http://vlabs.iiitdmj.ac.in/Manufacturing/Exp5/Milling Operations.

htm

Objective:
To perform milling operations, Profile milling, Pocket milling and Slot milling through basic operational differences

Equipment:
Milling Machine, Milling Cutters, Surface Roughness Gauge, Work piece

Theory and Background:

Milling:
Milling is a production process which is based on material removal. Most of the cutting tools used are multipoint cutting tools, as a result higher material removal rates can be achieved along with high surface finish. The common operations performed on milling machine are: facing, shaping, slot cutting, drilling, T-slot cutting etc.

Types of Milling Machines:

Milling machines are broadly classified as: Horizontal Milling Machine The horizontal milling machine can be recognized by its horizontal spindle. The cutter is mounted on a horizontal arbor and is rotated by supplying power. The work table can be fed in a longitudinal, cross or vertical directions. This type of machine is generally used for surface milling, profile milling, gear cutting etc. The profile cutters, plain milling cutters, gear cutters are the tools commonly used with this machine. Fig. 1 Horizontal Milling Machine Vertical Milling Machine The vertical milling machine can be recognized by the position of its spindle which is vertical (normal to the work table). The table can be moved in all the axes (X, Y and Z). The spindle head which is clamped to the vertical column can be swiveled at an angle, permitting the milling cutter mounted on the spindle to work on angular surfaces. In some machines spindle can also be adjusted up or down relative to work piece. The machine is adapted for machining grooves, slots and flat surfaces. The end mills and face milling cutters are the usual tools mounted on the spindle. Fig. 2 Vertical milling Machine

Milling Processes:
Milling Process can take place in two ways Up Milling In Up-milling process (also known as Conventional Milling) the direction of rotation of milling cutter and the direction of work piece feed are opposite to each other. As a result, the thickness of chip at the start is nil and is maximum when the cutting teeth leave the surface of the work piece. During this process the cutting teeth tend to uproot and lift up the work piece from the machine table. Fig. 3 Up-Milling Process

1 of 4

5/11/2013 3:33 PM

http://vlabs.iiitdmj.ac.in/Manufacturing/Exp5/Milling Operations.htm

Down Milling In Down-Milling process (also known as Climb Milling) the direction of rotation of milling cutter and the direction of work piece feed are same. As a result, the thickness of the chip at the start is the maximum and gradually becomes nil when the cutting teeth leave the surface of the work piece. During the process, the cutting teeth tend to push the work-piece into the table.

Milling Cutters:
Milling cutters can be classified mainly on the following bases: According to direction of rotation of the cutter: a) Right hand rotational cutter b) Left hand rotational cutter According to the helix of cutter teeth: a) Parallel or Straight teeth cutter b) Right hand Helical Cutter c) Left hand Helical Cutter d) Alternate Helical teeth Cutter Standard Milling Cutters: 1) Plain Milling Cutter a) Light duty plain milling cutter b) Heavy duty plain milling cutter

c) Helical plain milling cutter 2) Side milling cutter a) Plain side milling cutter b) Staggered teeth side milling cutter

c) Half side milling cutter d) Interlocking side milling cutter 3) Metal slitting saw a) Plain metal slitting saw b) 4) Staggered teeth metal slitting saw

Angle milling cutter a) Single angle milling cutter b) Double angle milling cutter

5)

End mill cutter a) Taper shank end mill b) Straight shank end mill

c) Shell end mill 6) 7) T-slot milling cutter Woodruff key slot milling cutter

2 of 4

5/11/2013 3:33 PM

http://vlabs.iiitdmj.ac.in/Manufacturing/Exp5/Milling Operations.htm

8) 9)

Fly cutter Formed cutter a) Convex milling cutter b) Concave milling cutter

c) Corner rounding milling cutter d) Gear cutter e) Thread milling cutter 10) Tap and reamer cutter

Milling Operations:
Profile Milling: Profile milling is the process of transferring a specific profile onto the work-piece. The formed cutters are used for this process. The cutter of required profile cuts out material from the work piece, transferring the profile onto it in multiple steps. Steps to perform Pro ile Milling
1. Install the Cutter on the arbor of horizontal milling machine a. Align the slot on the cutter with the slot on the arbor b. Insert key into the slot Fix the work-piece on the vice mounted on the work table Align the work-piece with the cutter Start the machine at low RPM Give a small depth of cut along the z-axis, and feed rate along x-axis and perform one run of cutting Return to the initial position by giving feed in the negative x-direction and repeat the process by incrementing the table position along the z-axis Continue till the desired profile is achieved

2. 3. 4. 5. 6. 7.

Videos: Pocket Milling: Pocket milling is the process of removing material inside some arbitrary closed boundary on a flat surface of work-piece up to a certain fixed depth. The end mill cutters are used for this process. Steps to perform pocket milling
1. 2. 3. 4. Install end mill cutter on the Vertical Milling Machine Fix the work-piece on the vice mounted on the work table Setup the spindle speed according to the work-piece and tool materials. Start the machine, with a small depth of cut, perform facing operation (machine the entire surface by giving feed along the x and y axis alternately) 5. Give a small depth of cut along the z-axis, and by giving appropriate feed along the x-axis and the y-axis, perform pocket milling operation. 6. Increment the table position along the z-axis and repeat the process till the desired depth of profile is achieved

Slot Milling: Slot milling is the process of cutting slots through a work-piece surface. These slots can be plain slots using the end mill cutter, or the T-slots, using the T-slot cutter. Steps to perform Slot Milling
1. 2. 3. Install the end mill cutter on the vertical milling machine Fix the work piece on the vice mounted on the work table Setup the spindle speed according to the work-piece and tool materials

3 of 4

5/11/2013 3:33 PM

http://vlabs.iiitdmj.ac.in/Manufacturing/Exp5/Milling Operations.htm

Start the machine, with a small depth of cut, perform facing operation (machine the entire surface by giving feed along the x and y axis alternately) 5. Align the center of the cutter with the center line of the desired slot 6. Give a small depth of cut along the z-axis and by giving appropriate feed along the x-axis perform cutting operation 7. Increment the table position along the z-axis and repeat the process till the desired depth of slot is achieved

4.

Videos: For TSlot Cutting (continue from above)

8. 9. 10. 11. Replace the end mill cutter with T-Slot cutter Align the center of the cutter with the center line of the slot (already cut) Move the table along the z-axis in order to align the plane of the cutter with the plane of desired T-slot Give a small depth of cut along the y-axis and by giving appropriate feed along the x-axis perform cutting operation 12. Increment the table position along the y-axis and repeat the process till the desired depth of T-slot (along y-axis) is achieved 13. Repeat the process for the negative y-direction

Videos:

4 of 4

5/11/2013 3:33 PM