UNIT – IV

Milling machine – Principle of working – specifications –

classifications of milling machines – Principal features,
Milling methods–Up & Down Milling, Milling operations,
Geometry of End milling cutter – Indexing Methods -
Problems – Machining time in milling.

Broaching -Types-Classification-Broach elements-

Advantages-Limitations.
Schematic illustration of milling machines
MILLING MACHINE - Principle

CUTTER

WORK

TABL
E
• Work is rigidly clamped on table of machine, or held b/n centres
& revolving multi teeth cutters are mounted either on spindle/
arbor.
• Cutter revolves at high speeds & work fed slowly past the
cutter.

 Work can be fed in vertical,

longitudinal/ cross direction.

 As work advances cutter teeth

remove metal from w/p surface to
produce desired shape.
• It is a machine tool that removes metal as work is fed
against a rotating multi point cutter for machining
flat, curved, irregular surfaces.
• Cutter rotates at high speed & bcz of multi point
cutting edges it removes metal at very fast rate.
Machine can hold one or more cutters at a time.

• Most versatile machining operation

• Machining of Parts without rotational symmetry
• Large number of cutting edges
 BASIC DIFFERENCES BETWEEN LATHE TURNING AND
MILLING OPERATION

S.No. Criteria Lathe Milling

1. Cutting Tool
2. Surface
generated
3. Cutting tool
action
4. Nature of
Chip
5. Applications
 Basic Milling Operations

Some of the basic type milling cutters and milling operations.

Schematic illustration of milling machines
Typical parts and shapes produced by various cutting processes
Milling machines may be manually operated,
mechanically automated, or digitally automated via
computer numerical control (CNC).

Milling machines can perform a vast number of

operations, some very complex, such as slot and
keyway cutting, planing, drilling, die sinking,
rebating, routing, etc.
• Milling machines exist in
two basic forms: horizontal
and vertical, which terms
refer to the orientation of
the cutting tool spindle.

• Machine consists
basically of a motor driven
spindle, which mounts and
revolves the milling cutter,
and a reciprocating
adjustable worktable,
which mounts and feeds
the work piece.
 Classification of Basic Milling Operations
1. Peripheral Milling :
• In peripheral (or slab) milling, the milled surface is
generated by teeth located on the periphery of the cutter
body. The axis of cutter rotation is generally in a plane
parallel to the work piece surface to be machined.
 Slab Milling
• Slab milling also called as peripheral milling
• Cutters have straight or helical teeth resulting in
orthogonal or oblique cutting action

Fig : (a) Conventional milling and climb milling (b) Slab milling operation, showing
depth of cut , d, feed per tooth, f, chip depth of cut, tc, and workpiece speed, v.
(c) cutter travel distance lc to reach full depth of cut.
2. Face Milling:
• In face milling, the cutter is mounted on a spindle
having an axis of rotation perpendicular to the work
piece surface.
• The milled surface results from the action of cutting
edges located on the periphery and face of the cutter.
 Face Milling
• The cutter is mounted on a spindle having an axis of rotation
perpendicular to the workpiece surface.

Fig:A face milling cutter with indexable inserts.

Fig : Face milling operation showing (a) action of an insert in face

milling; (b) climb milling; (c) conventional milling d)dimensions in
face milling. The width of cut, w, is not necessarily the same as
the cutter radius
3. End Milling :
• The cutter in end milling generally rotates on an axis
vertical to the work piece.
• It can be tilted to machine tapered surfaces.
• Cutting teeth are located on both the end face of the cutter
and the periphery of the cutter body.
 QUIZ
Face
What are these
milling operations
and on what type of
milling machine they
are performed

Slab/Peripheral
End
 TYPES OF MILLING MACHINES
1. Column & Knee type:
• These machines are all general purpose machines & have a
single spindle.
• Name is derived from fact that work table is supported on Knee
like casting, which can slide in vertical direction along vertical
column.
• Depending up on their spindle position & table movements these
are further classified as:
a) Hand milling machine
b) Plain/ Horizontal milling machine.
c) Vertical milling machine
d) Universal milling machine
e) Omniversal milling machine
2. Fixed Bed / Manufacturing Type:
• In comparison to previous , these machines are more study &
rigid, heavier in wt, larger in size.
• Not suitable for tool room work.
• These machines carry single / multiple spindles.
• Operations performed are slot cutting, grooving, gang milling &
facing.
a) Plain type.(Single horizontal spindle)
b) Duplex head.(Double horizontal spindle)
c) Triplex head.(2 horizontal & 1 vertical spindle.)
d) Rise & Fall type(profile milling)
3. Planer type Milling Machines:
• Used for heavy work.
• Up to max of 4 tool heads can be mounted over it, which can be
adjusted vertically & transverse directions.
4.Production Milling Machine:
For mass production of components
a) Rotary Table
b) Drum Type
c) Tracer Controlled
5. Special Purpose Milling Machine:
These machines are designed o perform various specific type of
operation only:
a) Thread milling machine.
b) Profile milling machine
c) Gear milling/ Gear hobbing. d) CAM milling machine
1. Column & Knee type Milling Machines:
• Used for general purpose milling operations, column and knee
type milling machines are the most common milling machines.
• The spindle to which the milling cutter is may be horizontal (slab
milling) or vertical (face and end milling).
• The basic components are:
a) Work table, on which the work piece is clamped using the T-slots.
The table moves longitudinally with respect to the saddle.
b) Saddle, which supports the table and can move transversely.
c) Knee, which supports the saddle and gives the table vertical
movements for adjusting the depth of cut.
d) Over arm in horizontal machines, which is adjustable to
accommodate different arbor lengths.
e) Head, which contains the spindle and cutter holders. In vertical
machines the head may be fixed or vertically adjustable.
1. a. Hand Milling:
• It is simplest of all types of
milling machines & small in
size.
• All operations except rotation
of arbor are performed by
hand.
• Table carrying work over it, is
moved by hand to feed the
work.
• Machine is relatively smaller in
size than that of other types &
is suitable for light & simple
milling operations like
machining slots, groves,
keyways, square heads on
bolts.
b. Plain/ Horizontal Milling Machine:
a. Column:
Vertical column houses the spindle, the bearings, the
gear box, the clutches, the shafts, the pumps, and the
shifting mechanisms for transmitting power from the
electric motor to the spindle at a selected speed.
b. Knee
The knee mounted in front of the column is for
supporting the table and to provide an up or down
motion along the Z axis.
c. Saddle
The saddle consists of two slide ways, one on the top
and one at the bottom located at 90º to each other, for
providing motions in the X or Y axes by means of lead
screws.
d. Table
The table is mounted on top of the saddle and can be
moved along the X axis. On top of the table are some
T-slots for the mounting of work piece or clamping
fixtures.
e. Arbor
The arbor is an extension of the spindle for mounting
cutters. Usually, the thread end of an arbor is of left
hand helix.
f. Over Arm:
It supports yoke which in turn supports the free end of
Arbor.
• Table is given straight motions in 3 directions:
i. For giving vertical movement to table knee itself,
together with whole unit above it , slides up &
down along ways, provided in to front of column.
ii. For giving cross movement to table, saddle is
moved towards/ away from column along with
whole unit about it.
c. Vertical Milling Machine:
• It derives its name from vertical position of spindle.
• Fig. shows a vertical milling machine which is of similar
construction to a horizontal milling machine except that the
spindle is mounted in the vertical position.
a. Milling head
The milling head consisting the spindle, the motor, and the feed
control unit is mounted on a swivel base such that it can be set at
any angle to the table.
b. Ram
The ram on which the milling head is attached can be positioned
forward and backward along the slide way on the top of the
column.
d. Universal Milling Machine:
• I t is most versatile of all milling machines, after lathes it is most
useful m/c tool which is capable of performing most of
machining operations.
• In Plain milling machine table can be given one/ more additional
movements, where as in this machine table can be swiveled on
saddle in horizontal plane.
• The table is permitted to swing up to 45° in either direction for
angular and helical milling operations.
• For this circular guide ways are provided on saddle along which it
can swiveled.
• A graduated circular base is incorporated under table ,with datum
mark on saddle , to read directly angle through which table has
been swiveled.
• By this work is set at an angle with cutter for milling helical &
spiral flutes & grooves.
 Plain Milling Machine Vs Universal Milling Machine

S.No Plain Milling Universal

Machine Milling
Machine
1 Work Table
Movement
2 Accessories
3 Type of operations

4 Construction

5 Applications
• Not only possess both horizontal milling arbour and the vertical
axis spindle, the latter spindle can be further tilted about one (X) or
both the horizontal axes (X and Y) as shown in diagram enabling
machining jobs of complex shape.
b. Duplex Head Milling m/c (2 horizontal spindles)
• It is another form of fixed bed type milling m/c.
• In construction it is similar to that of fixed bed type plain milling
machines, except that it carries 2 vertical columns, one each on
both sides of fixed bed type of machines.
• Both columns carries parallel vertical ways, on which are mounted
2 spindle heads/ carriers.
• Both these carriers carry a horizontal spindle each on which
cutters can be mounted.
• Spindle carriers can be adjusted up side down vertically to adjust
cutters to work.
• Table has only longitudinal movements.
 MILLING METHODS
Conventional / Up milling:

• In up cut milling, the cutter rotates

in a direction opposite to the table
feed as illustrated in figure.
• In this thickness of chip is
minimum at beginning of cut & it
reaches to max.
• In other words we can say chip
thick ness is min(zero) at start of
cut & max at end of cut.
• Cutting force is directed up wards
& this tend to lift work from
fixtures.
Climb/ Down Milling:
• The cutter rotates in the same
direction as the table feed as
illustrated in figure
• Thickness of chip is max when
tooth begins to cut & it reduces
to min when cut terminates.
• In other word we say that chip
thickness is max in beginning
& zero at end of cut.
• Fixture design becomes easier as
direction of cutter force is such
that it tends to seat work firmly in to
work holding devices.
• It gives better surface finish.
 DIFFERENCE BETWEEN UP-MILLING AND DOWN MILLING

S.No. Criteria Up-Milling Down Milling

1. Relative
movement
2. Cutting force
variation
3. Cutting force
direction and
Stress
4. Chip thickness

5. Safety

6. Applications

7. Limitations
DOWN UP
 Classification of Milling Cutters

(a) Profile sharpened cutters – the geometry of the machined

surfaces are not related with the tool shape

1. Slab or plain milling cutter : straight or helical fluted

2. Side milling cutters – single side or both sided type

3. Saw milling

4. End milling cutters – with straight or taper shank

5. Face milling cutters

(b) Form relieved cutters – the job profile becomes the replica of the
tool-form.
1. Form cutters

2. Gear (teeth) milling cutters

3. Spline shaft cutters

4. T-slot cutters

5. Thread milling cutter

Use of profile sharpened cutters
• The profile sharpened cutters are inherently used for making flat
surfaces or surface bounded by a number of flat surfaces only.
•Slab/ Plain Mills:
• For heavy cutting of large and flat surfaces.
• Plain milling cutters are hollow straight HSS cylinder of 40 to 80
mm outer diameter having 4 to 16 straight or helical equi-spaced flutes
or cutting edges and are used in horizontal arbor to machine flat
surface
• Side and Slot Cutters
• This type of cutters has cutting edges
on the periphery and sides of the teeth for
cutting shoulders and slots.
• These arbor mounted disc type cutters
have a large number of cutting teeth at
equal spacing on the periphery.
• Each tooth has a peripheral cutting edge
and another cutting edge on one face in
case of single side cutter and two more
cutting edges on both the faces leading to
double sided cutter.
• These cutters may be made from a
single piece of HSS or its teeth may be of
carbide blades brazed on the periphery or
clamped type uncoated or coated carbide
inserts for high production machining.
Slitting Saws:
• These milling cutters are very
similar to the slotting cutters
having only one peripheral
cutting edge on each tooth.

• However, the slitting saws

⎯ are larger in diameter and

much thin

⎯ possess large number of

cutting teeth but of small
size

⎯ used only for slitting or

parting
End milling cutters or End
mills
• The shape and the common
applications of end milling cutters
(profile sharpened type) are shown
in Fig. The common features and
characteristics of such cutters are :
– mostly made of HSS
– 4 to 12 straight or helical teeth
on the periphery and face
– diameter ranges from about 1
mm to 40 mm
– very versatile and widely used
in vertical spindle type milling
machines
• end milling cutters requiring larger diameter are made as a
separate cutter body which is fitted in the spindle through a taper
shank arbor as shown in the same figure.
Face Milling Cutters
• For heavy cutting.
• The main features are :
1. usually large in diameter (80
to 800 mm) and heavy
2. used only for machining flat
surfaces in different
orientations
3. mounted directly in the
vertical and / or horizontal
spindles
4. coated or uncoated carbide
inserts are clamped at the
outer edge of the carbon steel
body as shown
5. generally used for high
production machining of large
jobs.
Use of form relieved cutters (milling):
• The distinguishing characteristics of such cutters, in contrast to
profile sharpened cutters, are:
1. form of the tool is exactly replica of the job-profile to be made.
2. used for making 2-D and 3-D contour surfaces .
Form cutters
• Such disc type HSS cutters are generally used for making
grooves or slots of various profiles as indicated in Fig.
• Form cutters may be also end mill type like T-slot cutter as
shown in Fig.
Gear Teeth Milling Cutters
• Gear milling cutters are made of HSS & available mostly in disc
form like slot milling cutters and also in the form of end mill for
producing teeth of large module gears.
• The form of these tools conform to the shape of the gear tooth-gaps
bounded by two involutes as shown in Fig.

• 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.
Spline Shaft Cutters:
• These disc type HSS form relieved cutters are used for
cutting slots of external spline shafts having 4 to 8 straight
axial teeth.
Tool Room Cutters:
• Form milling type cutters are also used widely for cutting slots/ flutes
of different cross section e.g. the flutes of twist drills (Fig.) milling
cutters, reamers etc., and gushing of hobs, taps, short thread milling
cutters etc.
Thread Milling Cutters
• Such shank type solid HSS or carbide cutters having thread like
annular grooves with equi-spaced bushings are used in automatic
single purpose milling machines for cutting the threads in large lot
production of screws, bolts etc.
• Both internal and external threads are cut by the tool as shown in
Fig.
 Milling Machine Operations

JOB
JOB
STRADDLE
MILLING
GANG MILLING
END MILLING
Straddle Milling:
• For faster and accurate machining 2 parallel vertical
surfaces at definite distance, two separate side milling
cutters are mounted at appropriate distance on the horizontal
milling arbor as shown in Fig.
Gang Milling:
• In Gang milling, being employed, where feasible, for quick
production of complex contours comprising a number of parallel
flat or curved surfaces a proper combination of several cutters are
mounted tightly on the same horizontal milling arbor as indicated
in Fig.
 ELEMENTS OF PLAIN MILLING CUTTER

Principal Parts:
1) Body
2) Cutting Edge
3) Face
4) Fillet
5) Gash
6) Land
MILLING CUTTER MILLING CUTTER MILLING CUTTER
WITH POSITIVE RAKE WITH ZERO RAKE WITH NEGATIVE RAKE

Relief angle – 3o-5o for cutting mild steels

Rake angle – 10-15o for cutting mild steels
HELIX ANGLE OF HELICAL MILLING CUTTER
 CUTTING SPEED, FEED AND MACHINING TIME IN MILLING

CUTTING SPEED: V= πDN

1000

FEED: Rate at which the work table advances under the cutter

Feed in Milling is expressed in three methods

1) Feed per tooth (fZ): mm/tooth

Table travel during the period when the cutter revolves through an angle
corresponding to the distance between the cutting edges of two adjacent
teeth

2) Feed per revolution (frev): mm/revolution

3) Feed per minute (fmin): mm/min

 MACHINING TIME

1) PLAIN MILLING

Approach length (la) for

Plain Milling Cutter
Cutter

D/2-d
D/2

Work feed

la l
L
 FACE MILLING
Top View
Approach length (la) for
Face Milling Cutter
Cutter
C
W

W/2
D/2

la l
L