2.

MILLING MACHINE

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 COMPONENTS MADE
BY MILLING
 2 PRINCIPLE TYPES OF
MILLING

1. Face Milling.

2. Peripheral (side) Milling.

 TYPES OF MACHINE.
2 MAIN GROUPS OF MACHINE.

1. Horizontal spindle machines

2. Vertical spindle machines

HORIZONTAL.
VERTICAL.
VERTICAL MILLING MACHINE
(PERIPHERAL MILLING)
HORIZONTAL MILLING
MACHINE (FACE MILLING)

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During milling the work can be fed into the cutter or cutters two ways.

Up-cut milling and Down cut milling.

UP-CUT MILLING
 UP-CUT MILLING
Up-cut milling: the work piece is fed against
the direction of the material being cut.
This type of milling is the most common
used in milling.

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DOWN-CUT MILLING
 DOWN-CUT MILLING
Down-cut milling: is sometimes called ‘climb milling’ this
should only be carried out on machines that are fitted with
backlash eliminators as this method has a tendency for the
cutter to climb the work piece and pull the table also.

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TYPICAL
MILLING
OPERATIONS
PLAIN MILLING
PLAIN MILLING IS THE MILLING OF A FLAT SURFACE
WITH THE AXIS OF THE CUTTER PARALLEL TO THE
MACHINING SURFACE. IT CAN BE CARRIED OUT EITHER
ON A HORIZONTAL MACHINE OR A VERTICAL MACHINE
END MILLING
END MILLING IS THE MILLING OF A FLAT
SURFACE WITH THE AXIS OF THE CUTTER
PERPENDICULAR TO THE MACHINING SURFACE
GANG & STRADDLE MILLING
•Gang milling: when the cutters are mounted adjacently side
by side on the arbour.

•Straddle milling: when the cutters are mounted on the arbour

and are separated by spacing collars.

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TYPES OF CUTTERS
T Slot Cutter: use for milling tee-slots in machine tables.

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DOVE TAIL CUTTER
Dovetail Cutter: use to machine dovetails slideways on
machines.

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 END MILL CUTTER
End Mill: have cutting edges along their length and on
their ends, used to cut slots and shoulders on the edges of
a work piece.

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 SLOT DRILL
Slot Drill: They are so named for their use in cutting keyway
slots.

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BALL NOSE CUTTER
Ball Nose cutters: similar to slot drills, they are also used to add a
radius between perpendicular faces to reduce stress concentrations

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HORIZONTAL MACHINE
CUTTERS

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 CUTTING TOOLS FOR
HORIZONTAL MILLING

Arbour Mounted

a. Slab Mills

For heavy cutting of large

and flat surfaces.
b. Side and Face Cutters

This type of cutters has

cutting edges on the
periphery and sides of the
teeth for cutting shoulders
and slots.
c. Slitting Saws

For cutting deep slots

or for parting off.
WORKHOLDING.
PLAIN MILLING MACHINE
VICE

The milling machine

vice is the most
common type of
work holding devise
used on the milling
machine
 UNIVERSAL ANGLE MILLING VICE

For machining operations

involving compound angles,
a universal vice is commonly
used

The universal vice allows the

operator to tilt the workpiece
90 degrees in the vertical
plane as well as swivel it 360
degrees in the horizontal
plane
USING THE VICE

Locate the part in the

center of the vice. This Holding the workpiece off
equalizes the pressure on center puts unequal pressure
the vice jaws on the vice jaws. This can
cause the piece to loosen up.
Keep the workpiece as low in Work that extends out of
the vice has a greater
the vice as possible
chance of loosening up
under cutting conditions.
DIVIDING HEAD (N.B)
 DIVIDING HEAD
A dividing head is a tool that is used to divide a circle into equal divisions.
Indexing Plates

Crank Sector Arms

Crank turns = 40 / N
where N = the desired number of equal divisions at the spindle.

Reduce this fraction to its simplest form. Use any whole number to represent
complete turns, and use the denominator to determine the index plate to use.
The index plates with these hole circles were commonly supplied: 24, 25, 28, 30, 34,
37, 38, 39, 41, 42, 43, 46, 47, 49, 51, 53, 54, 57, 58, 59, 62, and 66.

These hole circles usually come on a set of two or three plates.

Of course, with a dividing head you can make your own index plates.

For the following examples we use the standard of 40:1.

 First a very simple example: we want to mill four flats on the side of a shaft to make a
square end to match the square. So we must divide the circle of the shaft into 4 parts:

40/4 = 10/1 = 10 full turns of the crank per division.

It doesn't matter which hole circle we use on the index plate since we have only
complete revolutions of the crank to make for each advance of the spindle.
Too easy?
How about another one?
We need to make a bolt hole pattern flange which has a 13 hole bolt pattern:

40/13 = 3 1/13.
Or in other words, 3 turns of the crank plus 1/13th of a turn per division.
So to proceed, we set the plunger over our 39 hole circle (3x13 = 39), advance the
crank a turn or so to take up any play in the divider, clamp the spindle, drill the first
hole, unclamp the spindle,
turn the crank 3 full turns plus 3 holes in our 39 hole circle,
clamp the spindle, drill the second hole, unclamp,
crank 3 turns plus 3 holes, clamp, drill, unclamp, 3 turns plus 3 holes, clamp, drill,
unclamp, crank, clamp, drill, unclamp, crank, drill, unclamp, crank...
 Question 7 (c) 2009
Describe, with the aid of suitable diagrams, the essential
features of the horizontal milling machine or the vertical
milling machine.
Question 7 (c) 2008
Describe, with the aid of suitable diagrams, the differences
between up-cut milling and down-cut milling
Question 7 (b) 2007
The milling machine is capable of producing a range of
cutting operations. Three milling cutters are illustrated
below: Identify a use for any two of the milling cutters
shown.
Question 7 (a) 2006
Answer any two of the following:
(i) Identify three machining processes used to produce a
cylindrical surface;
(ii) Differentiate between the milling operations shown;
(iii) Gang milling and straddle milling.
Question 7 (c) 2005
Outline the difference between the items in any one of the
following:
(i) Up-cut and down-cut milling;
(ii) Peripheral milling and face milling.
Question 7 (c) 2004
(c) Describe, with the aid of a suitable diagram, the main
features of peripheral milling or face milling.

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