Machines Using Multi-Point Cutting Tools: Milling

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Machines Using Multi-Point Cutting Tools:

Milling

Classification of Milling Machines


Based on spindle orientation

Vertical milling machine


Horizontal milling machine

Based on construction

Knee and column type


Ram type
Moving bed type
Stationary bed type

Horizontal Milling Machine

Slab Milling Operation on Horizontal


Milling Machine

Up/ Down Milling

Although the figure here shows for only slitting, this occurs in all
types of milling such as end milling and face milling..

Vertical Milling Machine

Face Milling on Vertical Milling Machine

Geometry of Face Milling Cutter

acmax = Vf / N Nt

Machining Time In Face Milling


Path of tool axis passes over
work piece
tm = (lw + dt ) / Vf
MRR in both cases = ae ap vf
Path of tool axis does not
pass over work piece

acmax same as in slab milling

Operations on Vertical Milling Machine

a) Horizontal surface milling

b) Slot Milling

Operations on Vertical Milling Machine

a) Dovetail milling

b) T Slot Milling

Classification of Milling Cutters


Criteria
Material
Number of flutes
Type

Shank

Types
HSS or Carbide
Two/ three/ four etc.
Face mills
Slab mills
Side and face cutters
Slitting saws
End mills
Special cutters: Angle cutters, T-slot
cutters, Form cutters
Parallel shank
Taper shank

Face Mill Carbide Insert Type

Face Mill Carbide Insert Type

Face Mill Integral Type

Slab Mill Brazed Carbide Tips

Slitting Saw

Angle Cutters

A Single angle cutter; B Double angle cutter


[Krar, Fig. 60-7]

Form Cutters

A Concave; B Convex; C Gear cutter


[Krar, Fig. 60-8]

Form Cutters

A T-slot cutter;
B Dovetail cutter;
C Woodruff key seat cutter

End Mills
Flat end mill;

Ball nose end mill;


Taper end mill

Ball ended taper end mill

Comparison of Milling Cutters


Cutter

Cutting Edges on

L/D Ratio

Side

High (>1)

End (bottom)
Side

High (>1)

Low (< 1)

Face mill

End (bottom)
Side partially

Low (<1)

Side and face mill

Both ends
Side

Slitting saw

Side

Low (<1)

Slab mill

End mill

Remarks

Most of the cutting is


by the side.
Therefore, End mill
is a misnomer.

Note: Consider the cutter as a cylinder. End refers to the circular face of the
cylinder; there will be two ends. Side refers to the cylindrical surface.

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