Machine Tools

UNIT-3

UNIT-2Straight Motion Mechanism

Dr. M Sandeep Kumar

08/06/2024 B. V. Raju Institute of Technology, Narsapur

1
 Milling Machine
•Milling is the machining process in which the metal removal takes place due to the
cutting action of a revolving cutter when work piece is fed past it.
•The revolving cutter is held on a spindle or arbor and the work piece clamped on
the machine table.
•Milling is a process of cutting a metal by using multi-teeth rotating tool which is
called as cutter.
•The form of each tooth of the cutter is similar to the single point tool.
•An important feature is that, each tooth after taking a cut comes in operation again
after some interval.
•This allows the tooth to cool down before the next cutting operation is done by it,
which minimizes the effect of heat developed in cutting on the cutting edge.
•Following two methods are commonly used for performing this operation by using
cylindrical cutter
Up milling :
Up milling is also called as conventional milling.
In this method, cutter rotates in a direction opposite to that in which the work
pieces fed.
Down milling :
Down milling is also called as climb milling.
In this method, the direction of rotation of the cutter and the direction of work
piece fed is same.
No. Up milling or conventional milling Down milling or climb milling
1. The cutter is rotate against direction of The cutter rotates in the same direction
travel of the work piece. of travel of the work piece.
2. The chip thicknessis minimum at the beginning of The chip thicknessis maximum at the beginning
the cut and or reaches to maximum when the cut of the cut and or reduces to minimum when the cut
terminates. terminates.
3. The cutting force is zero at the beginning of the cut The cutting force is maximum when the cut begins
and maximum at the end of the cut. and it reduces to minimum when the tooth leaves
the work.
4. The cutting force is directed upward and The cutting force is downwards Which tends to
this tend to lift the work piece from the fixture seat the work piece firmly in the fixture.
5. Difficulty in pouring the coolant just on the cutting The coolant can be poured directly at the cutting
edge, due to typical nature of the cut zone where cutting force is maximum.
6. The chip accumulate ate the cutting zone and may be Chips are disposed off easily and do not interfere
carried over with the cutter spoiling the work surface with the cutting.

7. The actual cutting does not start at zero chip thickness Chips are disposed off easily and do not interfere
as teeth slide through a minute distance which gives a with the cutting.
slightly wavy surface
 Types of Milling Machines

1. Column and knee type milling machines

a) Hand milling machine
b) Plain or horizontal milling machine
c) Vertical milling machine
d) Universal milling machine
e) Omniversal milling machine

2. Fixed bed or manufacturing type milling machines

f) plain type milling machine (having single horizontal spindle)
g) Duplex head milling machine (having double horizontal spindles)
h) Triplex head milling machine (having two horizontal and one vertical spindle)
i) Rise and fall type milling machine (for profile milling)

3. Planer type milling machines

4. Production milling machines:
j) Rotary table or continuous type milling machine
k) Drum type milling machine
l) Tracer controlled milling machine
5. Special purpose milling machines
a) Thread milling machine
b) Profile milling machine
c) Cam milling machine
d) Gear milling or gear hobbing machine
e) Planetary milling machine
Column and Knee Type Milling Machines
•Column and knee type milling machines are most commonly used in machine
shops and tool rooms.
•These machines are general purpose machines and have a single spindle only.
•The worktable is supported on a knee-like casting. Which can slide in vertical
direction along a vertical column?
•Depending upon the spindle position and table movements, they are further
classified as follows:

a) Hand milling machine

b) plain or horizontal milling machine
c) Vertical milling machine
d) Universal milling machine
e) Omniversal milling machine
Horizontal Milling Machine Vertical Milling Machine
• Horizontal milling machines feature a similar design in which a spindle
containing a rotating cutting tool presses against a workpiece to remove material
from the workpiece. With that said, horizontal milling machines differ from their
vertical counterparts in several ways. The biggest difference between these two
types of milling machines is the orientation of the spindle. With vertical milling
machines, the spindle features a vertical orientation. With horizontal milling
machines, the spindle features a horizontal orientation. In other words, horizontal
milling machines mount the cutting tool on a horizontally oriented spindle that’s
able to selectively remove material from the stationary workpiece.

• Furthermore, horizontal milling machines usually feature different cutting tools

than vertical milling machines. While vertical milling machines usually have long
and thin cutting tools, horizontal milling machines have shorter and thicker
cutting tools.

• Horizontal milling machines are able to perform heavier, deeper cuts than vertical
milling machines. As a result, manufacturing companies often use them to cut
grooves or slots into workpieces. Hopefully, this gives you a better understanding
of the differences between vertical milling machines and horizontal milling
machines.
 Universal Milling Machine
•Universal milling machines are most versatile of all the milling machines and
most useful because, they are capable of performing most of the machining
operations.
•By using this machine, large number of other machine tools can be avoided.
•Universal milling machine is similar to horizontal milling machine, except that
the table can be given one more additional movement.
•Its table can be swiveled in a horizontal plane and for this purpose circular
guide way are provided on the saddle.
•To read the angle of swiveling, a graduated circular base is provided under the
table with datum mark on the saddle. Hence, Work piece can be set at an angle
with the cutter for milling helical and spiral flutes and grooves.
 Omniversal Milling Machine
•Omniversal milling machine is a modified form of a plain milling machine.
•It is provided with two spindles, out of which one is horizontal and other is
carried by a universal swiveling head.
•The latter can be fixed in vertical position or can be set at any required angle up
to 90° on both the sides of vertical.
•One more special feature of this machine is that, it carries two more adjustments
in addition to all the adjustments provided in a universal machine.
•Its knee can be swiveled about a horizontal axis to tilt the table and can be
moved horizontally also.
•Hence, this machine is very useful for tool room work.
Principle Parts of Column and Knee Type Milling Machines

1. Base 2. Table 3. Saddle

4. Column 5. Knee 6. Over arm

1. Base:
•Base is a heavy casting and provided at
the bottom of the machine.
•On both the top and bottom surfaces, it is
accurately machined.
•It acts as a load taking member for all
other parts of the machine and a reservoir
for the coolant.
•Column of the machine is secured to the
base.
•Also, the base carries a screw jack which
supports and moves the knee.
2. Column:
•Column is very important part of a milling machine and produced under careful
attention because on the column many parts and controls are fitted.
•Vertical parallel guide ways are provided on front face of the column in which
knee slides up and down.
•Also, on the top of the column over arm is supported‘

3. Knee
•Knee is a rigid casting which is capable of sliding up and down along the guide
ways provided on front face of the column.
•With the movement of the knee, the table height or distance between the cutter
and work piece can be adjusted.
•By operating the screw jack with the help of hand wheel or Powel feed, the height
can be adjusted.
•For cross movement of the saddle and table, horizontal guide ways are provided
the top surface of the knee
4. Table:
•Table acts as a support for the work piece.
•Table is generally made of cast iron with its top surface accurately machined.
•To accommodate the clamping bolts for fixing the work piece, the top surface
of the table carries longitudinal T-slots.
•Also, the cutting fluid after it is used drains back to the reservoir through slots
these and for this purpose pipe is fitted.
•Longitudinal feed is provided to the table by using hand wheel fitted on one
side of the feed screw.
•Vertical feed is provided by raising or lowering the knee and cross feed by the
moving saddle.
5. Saddle :
•Saddle is the intermediate part between the table and knee which acts as a
support for the table.
•To provide cross feed to the table, the saddle can be adjusted crosswise along
the guide ways provided on the top of the knee.
•Also, horizontal guide ways are provided at the top of the saddle along which
the table can be moved in a longitudinal direction
6. Over arm :
It is the heavy support provided on the top of the milling machine (in plain and
universal milling machines).
To support the projecting arbor, it can slide horizontally, forward and backward
and adjusted at required position.

7. Arbor:
Arbor is used for holding the milling cutters during the operations.
It is a common method of mounting the cutters, although they are mounted on the
machine spindle directly too.
The arbors are mainly of two types i.e. standard arbor and stub arbor.
 Size of Milling Machine

1. The size of working surface of the table

2. The maximum length of longitudinal, cross and vertical travel of the table
3. The power of driving motor
4. Number of spindle speeds
5. Number of feeds
6. Floor space required
 Milling Cutters

1. Plain milling cutters

2. Side milling cutters
3. Metal slitting cutters
4. End milling cutters
5. T-slot milling cutters
6. Woodruff key slot milling cutters
7. Fly cutters
8. Angle milling cutters
9. Formed milling cutters
 1. Plain milling cutters

•Plain milling cutters are cylindrical in shape and have

the cutting teeth on their periphery.
•The cutting teeth may be either straight or helical
•Their end faces are either ground square with the axis
or slightly concave to reduce the friction.
•Hence, by side faces no cutting action is provided.
•These cutters are used for milling flat surfaces parallel
to the rotation axis.
•These cutters are available in diameters from 16 to
160 mm and width range from 20 to 160 mm
2. Side milling cutters

•Side milling cutters have teeth on their

periphery and on one or both sides.
•Also, for mounting them on the arbor, they
are provided with central hole
•When used in pairs they are called as straddle
mills'
•These cutters are employed for removing
metals from the side of a work piece. Side
milling cutters are generally used for slotting
and straddle milling.
•They are available from 50 mm to 200 mm in
diameter and 5 mm to 32 mm in width
 3. Metal Slitting Cutters

•Metal slitting cutters are also called as metal

slitting saws.
•They appear like plain or side milling cutter but
are of very small width.
•These types of cutters are mostly used for parting-
off operation and for slotting.
•Metal slitting cutters are available in following
varieties
 4. End Milling Cutters:

•End milling cutters have cutting teeth on the end as well as on the circumference
of the cutter.
•The teeth on circumference may be straight or helical and the helix may be left
hand or right hand.
•These cutters are used for light milling operations such as cutting slots, machining
accurate holes, profile milling, narrow flat surfaces, etc.
5. Face Milling Cutters

Face milling cutter is a disc-shaped, with

cutting blades around the body and the side
face. Such cutter is specialized in cutting
larger plane. The blade face is wider, and the
cutter body is made of general tool steel,
then embedded high-speed steel or carbide
blade.
 6. T-slot Milling Cutters

•T-slot milling cutters are special forms of end milling cutters used for producing
T-slots.
•In smaller size, it has the shank integral with the cutter, whereas large size
cutters are mounted on a separate shank
•During the operation, the narrow groove at the top is first milled by using a
slotting cutter or end milling cutter.
•After that, T-slot milling cutter is employed for milling wider groove
 7. Woodruff-key Milling Cutters

•It is a small type of end milling cutter which resembles plain and side milling
cutters
•Small size (up to 50 mm) diameter cutters have a solid shank, whereas larger
size cutters are provided with a central hole for mounting on an arbor.
•Smaller size cutters have straight teeth on the periphery, whereas larger cutters
have staggered teeth on the periphery and sides
 8. Fly Cutters

•It is actually a single point cutting tool, which is mounted on a cylindrical body
and held in a stub arbor or in a bar
•Generally, fly cutters are the simplest form of cutters and used in experimental
shops or tool room works.
•The cutting edge may be formed to reproduce countered surface.
•When standard cutters are not available, this cutter is considered as an
emergency tool
 9. Angle Milling Cutters

The cutting edges of the angle milling cutters are formed at the conical surface
around the periphery of the cutter. Its angular teeth are neither parallel nor
normal to their axes.
They are mostly used in milling v-grooves, notches, dovetail slots, reamer teeth
and other angular surfaces.

Single angle milling cutters Double angle milling cutters

 10. Formed Milling Cutters

•Formed milling cutters are also called as form relieved milling cutters or radius
cutters.
•The formed cutters have irregular profiles on the cutting edges, to generate an
irregular route line of the work.
•The teeth of formed milling cutters are provided with a certain angle of relief so
that their forms and sizes are retained even after resharpening

convex milling cutters Concave milling cutters

(I) R.H. corner (ll) L.H. corner (III) Double rounding cutter

(Roughing) (Finishing)
 Milling Machine Operations

1. Plain or slab milling

2. Face milling
3. Angular milling
4. Straddle milling
5. Slot and groove milling
6. Slitting or saw milling
7. End milling
8. Gear milling
9. Form milling
10. Gang milling
11. Keyway milling
12. Side milling
13. Profile milling
14. Thread milling
 1. Plain or slab milling:
•Plain milling is used for machining a flat, plain, horizontal surface, parallel to
the axis of cutter with the help of plain or slab milling cutter
•For machining of very wide surface, interlocking teeth plain milling cutters are
used instead of simple plain milling cutters.
•During the operation, the work piece and cutter are secured properly on the
machine and by rotating the vertical feed screw of the table and machine, the
depth of cut is adjusted.

w/p
2. Face milling

•Face milling is employed for machining a flat surface which is at right angle, to
the axis of revolving cutter.
•The cutter used in the process is face milling type which is rotated about an axis
Perpendicular to the work piece
•The operation is performed on plain milling machine and depth of cut is adjusted
by rotating the cross feed screw of the table.
 3. Angular milling

•Angular milling is used for machining a flat surface at an angle, other than
right angle, to the axis of milling machine spindle. For example, V-blocks
•According to the type of surface (single or two mutually inclined), the single or
double angle cutters may be used
 4. Form milling:

•Form milling is the operation of machining irregular contours by means of form

milling cutter
•The irregular contour may be concave, convex or of any other shape.
•The cutting speed of form milling process is 20 - 30 % less than that of the plain
milling.
 5. Straddle milling

•Straddle milling is the operation of flat vertical surfaces on both the sides of a
work piece simultaneously.
•For this purpose two side milling cutters are mounted on the same arbor
•By using suitable spacing collars, the distance between the two cutters can be
adjusted.
•This process is mainly used for production of square and hexagonal surfaces
 6. Gang milling

•Gang milling is the operation of machining several surfaces of the work piece
simultaneously.
•For this, table is fed against the number of cutters having same or different
diameters mounted on a common arbor
•This method saves machining time and is widely used in repetitive work
 7. Slot and groove milling

•slot milling is the operation of producing slots in solid work pieces.

•These slots can be of different shapes such as plain slots, T-slots, dovetail slots
etc.
•Plain slot can be milled by using plain milling cutter and end milling cutter
•Groove milling is the operation of producing grooves of various shapes like
plain grooves, curved grooves, v grooves, etc.
•According to the shape of slot or groove, the cutter is selected.
 8. Keyway milling

•Keyway milling is a common operation which is performed on milling machine

•In this a groove is milled on shafts and spindles, which is known as key seat
•A woodruff key seat which is milled with woodruff key seat cutter.
 9. Slitting or saw milling
•Saw milling is the operation of production of narrow slots or grooves on a work
piece by using a saw or slitting milling cutter.
•It is also used for complete parting-off operation
 10. Side milling

•In this operation a side milling cutter is used for machining a flat vertical surface
on one side of the work piece
•When two parallel vertical flat surfaces are required to be machined, then two
side milling cutters in pairs are used.
•By using spacer, the space between two cutters can be adjusted.
•Hence, this operation is similar to straddle milling.
 11. End milling

•This operation is used to machine and

produce a flat surface or a pair of flat
surfaces by using an end milling cutter.
•The surfaces produced may be horizontal,
vertical or inclined with respect to the top of
the machine table
 Gear milling

Thread milling
 Dividing Head or indexing Head

•The dividing head or indexing head is one of the most important of the milling
machine accessories.
•The dividing head is a mechanical device used to divide the circumference or
periphery of a job into a specified distance or angular separations.
•It is also used to hold the work piece securely.
•The dividing head rotate the work piece through a certain degree or certain
fraction part of complete circle of graduating the parts this operation is called as
indexing
Working Principle of Indexing Mechanism
 2. Universal Dividing Head
•For indexing the work piece, this type of dividing head is very useful.
•It consists of robust body and worm drive is enclosed in it, which is having
worm and worm wheel
•In this, the dividing head spindle carries a worm wheel, which meshes with the
worm.
•The worm carries a crank at its
outer end.
•The index pin works inside the
spring loaded plunger, which can
slide radially along as lot
provided in the crank.
•This plunger can slide, to adjust
the pin position along a desired
hole circle on the index plate
•The index plate is mounted on the same spindle as the crank, but on a sleeve,
hence the crank and worm spindle can move independent on the index plate.
•To set a definite distance along a desired hole circle, sector arms are used.
•Sector arms are of detachable type and can be set at a desired angle with one
another.
•The index plates are available in a set of two or three, with a number of hole
circles generally on both sides on them.
•The universal head is used to perform following operations :
To set the work piece in a desired position, in relation to the machine table.
To rotate the work piece through a desired angle, after each cut and hence,
index the periphery of the work Piece.
To provide, a continuous rotary motion to the work piece while milling of
helical grooves.
Direct Indexing
It is also named as rapid indexing. For this direct indexing plate is used which
has 24 equally spaced holes in a circle. It is possible to divide the surface of
workpiece into any number of equal divisions out of 2, 3, 4, 6, 8, 12, 24 parts.
These all numbers are the factors of 24.
In this case fist of all worm and worm wheel is disengaged. We find number of
holes by which spring loaded pin is to be moved. If we want to divide the
surface into 6 parts than number of holes by which pin is to be moved

for 6 parts
N = 6.
Simple Indexing
It is also named as plain indexing. It over comes the major limitation of direct
indexing that is possibility of dividing circumference of workpiece into some
fixed
number of divisions. In this case worm and worm gear is first engaged. So one
complete turn of indexing crank revolves the workpiece by 1/40th revolution.
Three indexing plates are used. These plates have concentric circles of holes with
their different numbers as described below :
(a) Divide 40 by the number of divisions to be done on the circumference
of workpiece. This gives movement of indexing crank.
Indexing crank movement = 40/N
N is the number of divisions to be made on the circumference of
workpiece.

(b) If the above number is a whole number, then crank is rotated by that much
number of revolutions after each milling operations, till the completion of the work.
For example, if we want to divide the circumference into 10 number
of parts. Indexing crank movement 40/10 = 4 revolutions.

That is the indexing crank is given 4 revolutions after each of milling

operation for 9 more milling operations.
3 – Which hole circle
1- no of crank revolutions
1- extra no of hole

15- hole circle