INTRODUCTION TO MACHINING

1.2 MILLING MACHINE:

Milling is a fabrication process during which a work-piece is moved past a rotating tool.

In comparison: during a drilling operation the work-piece is stationary, and the rotating

drill bit is moved, vertically, into and out of the work-piece.

The process of milling is capable of producing flat, angled or curved surfaces (or a

combination thereof), depending on the type(s) of tool(s) being used and the

sophistication and type of the milling machine.

Milling machines are referred to as 3-axis machines when the table can move in the x

and y directions and the tool in the z-direction. The most sophisticated milling machines

are also capable of rotating the table about the x and z axes, producing a so-called 5-

axis milling machine. (See http://www.youtube.com/watch?v=QsmiIeAkE-o for a video

demonstration of a 5-axis milling machine).

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1.2.1 Components of a milling machine:

The upper part of a milling machine is similar to that of a drill press, but built more

solidly (due to much higher cutting forces). The main difference between a drill press

and a milling machine lies in the table, which is (normally) fixed for a drill press, but can

move in the x and y directions for a milling machine.

The workpiece can be mounted either directly to the table, or to a vise which is mounted

to the table.

Figure 1.2.1: Vertical Milling Machine Figure 1.2.2: Vertical Milling Machine

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Based on Figures 1.2.1 1 and 1.2.2:

Spindle and quill: the spindle holds the tool-holding device and
rotates inside the quill (which can be moved
vertically).

Spindle speed selector: typically a wheel which allows the proper

spindle speed to be selected.

Motor and toolhead: this part provides the power for the machining
operation; it also houses the quill and spindle.

Manual spindle feed lever: allows for the manual lowering/raising of the
spindle; most machines have the option of an
automated spindle feed.

Column and knee: are the vertical and horizontal structural

elements of the machine; mounted to them are
the toolhead/motor and the table respectively.

Table: provides a mounting surface for the work-piece

or for a vise; it can move longitudinally as well
as in the transverse direction (by hand or
under power). Knee and table can also be
adjusted vertically on some machines.

Draw-in bolt: sits inside the spindle and extends just beyond
the top of the toolhead. It is used to pull (draw)
the tool arbour into the spindle and “lock” it in.
To change a tool, this bolt has to be “undone”.

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1.2.2 Milling tools:

A large variety of tools are available for milling operations; we will only look at the most

common ones:

-End mills

End mills have flat, horizontal cutting edges at

the bottom and, peripherally, spiral cutting
edges as well as grooves (called flutes) for
chip removal.
End mills can have 2 to 5 or more flutes. For
metal cutting 4 flute cutters are normally
used.
End mills produce a cut with a flat bottom; so
called “centre-cutting” end mills can be used
for plunge cutting (the tool moves vertically
into the workpiece to a desired depth). Under Figure 1.2.3: Endmills
“normal” working conditions an end mill is
moved in either the x or y direction into the workpiece (peripheral
cutting).

-Ball nose end mill:

Ball nose end mills produce a cut with

a semi-cylindrical bottom; they can be
used successfully when machining
advanced, sculpted surfaces.

Figure1. 2.4: Ball Nose Endmill

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-Special (form) mills:

Slot cutters are used to produce slots or

grooves with special profiles.

Figure1. 2.5: Slot Cutters

-Face mills:

These cutters are used to produce large, flat

surfaces or to quickly reduce the thickness of
stock material.

Figure 1.2.5: Face Mill

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1.2.3 Cutting speeds:

Even more so than with drilling operations, the selection of correct cutting speeds when

milling is very important: it can greatly affect the surface finish and the tool life.

As before, cutting speeds depend on the work-piece material ( Brinell hardness) and

the tool material. Cutting speeds are defined in “surface feet per minute”, the linear

velocity of a point on the cutting edge of the tool.

WORK MATERIAL Bhn HSS CARBIDE

[sfm] [sfm]
Plain Carbon Steel: AISI 1010 to 1030 up to 150 100 - 140 400 - 900
150 - 200 80 - 120 300 - 700

AISI B1111, AISI B1112, AISI B1113 140 - 180 110 - 200 400 - 1200

Plain Carbon Steel, AISI 1040 to 1095 120 - 180 80 - 120 400 - 800
180 - 220 70 - 110 300 - 500
220 - 300 30 - 80 100 - 300

Alloy Steels with <0.3% Carbon: Aisi 1320, AISI 3120, AISI 180 - 220 65 - 100 300 - 600
4130, AISI 4020, AISI 5020, AISI 4118 etc. 220 - 300 30 - 80 200 - 350
300 - 400 30 - 50 100 - 150

Alloy Steels with >0.3% Carbon: Aisi 1340, AISI 2340, AISI 180 - 220 65 - 100 275 - 450
4140, AISI 4150, AISI 5140, AISI 5150 etc. 220 - 300 30 - 80 180 - 300
300 - 400 20 - 50 80 - 130

Table 1.2.1: Recommended Milling Speeds

Use the same “formula” as before to determine the spindle rpm:

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1.2.4 Feed rates:

This is probably the most critical parameter when milling. It is directly affected by:

-the work piece hardness

-the tool diameter
-the tool material
-the type of tool (end mill, face mill etc.)
-the number of cutting edges ( = teeth = flutes)

These feeds are in some publications referred to as chip loads. To find the feed rate in

inches per minute the following “formula” has to be used:

When working on a mill with manual feed controls, make sure to keep the feed rates on

the low side. Note: if feed rates are too low, the tool will dull rapidly. To reduce friction

(= heat) and protect the tool (= wear), always use lubricants.

Recommended feeds for HSS tools, in inches per tooth (per revolution of spindle

speed):

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M ATERIAL Bhn END M ILLS FACE FORM

M ILL M ILL

DEPTH OF CUT = 0.250" DEPTH OF CUT = 0.050"

CUTTER DIAMETER CUTTER DIAMETER

3/8" 3/4" >1" 1/8" 3/8" 3/4" >1"

FEED PER TOOTH [IN] PER REVOLUTION OF SPINDLE SPEED

Plain Carbon Steel up to 150 .002 .004 .006 .001 .003 .006 .008 .012 .004
AISI 1010 to 1030 150 - 200 .002 .003 .005 .001 .003 .006 .007 .012 .004

AISI B1111, 140 - 180 .002 .004 .006 .001 .004 .006 .008 .012 .005
B1112, B1113

Plain Carbon 120 - 180 .002 .004 .006 .001 .003 .006 .008 .012 .004
Steels, AISI 1040 180 - 220 .002 .004 .005 .001 .003 .006 .007 .010 .004
to 1095 220 - 300 .001 .002 .003 .0005 .002 .003 .004 .008 .003

Alloy Steels with 180 - 220 .002 .004 .005 .001 .003 .006 .008 .010 .004
<0.3% Carbon 220 - 300 .001 .002 .003 .0005 .002 .003 .004 .008 .003
300 - 400 .0005 .002 .002 .0003 .001 .002 .003 .004 .002

Alloy Steels with 180 - 220 .002 .004 .005 .001 .003 .006 .008 .012 .004
>0.3% Carbon 220 - 300 .001 .002 .003 .0005 .002 .003 .004 .008 .003
300 - 400 .0005 .001 .002 .0003 .001 .002 .003 .004 .002

Tool Steel 200 - 250 .002 .004 .005 .001 .003 .006 .008 .010 .004
250 - 300 .001 .003 .004 .0005 .001 .002 .003 .004 .003

Cast Iron 150 - 180 .003 .006 .008 .001 .004 .007 .009 .014 .005
180 - 220 .002 .005 .006 .001 .003 .006 .007 .012 .004
220 - 300 .002 .004 .005 .0005 .003 .005 .006 .006 .003

Zinc Alloys .004 .008 .012 .002 .005 .008 .012 .020 .005

Brasses, Bronzes 100 - 150 .003 .006 .010 .001 .004 .008 .010 .014 .004
150 - 250 .002 .004 .006 .0005 .003 .005 .008 .010 .003

Cast Aluminum .003 .008 .010 .002 .003 .010 .012 .020 .005

Wrought Aluminum .003 .008 .010 .002 .003 .010 .012 .018 .005

Magnesium Alloys .003 .008 .012 .002 .004 .010 .014 .020 .005

Ferr. Stainl. Steel 135 - 185 .003 .004 .005 .001 .004 .006 .008 .012 .004

Aust. Stainl. Steel 135 - 185 .003 .004 .005 .001 .004 .006 .008 .012 .004
185 - 275 .002 .003 .005 .0005 .003 .004 .006 .010 .004

Mart. Stainl. Steel 135 - 185 .003 .005 .005 .001 .004 .006 .008 .012 .004
185 - 225 .003 .003 .005 .0005 .004 .005 .006 .010 .004
225 - 300 .002 .002 .003 .0005 .003 .003 .004 .008 .003

Plastics .003 .008 .010 .002 .004 .010 .014 .020 .006

Table 1.2.2: HSS Milling Cutters, Recommended Feed in Inches per Tooth per Revolution of Spindle Speed

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Example: You have decided to use a 4-flute HSS end mill, 0.375" in
diameter, to machine a slot 0.200" deep into a piece of plain
carbon steel with Bhn = 150. You decide to make the first
cut (roughing cut) 0.180" deep and then a finishing cut
0.020" deep. Determine the spindle speed and the feed rate.

From Table 1.2.1: milling speed for plain carbon steel, Bhn 150

Recommended milling speed is 100 [sfm]

Therefore, with

Spindle rpm

The most likely available spindle speed will be 1000 [rpm]

From Table 1.2.2: feeds for plain carbon steel, Bhn 150

Recommended feed for 0.375" Dia. HSS end mill ,

depth of cut 0.180", is 0.002"

And with

Feed rate for rough cut.

For the finishing cut (depth of cut 0.020") the recommended feed is
0.003", so that the feed rate is

Feed rate for finishing cut

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1.2.5 Table set-up:

For safety reasons as well as for precise machining performance it is critical that the

work-piece is properly fastened to the table.

For smaller work-pieces a machine vise is most commonly used.

Machine vise:

Machine vises consist of one fixed

and one moving jaw and a base that
is bolted to the mill table. Before
being able to use the vise, it must be
properly aligned: the jaws must be
parallel to the long axis of the table
and the plane of the two surfaces on
which the moving jaw slides, must be
perpendicular to the axis of the
quill/spindle. The process is called:
tramming the vise.

Figure 1.2.6: Machine Vise Mounted on Mill Table

Tramming:

Figures 1.2.7 and 1.2.8: Tramming a Machine Vise

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Parallels:

Great care must be taken to not, accidentally, machine into any of the vise
surfaces. Whenever a milling operation is required to pierce through the bottom
face of the work-piece, the work-piece must be elevated from the vise sliding
faces. Parallels (or Parallel Bars) are used for this purpose.

Figure 1.2.9: Parallels Figure 1.2.10: Parallels in a Vise

Parallels are fabricated in pairs and come in varying lengths, widths and heights.
They are considered precision tools and must be treated accordingly.
Parallels are used to elevate the work-piece above the sliding surfaces of the
vise.

Shown in Figures 1.2.11 and 1.2.12 are an angle vise and a rotating base for any
type of vise.

Figure 1.2.12: Angle Vise on Rotating Base

Figure 1.2.11: Angle Vise

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Step blocks:

They are used to clamp work-pieces which are too big for a vise or have
awkward shapes for clamping in a vise. They make use of the T-slots in the table
of the milling machine (and are therefore also referred to as T-slot clamps). As
Figure 1.2.13 shows, they consists of a step block, a T-slot nut, a machine screw
with washer and a clamping bar.

Figure 1.2.13: Step Block Clamping Components Figure 1.2.14: Step Block Clamp

Figures 1.2.14, 1.2.15 and 1.2.16 show the assembled clamp(s) holding down a
work-piece.

Figure 1.2.15: Step Block Clamps and Parallel Bars Figure 1.2.16: Step Block Clamp

For proper functioning of the clamps, the screws must be placed close to the
work-piece and the clamping bars must be parallel to the surface of the work-
piece.
In Figures 1.2.15 and 1.2.16 a T-slot screw and a nut are used instead of the T-
slot nut and the machine screw.

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V-blocks:

V-blocks are essential when setting up round-bar stock or cylindrical work-

pieces.

Figure 1.2.17: Various V-Blocks and Clamps Figure 1.2.18: V-Blocks, Parallels and Vise

Angle plates:

Angle plates are used to provide a vertical reference or mounting surface on the
horizontal table.

Figure 1.2.19: Angle Plate Figure 1.2.20: Angle Plates

For more complex set-ups, other specialty type of tools are available.

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