T.

SADASIVA RAO Assistant Professor Mechanical Engineering Department NIT Warangal 506 004
Disclaimer The content presented here is not entirely my own. Some portions are taken from different sources with great regard. This content is solely for class room teaching and not for any commercial use.

Flat surface in vertical, horizontal and inclined planes Making slots or ribs of various sections Slitting or parting Producing surfaces of revolution Making helical grooves like flutes of the drills Long thread milling on large lead screws, power screws, worms etc and short thread milling for small size fastening screws, bolts etc. like die or mould cavities

2-D contouring like cam profiles, clutches etc and 3-D contouring

Cutting teeth of spur gears, straight toothed bevel gears, worm

wheels, sprockets, clutches etc.

Producing some salient features like grooves, flutes, gushing and

profiles in various cutting tools, e.g., drills, taps, reamers, hobs, gear shaping cutters etc.

Types of Milling Machines

Column & Knee type Milling Machine

Vertical Milling Machine

Bed Type Milling Machine

Planer Type Milling Machine

Horizontal Mill

Slab milling

Vertical Mill

Face milling

Rotary Table Type Milling Machine

Tracer Control Copy Milling Machine

Fig. CNC Milling Machine

1 Workpiece; 2 Work Table; 3 Feed Screw Nut; 4 Feed Screw

Up Milling

Down Milling

Up Milling
The depth of the cut starts at zero thickness, and increases up to the maximum
Used to machine scaly surfaces. Tool life is shorter because of initial rubbing. The cutting forces are directed upwards, which tends to lift the workpiece from machine table. Surface finish is poor. Difficulty in pouring the coolant.

Down Milling
The depth of the cut starts at the maximum thickness and decreases to zero.
Used to machine non-scaly surfaces. Better tool life when workpiece doesnt have any scaly surface. The cutting forces are directed towards the table and hence small wok holding forces are enough. Surface finish is good. Easy to pour the coolant.

The chips accumulate at the cutting The chips are also disposed off easily zone and interfere with machining. and doesnt interfere with machining. Can be employed on older machines as the process eliminates backlash. Even with so many advantages, it cant be used on older machines due to backlash error

Milling Cutter Types

Face Milling

Milling

Face Milling: process where the cutter is mounted having an axis of rotation perpendicular to the workpiece surface. --used to create flat surfaces --cutting action may be both Up or Down milling -- leaves cutting marks on the machined surface

Slab/Plain/Peripheral milling cutters

Hollow straight HSS cylinder of 40 to 80 mm outer diameter having 4 to 16 straight or helical equi-spaced flutes or cutting edges Used in horizontal arbour to machine flat surface

Slab Milling

Slab Milling tools

End mills
(left to right) roughing end mill, center-cut end mill, ball mill.

Side/slot & Slit milling cutters

 mostly made of HSS 4 to 12 straight or helical teeth on the periphery and face diameter ranges from about 1 mm to 40 mm very versatile and widely used in vertical spindle type milling machines

End Milling Cutters (End Mills)

Peripheral Milling

Pocket Milling

Angular Milling

Face Milling Cutters

usually large in diameter (80 to 800 mm) and heavy used only for machining flat surfaces in different orientations mounted directly in the vertical and/or horizontal spindles coated or uncoated carbide inserts are clamped at the outer edge of the carbon steel body as shown generally used for high production machining of large jobs.

Photographic view

Schematic view

Form Milling Cutters

Fig. Short thread milling

Fig. Long thread milling

Milling Types

T-Slot Milling

Gang Milling

Vertical-Spindle Milling Machine Tools

Vertical-Spindle Milling Machine Tools

Face Milling

Face Milling tools

 Length of cut: Length of cut = L = Lj + L1 + approach and over travel = 300 + 22 +50 = 372 mm
Machining time can also be computed using any of the three forms of equation , Using F1, z and N we can compute machining time

t = 372/(0.118100) = 2.07 min

Example 8.2 Determine the cutting time for cutting a 125-mm long keyway using HSS end-mill of 20mm diameter, having four cutting teeth. The depth of keyway is 4.5 mm. Feed is 0.1 mm/tooth and cutting speed is 40 meter per minute. Assume approach and over travel (including L1 and L2 ) distance as half of the diameter of the cutter and a depth of 4.5 mm can be cut in one pass. Solution: Given data: Lj = 125 mm, D = 20 mm, n = 4, d = 4.5, feed(F1) = 0.1 mm/tooth and v = 40 m/min. RPM of the cutter is calculated as: N = 636 rpm

 Feed per minute = feed /tooth No. of teeth rpm = 0.1 4 636 = 254.4 mm/min.
Length of cut = L = 125 + 10 = 134 mm

Therefore,
Cutting time t = 134/254.4 = 0.53 minute

Example 8.3 For a given milling operation, it was decided to switch from HSS cutter to Carbide cutter, changing the cutting speed from 35 m/min to 110 m/min. The other parameters of the cutting operation in the two cases are: Carbide cutter Cutter Diameter (mm)
Feed (mm/tooth)

HSS cutter 125 0.0375

150 0.0425
12

Number of teeth

10

Calculate the following for each of the cutting tools

(a) Cutter rpm, (b) Feed in mm/min, (c) Time required to take 200 mm long cut including approach and over travel, and (d) Percentage saving in time by changing from HSS to carbide tool.
Solution: For HSS cutter:

(a)

1000 35 RPM of cutter N 89 rp 125

(b) Feed rate f = feed in mm/tooth(F1) z N = 0.0375 10 89 = 33.375 mm/min

(c)

Cutting time t = L / feed (in mm/min) = 200 / 33.375

= 6 min

For Carbide Cutter

(a) RPM of cutter N = 233 rpm

(b) Feed rate f = 118.8 mm/min

(c) Machining time t = 1.68 min (d)

6 1.68 Percentage saving in time 100 72% 6