MANUFACTURING PROCESSES

- AMEM 201
Lecture 8: Machining Processes 8: Milling

DR. SOTIRIS L. OMIROU

Milling Machining - Definition

Milling is one of the basic machining processes that allows large amounts of material to be removed quickly. Milling is a very versatile process capable of producing simple two dimensional flat shapes to complex three dimensional interlaced surface configurations.
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Milling Machining - Definition At all types of milling machines, the cutting tool performs a rotational motion, that is the cutting motion. The rotation axis of the tool could be horizontal or vertical, depending on machinetool version.

The feeding motion is achieved either by part or tool, or both, usually on three perpendicular directions.
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Milling Machining - Definition

The Milling process

Milling Machining video 1

Milling Machining video 2

Milling Machining video 3

Click here for animation

In order to perform a In order to perform a flat surface by milling flat surface by milling operation, a relative operation, a relative motion has to be motion has to be between the milling between the milling tool and part. In this tool and part. In this respect the milling respect the milling tool will have a tool will have a rotation motion, that rotation motion, that is the main cutting is the main cutting motion, and either the motion, and either the tool or part has to tool or part has to perform a translation perform a translation motion, that is the motion, that is the feeding motion. feeding motion.
Feeding motion

Main cutting motion

Milling Tool

Machined Surface

Swarfs Part 7

Milling Machine Tools - Types

Horizontal Milling Machine

X axis motion

Y axis motion Z axis motion

Horizontal spindle - Designed for peripheral milling operations 8

Milling Machine Tools - Types

Vertical Milling Machine

X axis motion

Y axis motion Z axis motion

Vertical spindle - Designed for face milling operations

Milling Machine Tools - Types

Vertical Milling Machining center

Tool Post

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Milling Machine Tools - Types

Automatic Tool Change on a Vertical Milling Machining center

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Up Milling & Down Milling

Up milling Down milling

Also called conventional milling, 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.

Also called climb milling, 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.

Milling Operations on a Horizontal Milling Machine

Slab milling: Cutter width extends beyond the work piece on both sides

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Milling Operations on a Horizontal Milling Machine

Slotting (Slot milling): Cutter width is less than the work piece width, creating a slot. If the cutter is very thin, it can be used to cut a work part into two, called saw milling. milling.

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Milling Operations on a Horizontal Milling Machine

Side milling: Cutter, machines the side of the work piece.

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Milling Operations on a Horizontal Milling Machine

Straddle milling: Similar to side milling, but cutting takes on both sides of the work part simultaneously.

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Milling Operations on a Horizontal Milling Machine

Form milling: The cutter has the desired form of the part

Milling of a concave half circle

Milling of a gear

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Milling Operations on a Vertical Milling Machine

Face milling: The cutter with a relatively large diameter removes a layer from from the upper side of the part

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Milling Operations on a Vertical Milling Machine

End milling: Cutters diameter is less than the work parts width

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Milling Operations on a Vertical Milling Machine

Profile milling (also contouring or shaping): shaping): Outside periphery of flat part is cut

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Milling Operations on a Vertical Milling Machine

Pocket milling: The cutter removes material creating a cavity (rectangular, circular etc.)

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Milling Operations on a Vertical Milling Machine

3-Dimensinal surface milling: The cutter (ball end mill) removes material, moving in 3 directions simultaneously.)

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Milling Operations on a Vertical Milling Machine

3-Dimensinal surface milling:

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Milling Operations on a Vertical Milling Machine

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Milling Operations on a Vertical Milling Machine

Slot milling T-Slot milling

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Surface Machining on a Vertical Milling Machine

Horizontal flat surface Vertical flat surface

Profile surface

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Milling Tools - End Mills

The most common cutting tool used with a vertical mill is an end-mill, which looks like a stubby twist drill with a flattened end.

An end mill can cut into a workpiece either vertically, like a drill, or horizontally using the side of the end mill to do the cutting. This horizontal cutting operation imposes heavy lateral forces on the tool and the mill, so both must be rigidly constructed 27

Milling Tools - End Mills

Flat end-mills for:: pockets slots edge trim facing

Ball-end mills make rounded pockets or spherical pockets; also fillets

Corner-rounders form rounded corners!

Conical end-mill for chamfers

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Milling Tools - Drills and Reamers

standard drill: will flex/walk, follow pilot stub drill for less walk/greater rigidity

center drill establishes hole position with no walk

reamers (straight or spiral) finish off hole (last several thousandths) precise hole diameter for insertion of dowel pins, bearings, etc. plunge while spinning, extract still countersink: for screw heads & deburring hole
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Work-holding for milling operations

Several types of fixtures are commonly used to hold parts while milling them. The most common is a vise. vise.

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Work-holding for milling operations

Another common alternative is to clamp the part directly to the machine table using clamps. Therefore all milling machine tables have T-slots along the length to allow placement of the clamps. clamps.

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Work-holding for milling operations

Another common work-holding method is an indexed vise, workvise, which allows the part to be rotated so as to expose a different surface to the milling tool quickly.

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Work-holding for milling operations

Definition of part Setup If the machine tool needs to access different facets of the part to cut some shapes, then the part may need to be released and re-fixtured. Each fixed position is called a re- fixtured. setup. In one setup, multiple tools can be used to cut setup. setup, different shapes, or features on the part. When the setup or tool is changed, the machinist must locate the part that is, the coordinates of the part with respect to the tool must be determined. Each machine table gives feedback about the relative motion of the table along each axis (X, Y, and Z). A primary goal in every machining process is to limit to minimum the number of required part setups.
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