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    Milling Machines

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    Sahil Sheth
    Milling machines are used to machine flat, angled, and contoured surfaces on workpieces. There are several types of milling machines including horizontal, vertical, and universal varieties. Milling operations include peripheral milling to cut surfaces parallel to the cutter's axis, face milling perpendicular to the axis, and end milling combining the two. Additional operations are side, straddle, angular, gang, form, and profile milling as well as cutting keyways, grooves, slots, and threads.

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    Milling Machines

    Uploaded by

    Sahil Sheth
    291 views39 pages
    Milling machines are used to machine flat, angled, and contoured surfaces on workpieces. There are several types of milling machines including horizontal, vertical, and universal varieties. Milling operations include peripheral milling to cut surfaces parallel to the cutter's axis, face milling perpendicular to the axis, and end milling combining the two. Additional operations are side, straddle, angular, gang, form, and profile milling as well as cutting keyways, grooves, slots, and threads.

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    as per GTU syllabus

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    Milling machines are used to machine flat, angled, and contoured surfaces on workpieces. There are several types of milling machines including horizontal, vertical, and universal varieties. Milling operations include peripheral milling to cut surfaces parallel to the cutter's axis, face milling perpendicular to the axis, and end milling combining the two. Additional operations are side, straddle, angular, gang, form, and profile milling as well as cutting keyways, grooves, slots, and threads.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    291 views39 pages

    Milling Machines

    Uploaded by

    Sahil Sheth
    Milling machines are used to machine flat, angled, and contoured surfaces on workpieces. There are several types of milling machines including horizontal, vertical, and universal varieties. Milling operations include peripheral milling to cut surfaces parallel to the cutter's axis, face milling perpendicular to the axis, and end milling combining the two. Additional operations are side, straddle, angular, gang, form, and profile milling as well as cutting keyways, grooves, slots, and threads.

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    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
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    of 39

    CHAPTER 5 MILLING MACHINES

    PURPOSE OF MILLING MACHINES

    Milling is

    basic machining process by which surface is

    generated progressively by the removal of chips from a work piece


    as it is fed against a multitooth rotating cutter.
    Milling

    machine is used for machining flat surfaces, angled

    surfaces, contoured surfaces, key slots, external and internal threads, helical surfaces of various cross-sections etc.

    TYPES OF MILLING MACHINES

    The milling machine supplies an accurate rotating spindle for the cutter and a table (vise) to fix and position the work part.

    1. Column and knee type milling machines (a) Hand milling machine (b) Horizontal milling machine (c) Universal milling machine (d) Vertical milling machine 2. Planer milling machine 3. Fixed-bed type milling machine (a) Simplex milling machine. (b) Duplex milling machine. (c) Triplex milling machine. 4. Machining centre machines 5. Special types of milling machines (a) Rotary table milling machine. (b) Planetary milling machine. (c) Profiling machine. (d) Duplicating machine. (e) Pantograph milling machine. (f) Continuous milling machine. (g) Drum milling machine (h) Profiling and tracer controlled milling machine
    5

    COLUMN & KNEE MILLING MACHINE


    Column, spindle, cutter, table, knee, base are the common parts of the vertical and horizontal milling machines The milling machines having only the three mutually perpendicular table motions (x-y-z axes) are called plain column and knee type Vertical type is especially well suited for face and end milling operations

    HAND MILLING MACHINE

    HORIZONTAL MILLING MACHINE


    In horizontal, arbor supports the cutter and an over arm supports arbor The vertical column houses the electrical, main drive, spindles etc mounted on a heavy base

    UNIVERSAL MILLING MACHINE


    Has a table that can be rotated in a horizontal plane to any specified angle

    10

    UNIVERSAL MILLING MACHINE

    11

    VERTICAL MILLING MACHINE


    In vertical, milling cutters can be mounted directly in the spindle Housing (Head) can be fixed or Swiveling type Fixed Type - Head is always vertical and can be adjusted up and down Swiveling Type Head can be swiveled to any desired angle

    12

    KEY SLOT MAKING IN VERTICAL MILLING MACHINE


    13

    PLANNER TYPE MILLING MACHINE


    Consists of a fixed bed carrying a table having longitudinal movements It is a heavy duty milling machine. Consists of 2 vertical columns on each side of the bed Cross rail fitter across columns can be raised or lowered Each column carries a milling head(side/horizontal) moving upwards or downwards All cutters can be operated simultaneously to machine 4 surfaces at a time

    14

    BED TYPE MILLING MACHINE

    15

    Bed Type Milling Machines

    Designed for mass production


    Achieves heavier feed rates and depth of cuts, high MRR

    Work table is directly fixed on the bed of the machine tool

    The cutter mounted in a spindle head that can be


    adjusted vertically along the machine column

    Three types are available w.r.t. the count of spindles available

    16

    FIXED BED TYPE MILLING MACHINE


    SIMPLEX
    Fixed bed replaces saddle and knee.
    The table has longitudinal travel only Spindle head carries spindle to which arbor is fitted to carry cutter that moves up and down along column ways

    17

    DUPLEX
    Has two spindles, permitting simultaneous milling of two surfaces at a single pass

    TRIPLEX
    Has three spindles, permitting simultaneous milling of three surfaces at a single pass
    18

    CNC Milling Machines


    Cutter path controlled by numerical data Suited to profile, pocket, surface contouring.

    19

    DIFFERENT MILLING OPERATIONS


    Milling operations can be classified into two broad categories

    1. Peripheral Milling

    2. Face Milling

    20

    PERIPHERAL MILLING

    Operation performed by milling cutter to produce a machined surface parallel to axis of rotation of cutter Cutting force is not uniform throughout the length of the cut by each tooth Quality of surface generated and shape of the chip formed depends upon the rotation of cutter relative to direction of feed movement It can be either UP milling or DOWN milling
    21

    UP MILLING

    Also called conventional milling, - Wheel rotation opposite of the feed - The chip formed by each cutter tooth starts out very thin & increases its thickness - The length of the chip is relatively longer - Tool life is relatively shorter - Need more clamping force to hold the work part still.
    22

    DOWN MILLING:

    Also called climb milling, - Wheel rotation is parallel to the feed - The chip formed by each cutter tooth starts out thick and leaves out thin - The length of the chip is relatively short - Tool life is relatively longer - Need less clamping force to hold the work part still.
    23

    1. PLAIN MILLING(SLAB MILLING)

    Operation of production

    of

    plain

    flat
    to

    surface
    axis of

    parallel cutter

    rotation of plain milling

    Cutter

    width extends

    beyond the work piece on both sides

    24

    25

    2. FACE MILLING

    The generated surface is at right angles to the cutter axis is axis work

    The

    face

    milling about to

    cutter an the

    rotated

    perpendicular

    surface.

    It is the combined result of actions of the portions of the teeth located on both periphery and the face of the cutter

    Most of the cutting is done by the peripheral portions of the teeth, with the face portions provides the surface finish.
    26

    27

    28

    More Examples on Face Milling

    29

    3. END MILLING

    Combination of peripheral and face milling Cutter has teeth both on end face and periphery Vertical milling machine is most suitable for end milling operation

    30

    4. SIDE MILLING

    Operation of production of flat vertical surface on side of work piece by using side milling cutter
    Depth of cut adjusted by rotating vertical feed screw of

    the table
    31

    5. STRADDLE MILLING

    Operation of production of flat vertical surfaces on both side of the workpiece by using two side milling cutters mounted on the same arbor
    32

    6. ANGULAR MILLING

    Operation of production of angular surface on a workpiece other than at right angles to the axis of milling machine spindle
    33

    7. GANG MILLING

    Operation of milling several surfaces of the workpiece simultaneously by feeding the table against a number of cutters having same or different diameters
    34

    8. FORM MILLING

    It is the operation of production of irregular contours using form cutters The contours maybe convex, concave or any other shape

    35

    9. PROFILE MILLING

    It is the operation of reproduction of an outline of a template or complex shape of a master die on a workpiece
    36

    10.MILLING KEYWAYS, GROOVES & SLOTS

    Operation of production of keys, grooves and slots of varying shapes and size by using a plane milling cutter, a metal slitting saw, an end mill or by side milling cutter

    37

    11. THREAD MILLING

    Operation of production of threads by using a single or multiple thread milling cutter. It is performed in special thread milling machine to produce accurate threads

    38

    BIBLIOGRAPHY

    Reading Material Wikipedia www.howstuffworks.com www.custompart.net Workshop Tech - Hajra Choudhury Vol 2 Images/Videos Google Image Search Efunda.com Youtube.com

    39

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