similar to a single point cutting tool, the milling cutter teeth
are also provided with rake, clearance and other cutting angles in order to
remove metal efficiently. The following are the different cutter angles.

Prepared by: Dinbandhu Singh

20 | P a g e

1. Relief angle: - The angle in a plain perpendicular to the axis, which is the
angle between the land of a tooth and the tangent to the outside diameter
of cutter at the cutting edge of that tooth.
2. Primary clearance angle: - The angle formed by the back of the tooth with a
line drawn tangent to the periphery of the cutter at the cutting edge.
3. Secondary clearance angle: - The angle formed by the secondary clearance
surface of the tooth with a line drawn tangent to the periphery of cutter at
the cutting edge.
4. Rake angle (Radial): - The angle measured in the diametral plane between
the face of the tooth and a radial line passing through the tooth cutting
edge.
5. Zero rack: - If the radial line and tooth face coincide in the diametral plane,
the rake angle is zero.

Fig. 31:- Milling cutter having zero rake.

6. Positive rake: - If the tooth face is titled, so that the face and the tooth body
are on the same side of the radial line, then the rake angle contained by the
radial line and the tooth face is positive.

Fig. 32:- Milling cutter having positive rake.

7. Negative rake: - If the tooth face titled, so that the face and the tooth body
are on the opposite side of the radial line, then the rake angle contained by
the radial line and the tooth face is negative.
Prepared by: Dinbandhu Singh

21 | P a g e

Fig. 33:- Milling cutter having negative rake.

8. Axial rake angle (for helical teeth): - The angle between the line of
peripheral cutting edge and the axis of the cutter when looking radially at
the point of intersection.
9. Lip angle: - The included angle between the land and the face of the tooth.
10. Helix angle: - The cutting edge angle which a helical cutting edge makes
with a plain containing the axis of the cylindrical cutter.
Elements of a Face Milling Cutter: The principle parts and angles of a face milling cutter are illustrated in Fig. 34.
The definitions of different tooth elements, which are already described
above, are applied to face milling cutters also.
1. Peripheral cutting edge: - The part of the cutting edge of the blade which in
on the periphery of the cutter.
2. Peripheral relief angle: - The angle between the relieved flank of the tooth
or blade and a tangent to the periphery in a diametral plane passing
through the cutting edge.

Prepared by: Dinbandhu Singh

22 | P a g e

Fig. 34:- Elements of face milling cutter.

3. Peripheral clearance angle: - The angle between the cleared flank of the
blade and a tangent to the periphery in a diametral plane passing through
the cutting edge.
4. Face cutting edge: - The part of the cutting edge of the blade which is on
the face of the cutter.
5. Face relief angle: - The angle between the land or relieved flank of the
tooth immediately back of the cutting edge and cutter face.
6. Face clearance angle: - The angle between the cleared flank of the tooth
back of relieved surface and the cutter face.
7. Corner angle: - The angle between an angular cutting edge of a cutter tooth
and the axis of the cutter.
8. Radial rake: - The angle between the blade face and a radial line or plane
passing through the cutter axis and blade nose.
9. Axial rake: - The angle between the face of the blade and a line passing
through the nose parallel to the cutter axis.

Prepared by: Dinbandhu Singh

23 | P a g e