Machining

12/10/2022
:MACHINING:
MILLING
BROACHING
SHAPING
PLANING
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METAL WORKING PROCESS

CLASSIFICATION
Nature of Relative Motion for Various Cutting Operations
Shaping Intermittent translation Translatory
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Types of Cutting Tools
Single Point Cutting Tool Multi – point Cutting Tool
Slab Milling
Cutter
Drill
Face Milling Reamer Broach

Cutter
MILLING
• Milling is a process of removing metal by means of a rotary multi-

point cutter as the workpiece is fed against it.
• Highly versatile machining operation,
• Multiteeth tool that produces a number of chips in one revolution,
• High Accuracy, and better surface finish.
Basic cutter types and related Milling Process:
Some of the basic type milling cutters and milling operations.
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Cutters for different types of Milling
Fig : Cutters for (a) Straddle Milling, (b) form milling, (c) slotting, and (d) slitting with a milling cutter.
Fundamentals of Milling
• Two Groups: 1) Peripheral/ Slab milling,
2) Face Milling.
• Cutters have straight or helical teeth resulting in
orthogonal or oblique cutting action
Fig : (a) Conventional/ Up milling and climb/ Down milling (b) Slab milling operation,
showing depth of cut , d, feed per tooth, f, chip depth of cut, tc, and workpiece speed, v.
(c) cutter travel distance lc to reach full depth of cut.
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Up/conventional Milling and Down/Climb Milling

• Up/conventional Milling:
1. Initial chip thickness is min. Goes on increasing as cut
progresses.
2. Cutting force is directed upwards, which tends to lift the
work piece. High fixture clamping force.
3. Difficulty in cooling while max. material removing.
4. Safer than Down milling.
• Down/Climb Milling:
1. Initial chip thickness is max. Goes on decreasing as cut
progresses.
2. Cutting force is directed downwards, which tends to keep
the work piece in position. Low fixture clamping forces.
3. Coolant can be poured directly at cutting zone where
cutting force is max.
Fundamentals of Milling
Face Milling:
1. To produce flat surfaces
perpendicular to the axis of
rotation of cutter.
2. Both Up Milling and Down
Milling exist.
End Milling:
1. Combination of Slab and

Face Milling.
2. Material can be removed by
both edges.
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Face Milling
• The cutter is mounted on a spindle having an axis of rotation perpendicular
to the workpiece surface.
Fig:A face milling cutter with indexable inserts.
Fig : Face milling operation showing (a) action of an insert in face

milling; (b) climb milling; (c) conventional milling d)dimensions in
face milling. The width of cut, w, is not necessarily the same as
the cutter radius
Types of Milling Machines
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Horizontal and Vertical Spindle Column and Knee

type Milling Machines
Fig : Schematic illustration of a horizontal-spindle

column-and-knee type milling machine.
Fig : Schematic illustration of a vertical-spindle

column-and-knee type milling machine.
Fig : Arbor
Types of Milling Machines
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Bed Type Milling Machine
Fig : Schematic illustration of a bed-type milling machine. Note the single vertical-spindle cutter
and two horizontal-spindle cutters.
Elements of Plain Milling Cutter
a. Cutting Edge: Intersection of

face & land,
b. Gash: Chip space between two
adjacent teeth of cutter,
c. Fillet: Curved surface at bottom
of Gash,
d. Land: Relieve at the edge to
avoid interference with the w/p.
Angles:
1. Relief Angle,
2. Primary & Secondary Clearance
Angle,
3. Lip Angle,
4. Radial Rake Angle,
5. Helix Angle.
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Elements of Face milling cutter
Fig:Terminology for a face milling cutter
Gear Cutting Methods
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Gear Generation
Fig : (1a) Fig : (3b)
Fig : (1d) Fig : (3a)
Fig : (1a) Producing gear teeth on a blank by form cutting. (3b) Schematic illustration of gear generating with a
pinion-shaped gear cutter. (1d) Schematic illustration of gear generating in a gear shaper using a pinion-
shaped cutter. Note that the cutter reciprocates vertically. (3a) Gear generating with rack-shaped cutter.
Indexing & Dividing Head Application
1. Gear Cutting,
2. Hexagonal & Square headed bolt
Manufacturing,
3. Cutting Splines on shaft,
4. Fluting drills,
5. Taps & Reamers, etc.
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Dividing Head for Indexing
Types of Dividing head:

1. Plain or simple dividing head,
2. Universal dividing head,
3. Optical dividing head,
Index Plate
Brown & Sharp mfg. Company:

Plate no.1:15,16,17,18,19,20
Plate no.2: 21,23,27,29,31,33
Plate no.37,39,41,43,47,49
Cincinnati and Parkinson Dividing

Heads:
First side:
24,25,28,30,34,37,38,39,41,42,43
Second Side:
46,47,49,51,53,54,57,58,59,62,66
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Universal Dividing Head

Purpose:
1. Setting work in
vertical, horizontal or
inclined position
relative to table.
2. For turning work
through a given angle
periodically.
3. For imparting
continuous rotary
motion to work for
milling helical
grooves.
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12/10/2022

METAL WORKING PROCESS

Nature of Relative Motion for Various Cutting Operations

Shaping Intermittent translation Translatory

Types of Cutting Tools

Single Point Cutting Tool Multi – point Cutting Tool

Face Milling Reamer Broach

• Milling is a process of removing metal by means of a rotary multi-

Basic cutter types and related Milling Process:

Some of the basic type milling cutters and milling operations.

Cutters for different types of Milling

Up/conventional Milling and Down/Climb Milling

1. Combination of Slab and

Fig:A face milling cutter with indexable inserts.

Fig : Face milling operation showing (a) action of an insert in face

Types of Milling Machines

Horizontal and Vertical Spindle Column and Knee

Fig : Schematic illustration of a horizontal-spindle

Fig : Schematic illustration of a vertical-spindle

Types of Milling Machines

Bed Type Milling Machine

Elements of Plain Milling Cutter

a. Cutting Edge: Intersection of

Elements of Face milling cutter

Fig:Terminology for a face milling cutter

Gear Cutting Methods

Fig : (1d) Fig : (3a)

Indexing & Dividing Head Application

Dividing Head for Indexing

Types of Dividing head:

Brown & Sharp mfg. Company:

Cincinnati and Parkinson Dividing

Universal Dividing Head

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