Chapter 4

Milling Machines

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PARTS OF MILLING MACHINES

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What is milling
machines??
Are machine tools used to produce one
or more machined surfaces accurately
on a piece of material.
This is done by one or more rotary milling cutters
having single or multiple cutting edges.
 The work piece is held securely on the work table of
the machine or in a holding device clamped to the
table.
 It is then brought into contact with a revolving cutter.

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Types of milling machines
1. Column & knee type milling machine:
- Plain Horizontal milling machine
- Universal Horizontal milling machine
- Vertical milling machine

(Relationship between cutter height and work controlled by

vertical movement of table)

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2. Production milling machine

Cutter height is controlled by vertical

movement of headstock. Used primarily
for quantity production of identical parts.
Distinctive features:
- Automatic cycle of cutter and work approach
- Rapid movement during non-cutting cycle
- Automatic spindle stop

Two common types

i. Plain manufacturing type
ii. Small plain automatic knee and column type
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3. Automatic milling machine (special type)-CNC

Designed for specific milling operations.

- Used for only one particular type of job
- Completely automatic
- Employed when hundreds or thousands of
similar pieces are to be machined

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 Vertical Milling Machine
• In vertical, milling cutters can
be mounted directly in the
spindle

• Housing (Head) can be fixed

or Swiveling type

• Fixed Type - Head is always

vertical and can be adjusted up
and down

• Swiveling Type – Head can be

swiveled to any desired angle

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 Horizontal Milling Machine

• In horizontal, arbor supports

the cutter and an over arm
supports arbor

• The vertical column houses

the electrical, main drive,
spindles etc mounted on a
heavy base

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Universal Milling Machine

• Has a table
that can be
rotated in a
horizontal
plane to any
specified
angle

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Universal milling machines
Difference from plain horizontal machine is addition
of table swivel housing

-Located between table and saddle

-Permits table to be swiveled 45º in either direction in
a horizontal plane

Used for milling of helical grooves in twist drills,

milling cutters, and gears

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Parts of machines

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Basic Principles of Milling Machine
 Milling is the cutting operation that removes metal by feeding the work
against a rotating cutter having single or multiple cutting edges.
 Flat or curved surfaces of many shapes can be machined by milling with good
finish and accuracy.
 A milling machine may also be used for drilling, slotting, making a circular
profile and gear cutting by having suitable attachments.

Working Principle:
1. The work piece is holding on the worktable of the machine.
2. The table movement controls the feed of work piece against the rotating
cutter. The cutter is mounted on a spindle or arbor and revolves at high speed.
3. Except for rotation the cutter has no other motion.
4. As the work piece advances, the cutter teeth remove the metal from the surface
of work piece and the desired shape is produced

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Two method of up milling process
1. Up Climb (Up Cut Machine)
 Also called conventional milling,
 - Wheel rotation opposite of the feed
 - The chip formed by each cutter tooth starts out very thin and increases its
thickness
 - The length of the chip is relatively longer
 - Tool life is relatively shorter
 - Need more clamping force to hold the work part still.

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2. Down climb (Down Cut Machine)
 Also called climb milling,
 - Wheel rotation is parallel to the feed
 - The chip formed by each cutter tooth starts out thick and leaves
out thin
 - The length of the chip is relatively short
 - Tool life is relatively longer
 - Need less clamping force to hold the work part still.

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Advantages of climb milling (down climb)
1. Increased tool life. Since the chips pile up behind or to the left of the
cutter, tool life can be increased by as much as 50%
2. Less costly fixture required- simpler holding required
3. Improved surface finishes. Chips are less likely to be carried into the
workpiece by the cutter teeth, which prevent damage to the work
surface.
4. Less edge breakout, because the thickness of the chip tends to get
smaller as it nears the edge of a workpiece, there is less chance of
breaking, especially with brittle materials.
5. Easier chip removal. The cutter teeth force the chips to fall behind the
cutter and make it easier to remove the chips.
6. Lower power requirements. Since a cutter with a higher rake angle
can be used, approximately 20% less power is required to remove the
same amount of metal.

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Disadvantages of down climb
This method cannot be used unless the machine has a
backlash eliminator and the table gibs have been
tightened
It cannot be used for machining castings or hot rolled
steel, since the hard outer scale will damage the cutter

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Usage of various types of milling cutter

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Milling cutters are one of the most important elements of a milling
machine.
 Cutting Tools for Horizontal Milling
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.

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Cutting tools for Vertical Milling

a. End Mills
Commonly used for facing, slotting and profile
milling.

b. Rough Cut End Mills

For rapid metal removal.

c. Slot Drills
For producing pockets without drilling a hole
before hand.
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 d. Face Milling Cutters
For heavy cutting.
e. Woodruff Milling Cutter
This is actually a special cutter used to cut the
keyways. It is a very important piece for key makers

f. Dovetail Milling Cutter

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MILLING OPERATIONS
1. Plain Milling (Slab Milling)
2. Face Milling
3. End Milling
4. Side Milling
5. Straddle Milling
6. Angular Milling
7. 4gang Milling
8. Form Milling
9. Profile Milling
10. Keyways, Grooves & Slots Milling
11. Thread Milling

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Method of holding cutting tool
Milling cutter is attached to the machine using arbor
or collet.
It is inserted and held in main spindle by draw bolt.

horizontal

Arbor
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Collet, sleeves and adapters is used for mounting drills
or other tapered-shank tools in main spindle of
machine or vertical milling attachment

horizontal
Vertical

Vertical

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Method of holding workpiece
Many attachments or accessories are available for use on
milling machine.
 Work piece holder is used to hold the work piece tightly
and effectively during cutting operations.
A few factors that affect the method of holding the work
piece are:
i. Size & shape of work piece
ii. Type of cutter used
iii. Direction of cutter rotation
iv. Type of finishing ( rough, smooth)
v. Number of pieces to be cut
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The commonly used are:
a. Plain Vise- Jaws parallel or 90º to axis of spindle

b. Swivel Base Vise -Can swivel through 360º in

horizontal plane

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c. Universal Vise - Can swivel through 360˚ in horizontal plane and
tilted from 0 ˚ to 90 ˚ in vertical plane

d. Rotary Table

e. Angle Plate

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Revolution per minute, feed rate and
cutting time
Several factors must be considered when determining
the proper r/min at which to machine a metal. The
most important are:
The type of work material
The cutter material
The diameter of the cutter
The surface finish required
The depth of cut taken
The rigidity of the machine and work setup

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Cutting speed for the common metals:

High-Speed Steel Cutter Carbide Cutter

Material ft/min m/min ft/min m/min
Alloy steel 40–70 12–20 150–250 45–75
Aluminum 500–1000 150–300 1000–2000 300–600
Bronze 65–120 20–35 200–400 60–120
Cast iron 50–80 15–25 125–200 40–60
Free m steel 100–150 30–45 400–600 120–180
Mach steel 70–100 21–30 150–250 45–75
Stnless steel 30–80 10–25 100–300 30–90
Tool steel 60–70 18–20 125–200 40–60

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The Formula:

1) RPM

2) FEED RATE

Feed = (no. of cutter teeth x feed/tooth) x r/min

F (mm/min) = (N x CPT ) x r/min

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Example 1:
Calculate the rpm for 76.2 mm diameter cutter that is
to mill steel at 27.43 mpm.

A. r/min = CS (mpm) X 1000

D (mm) x ∏
= 27.43 x 1000
76.2 x 3.1416
= 27430
239.39
= 114.6 rpm

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Example 2:
Determine the feed rate for milling low carbon steel at
30.5 mpm and 127 rpm, using a heavy duty plain milling
cutter 76.2 mm in diameter with 10 teeth and a feed of
0.20 mm per tooth.
F = (N x CPT ) x r/min
F = 10 x 0.20 mm x 127
= 254 mm /min

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Safety procedure using milling machines

1. Do not make contact with the revolving cutter.

2. Place a wooden pad or suitable cover over the table surface to protect it
from possible damage.
3. Use the buddy system when moving heavy attachments.
4. Do not attempt to tighten arbour nuts using machine power.
5. When installing or removing milling cutters, always hold them with a
rag to prevent cutting your hands.
6. While setting up work, install the cutter last to avoid being cut.
7. Never adjust the workpiece or work mounting devices when the
machine is operating
8. Chips should be removed from the workpiece with an appropriate rake
and a brush
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9. Always use cutters which are sharp and in good
condition.
10. Don't place anything on the milling machine table such
as wrenches, hammers, or tools.
11. Always stay at the machine while it is running.
12. Don't take too heavy a cut or use too rapid a feed.
13. Remove the collet tightening wrench immediately after
using it.
14. If at all feasible rig a guard or shield to prevent chips
from hitting other people.
15. Use the milling machine spindle brake to stop the
spindle after the power has been turned off.
16. Before cleaning the mill remove cutting tools from the
spindle to avoid cutting yourself
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