MILLING

Group 2

(Manufacturing Process)
• Definition of Milling Process
• Classification of Milling
• Methods of Milling
• Types of Milling Machine
• Cutting Parameters
• Types of Milling Cutters
• Advantages and Disadvantages
• Application of Milling
 Milling Process
Milling is the machining process of using rotary cutters to
remove material from a workpiece by advancing (or feeding) in a
direction at an angle with the axis of the tool.
 Classification of Milling
During the process cycle, a variety of operations may be
performed to the workpiece to yield the desired part shape. The
following operations are each defined by the type of cutter used and
the path of that cutter to remove material from the workpiece.
1. End milling
An end mill makes either peripheral or slot cuts, determined
by the step-over distance, across the workpiece in order to machine
a specified feature, such as a profile, slot, pocket, or even a complex
surface contour. The depth of the feature may be machined in a
single pass or may be reached by machining at a smaller axial depth
of cut and making multiple passes.
End Milling (Profile)
End Milling (Slot)
End Milling (Pocket)
2. Face Milling
A face mill machines a flat surface of the workpiece in order to
provide a smooth finish. The depth of the face, typically very small,
may be machined in a single pass or may be reached by machining at
a smaller axial depth of cut and making multiple passes
Face Milling
 3. 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 workpiece
surface to be machined.
 Methods of Milling
• Up Milling
• Down Milling
Up Milling
Down Milling
 Type of Milling Machine
Horizontal Milling Machine Vertical Milling Machine
Types of Milling Machines

The two main configurations of the milling machining operations are the types of
milling machines. These are the vertical mill and the horizontal mill.
 Vertical Milling Machines
• The vertical mill has a vertically arranged spindle axis and rotate by staying at the
same axis. The spindle can also be extended and performing functions such as
drilling and cutting. Vertical mill has got two further categories as well: turret mill
and bed mill.
• The turret mill has got a table that moves perpendicularly and parallel to the spindle
axis in order to cut the material. The spindle is, however, stationary. Two cutting
methods can be performed with this by moving the knee and by lowering or raising
the quill.
• The other is the bed mill in which the table moves perpendicular to the axis of the
spindle and the spindle moves parallel to its axis.
 Horizontal Milling Machines
The horizontal mill is also the similar cutter but their cutters are placed on a
horizontal arbor. A lot of horizontal mills have got rotary tables that help in milling in
various angles. These tables are called the universal tables. Apart from this all the
tools that are used in a vertical mill can also be used in the horizontal mill.
Milling Machine Component
 Cutting Parameters
In milling, the speed and motion of the cutting tool is specified
through several parameters. These parameters are selected for each
operation based upon the workpiece material, tool material, tool
size, and more.
1. Cutting feed
The distance that the cutting tool or workpiece advances
during one revolution of the spindle and tool, measured in inches
per revolution (IPR). In some operations the tool feeds into the
workpiece and in others the workpiece feeds into the tool. For a
multi-point tool, the cutting feed is also equal to the feed per tooth,
measured in inches per tooth (IPT), multiplied by the number of
teeth on the cutting tool.
2. Cutting speed
The speed of the workpiece surface relative to the edge of the
cutting tool during a cut, measured in surface feet per minute (SFM).
3. Spindle speed
The rotational speed of the spindle and tool in revolutions per
minute (RPM). The spindle speed is equal to the cutting speed
divided by the circumference of the tool.
4. Feed rate
The speed of the cutting tool's movement relative to the
workpiece as the tool makes a cut. The feed rate is measured in
inches per minute (IPM) and is the product of the cutting feed (IPR)
and the spindle speed (RPM).
5. Axial depth of cut
The depth of the tool along its axis in the workpiece as it
makes a cut. A large axial depth of cut will require a low feed rate, or
else it will result in a high load on the tool and reduce the tool life.
Therefore, a feature is typically machined in several passes as the
tool moves to the specified axial depth of cut for each pass.
6. Radial depth of cut
The depth of the tool along its radius in the workpiece as it
makes a cut. If the radial depth of cut is less than the tool radius, the
tool is only partially engaged and is making a peripheral cut. If the
radial depth of cut is equal to the tool diameter, the cutting tool is
fully engaged and is making a slot cut. A large radial depth of cut will
require a low feed rate, or else it will result in a high load on the tool
and reduce the tool life.
Peripheral cut Slot cut
Adantages of Milling Process
1) The metal is removed at a faster rate as the cutter has got multiple cutting edges
and rotates at a higher speed.
2) It is possible to perform machining by mounting more than one cutter at a time.
3) The table of the machine can be moved to an accuracy of 0.02mm.2
4) It is very useful since various cutters and precise tools can be machined.
5) Special attachments can be mounted on the machine to perform operations that
are performed in other machine tools.
6) The quality of the shop is enhanced with the presence of this machine.
Disadvantages of Milling Process
1) The cost of the milling machine is high.
2) As milling cutters cost high, the investment for procuring tools is more.
3) The production cost will increase if we carry out the operations performed in a
shaper or a drilling machine with a milling machine.
4) Chisel is broke quickly.
5) The pruduct of cutting is less of smooth.
6) Need a big power.
7) Produce more waste.
Milling application
Milling machines have been widely used in the tool and die making industry and they
are commonly used in the manufacturing industry for the production of a wide range
of components . Typical examples are the milling of flat surface, indexing, gear
cutting, as well as the cutting of slots and key-ways. When equipped with digital
readout, the machine is capable of producing more precise work for the
manufacturing of plastic moulds, tool & dies, and jigs & fixtures.
References
(Kalpakjian S., Introduction to Manufacturing Processes)
(Boothroyd G. & Knight W., Fundamentals of Machining and Machine Tools)
(Olivo C.T., Machine Tool Technology and Manufacturing Processes, C Thomas Olivo and
Associates)
https://www.educationdiscussion.com/advantages-and-disadvantages-of-milling-
machine/ ( access at Thursday, 07.00 WIB )
www.polyu.edu.hk ( acess at Thursday, 09.00 WIB )