Mod 2

Milling Machines
• Machine tool that removes metal as work is fed against a rotating
multipoint cutter
• Can hold more than one milling cutter at a time
Parts
1.Base – made of grey cast iron machined accurately on top and bottom
surface
• Foundation member , carries column at one end
• Some machines have hollow base that act as reservoir for cutting fluid
2. Column
• supporting framework mounted vertically on base
• Box shaped, houses driving mechanisms for spindle and table feed
3.Knee
• Slides up and down on vertical guide ways
• Lifted up and down by elevating screw
• Top face has slide way for cross saddle movement
4. Table
• moves longtitudinally
• Hand or power driven
• Has t slots to clamp work
5. Overhanging arm
• Mounted on top of column
• Support other end of arbor
6. Front brace
• Extra support between knee and overarm for further rigidity
7. Spindle
• Recieves power from motor through belt, gear and transmit to arbor
• Front end has a tapered hole into which various tools and arbors may be
inserted
8. Arbor
• Extension of spindle
• Cutters mounted on it
• Has a taper shank
 Types of Milling Machines

1. Column and knee type

• Knee mounted on vertical slides of column and table mounted on
knee
• classified based on mode of power supply, table movements,
spindle rotation axis
a. Hand milling machine
• Table feed in by hand
• Cutter mounted on arbor and rotated by power
• For light and simple milling operations like slots, grooves
b. Plain milling machine
• Table is hand or power fed
• Has horizontal arbor
• Table can be fed longitudinally, cross, and vertical
c. Universal milling machine
• Table mounted on a circular swivelling base
• Table can be swivelled by 45 degree to any side about a vertical
axis
• Work can be fed at an angle to cutter
• Can do helical milling
• Can produce spur, bevel, spiral gear, milling cutters etc
• Mainly for tool room work and for special machining operations
d. Omniuniversal machine
• Has all movements of a universal milling machine
• Table can be tilted in a vertical plane by a swivelling
arrangement at knee
• Can machine taper spiral grooves in reamers, bevel gears etc
• Mainly for tool room work and for special machining operations
2. Vertical milling machine
• Spindle is vertical or perpendicular to work
• Machine may be universal or plain
• Spindle head clamped to vertical column may
be swivelled at an angle permitting cutter to
work on angular surfaces
• For grooves slots and flat surfaces

3. Manufacturing or fixed bed type

• Larger and heavy comparitively
• Table mounted directly on the bed
• Table has no cross or vertical movements
• Cutter can be moved vertically and spindle can
be adjusted horizontally for cross adjustment
• Can accommodate multiple spindle heads
• Automatic cycle of operation for feeding the
table is possible and suitable for repetitive
works
4. Planer type
• For heavy duty work
• Spindle adjustable in vertical and transverse
directions
• In a planer, table movement gives cutting speed,
in plano milling machine table movement gives
feed
• Has good material removal rate
5. Special types
a. Rotary table type
• Modification of vertical milling machine, used
to machine flat surfaces
• Has a circular table that rotates about a vertical
axis
• Have more than one spindle, face milling
cutters mounted and work pieces mounted on
table
• Cutters set at different height so that one does
roughing while other do finishing
b. Planetary milling machine
• Work held stationary while cutter is revolved in a planetary
path to finish a cylindrical surface internally or externally
c. Pantograph milling machine
• To duplicate a job by a pantograph mechanism
• Permit size of workpiece reproduced to be same, small, larger
sizes
• Tracing stylus moved manually on contour of model , milling
cutter move in a similar path
 Types of milling cutters

1. Plain milling cutter

• Cylindrical shape, teeth on
circumference
• Produce flat surface parallel shaft
axis
• Teeth may be straight or helical
• Available in diameters from 16 to
160 mm
and width 20 to 160 mm
• Light, heavy duty, helical cutters
2. Plain Side milling cutters
• Has teeth on its periphery and also on its sides
• For removing metals from side of a work
3.Staggered teeth side milling cutter
• Have alternate teeth with opposite helix angle
• Increases space for chip flow
• Suitable for milling deep narrow slots or keyways
4. Metal slitting saw
• Small width, used for slotting or parting off
a. Plain metal slitting – 5mm width, sides relieved to avoid
rubbing against work
b. staggered teeth slitting saw – teeths staggered to both
sides, width 6.5 to 7 mm
5. Angle milling cutter
• To machine surfaces to an angle other than
90 degree
• Single and double angle milling cutter
• Single angle cutters available in angles of 30,
45,60,65,70,75,80,85 degrees
• Double angle cutters available at angles of
55 to 100 degrees
7. End mill
• Have cutting teeth on end as well as on
periphery of cutter
• Peripheral teeth may be straight or helical
• For cutting slots, holes, narrow flat surfaces
a. Taper shank end mill
b. Straight shank
c. Shell end mill – larger and heavier end mills,
has central hole to mount cutter on a short
arbor
 Milling operations

1. Plain milling
• Plain flat horizontal surface parallel to axis of
rotation of cutter
• Depth of cut adjusted by vertical feed screw
of table

2. Face milling
• Done by face milling cutter
• Cutter mounted on stub arbor, axis of cutter
perpendicular to work surface
• Depth adjusted by cross feed screw
3. Side milling
• Flat vertical surface on side of work piece by
side milling cutter
• Depth adjusted by vertical feed screw of
table
4. Straddle milling
• Production of flat vertical surfaces on
both sides of a workpiece using two side
milling cutters on same arbor
• Distance between cutters set using collars
• Used for making square, hexagonal
surfaces

5. Gang milling
• Machining several workpieces
simultaneously by feeding table against
number of cutters
• Saves machining time, useful for repetitive
works
6. Form milling
• Operation of producing
irregular contours by form
cutters

7. Profile milling
• Reproduction of template of
master die on a workpiece
• End mill cutter is mostly used
8. End mill
• Production of flat vertical,
horizontal surfaces
• Also for production of slots,
grooves, keyways

9. Gear cutting
• Cutter profile corresponds exactly
with tooth spacing
• Work held on an universal dividing
head and then indexing it
Milling tool nomenclature
• Body – portion to which teeth attached
• Cutting edge – edge formed by intersection of land and face
• Face – portion where chip impinges as it is cut
• Gash – chip space between back of one tooth and face of next
• Land – part behind cutting edge which is relieved to avoid contact with
work surface
• Outside diam. – diameter of circle passing through outside cutting edge
• Root diameter – circle passing through bottom of fillet
• Relief angle – angle between land and tangent to outside diameter of
cutter
• Primary clearence angle - angle between back of tooth and tangent to
outside diameter of cutter
• Secondary clearence angle - angle between secondary clearence surface
and tangent to outside diameter of cutter
• Rake angle – angle in diametrical plane between face and radial line
passing through cutting edge.
Helix angle – angle made by helical cutting edge with plane containing axis of
cutter
• Helix angles - engages cutting edges progressively, smoother
cutting, better finish, reduce power consumption.
25 to 45 degrees
• Relief and clearance angles – prevent interference between
land and work. Clearence angle to allow resharpening of tool
• Rake angle – reduce cutting force, higher rake reduce tool life.
Machining Time
 Indexing head
• Indexing is the process of evenly dividing the circumference of a circular
workpiece into equally spaced divisions, such as in cutting splines, cutting
gear teeth, milling grooves in taps and reamers, spacing holes on a circle
1. Plain Dividing Head
• carries an indexing plate directly mounted on its spindle
• The index plate carries 12-24 equispaced slots on its periphery.
• The workpiece is held between two centers i.e. one on the dividing head
spindle and the other on the tailstock.
• For locking the spindle in its position hand lever is used.
• The plate, together with the spindle can be rotated by means of hand
2. Universal dividing head
• To set the workpiece in the desired position, in relation to the machine table.
• To rotate the workpiece through the desired angle, after each cut and hence,
index the periphery of the workpiece.
• To provide continuous rotary motion to the workpiece while milling of helical
grooves.
• The worm gear has 40 teeth and the worm has simple thread. Crank is
directly attached with
• the worm. Since the gear ratio of worm and worm wheel is 40:1, it takes 40
turns of the crank
• to rotate the spindle and hence the work piece through one complete
revolution. One
• complete turn of the crank will revolve the spindle only by 1/40th revolution
(turn).
3. Optical indexing head
• These models are used for high precision angular setting of the work piece
with respect to the cutter. For reading the angles, an optical system is built
into the dividing head.
• Circular glass scale of 1 degree division is mounted on worm wheel and is
read off by a microscope
 Indexing methods

1. Direct or rapid indexing

• Used when many identical pieces to be indexed by very
small divisions
• Rapid index plate of 24 holes fitted to front end of spindle
• No. of holes to be moved = 24/N
N – no. of divisions needed
2. Simple or plain indexing
• 40 rotation of crank rotates index head spindle
by 1 rotation
• Index plates with circles of holes from 15 to 49
are available
• Index crank movement = 40/N
3. Compound indexing
• To obtain crank movement not possible by plain indexing
4. Differential indexing
• In this the required division is obtained by a combination of two movements
• The movement of the index crank similar to the simple indexing.
• The simultaneous movement of the index plate, when the crank is turned
through the back gears.
 Grinding
• manufacturing process used to achieve a smooth finish or
precise dimensions on a material
• Cutting by rotating abrasive wheel that act as tool
• Remove less material, 0.25 to 0.5 mm depth
• Rough grinding –considerable amount of material removed,
accuracy and finish and secondary importance. Eg trimming
surface left by sprues and risers on castings, remove flash on
forgings
• Precision grinding – surface finish and accuracy is important.
• the abrasives of grinding wheel and work piece comes into
contact and due to the rubbing force the initial layer from the
grinding wheel is worn out and a fresh layer of the abrasives
involve in machining
 Honing operation
• honing utilises a set of abrasive stones guided in and out of the
workpiece with a tool known as a hone
• utilised for enhancing the quality of previously machined surfaces,
particularly internal cylindrical surfaces and drilled or bored holes.
• micro-finishing process utilised to rectify hole geometry, correcting
irregularities such as out-of-roundness, taper, tool marks, and axial
distortion.
• Abrasives commonly employed in honing encompass Silicon
carbide, aluminium oxide, diamond, or cubic boron nitride.
• When comparing grinding and honing in terms of surface finish, honing
generally provides a better surface finish than grinding.
• tool undergoes a slow reciprocating motion while it rotates, resulting in
a complex motion that combines rotation with oscillatory axial
movement. These combined motions create a distinctive cross-hatch
pattern on the workpiece surface.
 Lapping operation

• When comparing grinding, lapping, and honing in terms of

surface finish, lapping typically provides the best finish,
followed closely by honing
• Lapping can achieve surface roughness values (Ra) as low as
0.05 micrometers
• three key components: a workpiece, a lapping plate, and
abrasive particles.
• abrasive particles are distributed onto the lapping plate, and
the workpiece is then moved across it through rubbing action.
• The primary effect of this abrasive action is to diminish or
flatten the microscopic peaks and valleys that exist on the
surface of the workpiece.
 Grinding machines
• Acc to quality of finish
1. Rough grinders 2. Precision grinders

Rough grinders – Floor stand and bench

grinder, portable grinder, swing frame
grinders, abrasive belt grinders
1. Floor stand grinder
wheels mounted on the stand.
Driven by motor through a belt.
Motor kept at floor level
Bench grinder
small size machine mounted on a bench.
Used for grinding tools
2. Portable grinder
Hand held electric drill with a grinding wheel
on the spindle
3. Swing frame grinders
Horizontal frame having a grinding wheel and
suspended at its centre of gravity
Used for snagging castings that are of large
size
4. Abrasive belt grinders
Abrasive is formed as endless belt and driven
at high speeds over two drum
Workpiece is pressed against the belt to do
Precision grinders-
1. Cylindrical centre type grinders –
for grinding plain cylindrical parts, also for contoured cylinders.
Work and wheel rotates, wheel moved over work.
a) Plain b) Universal type
Plain centre type cylindrical grinders –
Plain centre type cylindrical grinders –

• Lower table slides on guide ways on the bed for moving work piece
past the grinding wheel
• Headstock and tailstock are secured on the t slots of the upper table
• Upper table can be swivelled
• Wheel head can slide over the bed and can move perpendicular to
table guide ways to give cross feed.
Universal centre type grinders
• Headstock can be swivelled at angle in horizontal plane
• Wheel head and slide can be swivelled and traversed at any
angle.
2. Centreless grinders
to grind cylindrical, tapered and formed surfaces that are not
held between centres
Regulating wheel is slightly tilted horizontally so that work
moves axially on its own
Axial movement of work obtained by tilting regulating wheel at a
slight angle from horizontal
Advantages of centreless grinding
• eliminates the need for holding the workpiece in place, which
reduces setup time.
• less risk of deformation, especially for thin or delicate
components.
• centerless grinding does not require the workpiece to have a
central axis or a center hole. This reduces the need for
additional pre-processing steps.
3. Internal Grinders
• To finish straight, tapered, formed
holes
• 3 types
a) Chucking grinders –
work is chucked and rotated about
its own axis.
Wheel is rotated and reciprocated
through length of hole
Workhead can be swivelled and
cross fed
b) Planetory grinders – work mounted
on reciprocating table, not revolved,
Wheel rotates and has planetory
motion in hole. For large workpieces
c) Centreless internal grinders
Work supported by 3 rolls
Grinding wheel contacts the inside diameter of workpiece
directly opposite regulating roll
4. Surface grinders
• To finish flat
surfaces
• Horizontal and
vertical spindle
types.
• Reciprocating
and rotary table
types
Majority are
horizontal types
Horizontal spindle reciprocating Vertical spindle rotary table
table surface grinder surface grinder
Grinding wheel can be moved up and Magnetic chuck to hold workpiece
down on a vertical guide way It can slide on horizontal bedways
Grinding wheel can be cross fed Wheel has vertical axis and has up
Workpiece reciprocates under the wheel and down motion
5. Tool and cutter grinders
To sharpen and recondition
multiple tooth cutters like
reamers, milling cutters, drills,
taps etc
With attachments, they can also
do cylindrical, internal grinding,
sharpen single point tools.
Universal tool and cutter grinders
– to resharpen cutters
Single purpose type – for drills,
tool bits etc in large production
plants where regular grinding
of tool needed
 Grinding Wheels
• Hard particles called abrasives are crushed to form sharp edges,
mixed with suitable bond that act as matrix to hold abrasive grains to
form a block.
• Natural and artificial
• Natural – sandstone(quartz), corundum(aluminium oxide 75 to 95%),
emery(aluminium oxide 55 to 65%), diamond
• Natural abrasives not much used due to impurities and lack of
uniformity
• Artificial –
SiC – made of silicon sand, coke, salt, saw dust. Denoted by ‘S’. Hardness
is next to diamond but not as tough as aluminium oxide. For grinding
low tensile strength items like cemented carbides, ceramic material,
brass,bronze, Cu etc
Aluminium oxide – Tough, not easily fractured, for grinding high tensile
strength materials like steels, HSS. Denoted by ‘A’.
 Bonds

• Adhesive to hold abrasive grains in form of wheel

Vitrified Bond
• Made from ceramic materials like clay
• Strong, rigid, and can withstand high temperatures.
• Provides a high rate of material removal.
• Commonly used in precision grinding
• Denoted by ‘V’.

Silicate Bond
• Made from silicate-based compounds.
• Softer and more heat-resistant.
• Breaks down more easily, allowing for a self-sharpening effect.
• Used in applications where heat generation needs to be minimized.
• Denoted by S.
Resinoid Bond
• Composed of synthetic resins like phenolic resins.
• Flexible, with good impact resistance.
• Ideal for high-speed operations and producing fine finishes.
• Denoted by letter B
Rubber Bond
• Consists of natural or synthetic rubber.
• Flexible and elastic, less heat resistent
• Provides smooth finishes.
• Used for fine finishing, polishing, and centerless grinding.
• Denoted by letter R
Shellac Bond
• Composed of natural shellac.
• Provides a fine finish with a smooth cutting action.
• Used in applications requiring a high surface finish, like tool sharpening.
• Has high elasticity than other bonds
• Denoted by E
• Epoxy Bond (E)
• Formed using epoxy resins.
• Strong with good heat resistance.
• Suitable for high-performance and high-speed grinding
operations.
Metallic Bond (M)
• Made from metal powders like bronze, copper, or other alloys.
• High strength and durability.
• Good for heavy-duty grinding and superabrasives like diamond
and CBN wheels.
• Used in grinding hard materials like ceramics and glass.
 Grit of wheel
• Grit refers to the size of the abrasive particles used in the
grinding wheel.
• The grit size is measured in mesh numbers, which
represent the number of openings per linear inch in a sieve.
The higher the number, the finer the abrasive particles.
– Coarse Grit (8-24): Used for rapid material removal, rough
grinding, and large surface areas.
– Medium Grit (30-60): Suitable for general-purpose grinding and
providing a balance between material removal and surface
finish.
– Fine Grit (70-180): Used for fine finishes and precision work,
often in applications requiring high accuracy.
– Very Fine Grit (200-600): Typically used for superfinishing,
lapping, and polishing operations.
 Grade
• Grade refers to the hardness of the grinding wheel, which
indicates how strongly the bond holds the abrasive grains in
place.
• Scale: The grade is usually represented by letters,
• Soft Grade (A-H): The bond releases abrasive grains more
easily, leading to faster wear of the wheel. Suitable for
grinding harder materials
• Medium Grade (I-P):
• Hard Grade (Q-Z): The bond holds the abrasive grains tightly,
resulting in slower wear of the wheel. Ideal for grinding softer
materials
 Structure

• Structure refers to the spacing between the

abrasive grains in the grinding wheel.
– Dense Structure (1-6): Contains more abrasive
grains closely packed together.
– Open Structure (7-15): Has fewer abrasive grains,
with more space between them.
• Soft tough and ductile material and heavy cut
require open structure
• Hard and brittle materials and finishing cuts need
dense structure
Standard marking system