GROUP 6

MILLING
OPERATION
What is Milling?
It is one of the most widely used processes of machining custom parts with
precise tolerances.

The process of machining using rotating cutters to remove material by

advancing a cutter into a workpiece. Milling covers various operations and
machines, from small individual parts to large, heavy-duty group milling
operations.

Milling can be done in different directions on one or more axes, cutting

head speed and pressure.
What is Milling?
This can be done with a variety of machine tools.
The milling process requires a milling machine, workpiece, jig, and
milling cutter.
The workpiece is a piece of pre-shaped material that is attached to the
fixture, which in turn is mounted on a platform within the milling
machine.
 Parts of a Milling Machine
1. MOTOR SWITCH
2. TOOL HEAD 15. QUILL FEED HAND LEVER
3. QUILL FEED RATE SELECTOR 16. DIGITAL READOUT
4. QUILL 17. RAM
5. TABLE 18. RAM LOCKS
6. SPINDLE 19. RAM ADJUST HANDLE
7. TABLE LOCKS 20. TABLE STOP DOGS
8. TABLE TRAVERSE CRANK HANDLES 21. TABLE POWER FEED
9. SADDLE 22. COLUMN
10. KNEE 23. SADDLE TRAVERSE CRANK
11. VERTICAL KNEE TRAVERSE CRANK
12. BASE
13. MOTOR
14. VARIABLE SPEED CONTROL
Functions
MOTOR - generate or convert power (electrical to mechanical)
VARIABLE SPEED CONTROL - control the speed of the machine
QUILL FEED HAND LEVER - combine the quill mechanism with the shaft
DIGITAL READOUT - showing the position of the part of the vise table or tool
RAM - part of protruding arm on the vertical milling machine
RAM LOCKS - lock part of the ram on the position for stability
RAM ADJUST HANDLE - lever to adjust the position of the ram or arm
TABLE STOP DOGS - functions as a table stop
TABLE POWER FEED - adjust the table by rotating the available lever
COLUMN - supports or cradles for the other milling machine parts.
SADDLE TRAVERSE CRANK - connecting saddle and engine crank.
KNEE - On the knee, there are various wheels that have a function to automatically
manage the movement.
BASE - the foundation for the milling machine
VERTICAL TRAVERSE CRANK - connecting part of the vertical knee with the
machine arm.
SADDLE - becomes the cradle of the table
TABLE TRAVERSE CRANK HANDLE - a handle/lever connecting the table with the
crank, so you adjust it easily.
TABLE - a place to bind workpieces for the milling process
QUILL FEED HANDWHEEL - allows the milling cutter to be raised and lowered

QUILL FEED RATE SELECTOR - adjust the quill speed (Inches per revolution;

.001, .003, .005)

TOOL HEAD - It holds and rotates the cutting tool of the milling machine on

specific or even custom-built centers of machining.

MOTOR SWITCH - adjust the motor drive

TABLE LOCKS - make the table position fixed.

SPINDLE - a holding place for cutting tools on the vertical milling machine

QUILL - cutting part of the milling machine

Significance of a Milling Machine

Provides
high accuracy and precision of finished workpiece
cuts metal at great speed
can hold multiple cutting tools at the same time
widely used in production works
 QUESTION:
HOW DOES A MILLING MACHINE
OPERATES?
 (VIDEO PRESENTATION)
LISTEN TO THE REPORTER!
TYPES
1. COLUMN AND KNEE TYPE
a. Hand Milling Machine
b. Plain or Horizontal MIlling Machine
c. Vertical Milling Machine
d. Universal Milling Machine
e. Omniversal MIlling Machine
TYPES
2. MANUFACTURING TYPE OR FIXED BED TYPE MILLING MACHINE
a. Simplex Milling Machine
b. Duplex Milling Machine
c. Triplex Milling Machine

3. PLANER-TYPE MILLING MACHINE

a. Double Housing Planer Machine
b. Pit Planer Machine
c. One Side Planer Machine
d. Edger Planer Machine
e. Double Table Planer Machine
TYPES
4. SPECIAL TYPE MILLING MACHINE
a. Rotary Table Milling Machine
b. Drum Milling Machine
c. Profile Milling Machine
d. Planetary Milling Machine
e. Tracer Control Milling Machine
f. Pentahraph Milling Machine
g. NC/CNC MIlling Machine
COLUMN AND KNEE TYPE
In this type of machine, the
table is mounted in the knee
casting which in turn is
mounted on the vertical slides
of the main column. The knee is
vertical and adjustable in the
column and the table can be
moved up and down to
accommodate work in various
height.
HAND MILLING MACHINE
controlled by hand
cutter is mounted on a
horizontal arbor and is
rotated by power
small in size, suitable for light
and simple milling operations
(examples: machining slots,
grooves, and keyways)
PLAIN MILLING MACHINES
stronger than hand millers
table feeding is done either
by hand or by power
a plain milling machine with a
horizontal spindle is also
called a horizontal spindle
milling machine
the table may be feed on
longitudinal, cross, or vertical
directions
UNIVERSAL MILLING MACHINE
The table can be swiveled to any
angle up to 45 degrees on either
side of the normal position
Helical milling operations can
also be performed
This machine can make spur,
bevel, spiral, twist drill, reamer,
milling cutter
All operations done by a shaper
can also be performed in
universal milling machine
OMNIVERSAL MILLING MACHINE
The table has 4
movements

The additional swiveling

arrangement of the
table helps in
machining spiral
grooves in reamers and
bevel gears
VERTICAL MILLING MACHINE
Plane or Universal type
Spindle is vertical or
perpendicular to the table
For machining grooves,
slots, and flat surfaces
has all the movement of a
table for proper setting and
feeding thw work.
MANUFACTURING TYPE
OR FIXED BED TYPE
MILLING MACHINE
 SIMPLEX MILLING MACHINE
•The spindle or the spindle head can travel in one direction only.
•The most common direction in which it can move is vertical.
•These types of milling machines have:
Stable Milling
Excellent Surface Finish and Flatness of Milled Surfaces.
High tool life, high productivity & low maintenance.
 DUPLEX MILLING MACHINE
•Duplex milling machines are two machines located opposite the
other, which can work separately or as a single milling machine when
the workpiece can be machined with 2 simultaneous spindles.
•The spindle can move in both horizontal and vertical directions.
 Main advantages of the duplex solution:
•Production increase of up to 50% in relation to conventional solutions, i.e.
individual milling machines
•Improvements in part precision, by managing to do the machining of the part
in one single setup, in most the cases
•One sole operator can control the duplex milling machines
•Reduced space and investment requirements compared with two single
machines
•Fast investment amortization due to the high productivity
•Duplex solution admits different configurations: a single working area,
pendulum working areas, or pallet changing system
TRIPLEX MILLING MACHINE
The spindle can move in all three
directions i.e. X Y and Z axis.
Special application based on the
customer’s requirements of related
accuracies.
Highly productive and accurate.
PLANER TYPE MILLING MACHINE
Planer Machine is a machine
in which unwanted material
is cut from the workpiece to
produce a flat surface on the
workpiece. Unlike Shaper
Machine, in this machine,
more than one tool can be
set and perform an
operation.
PLANER MACHINE TYPES
DOUBLE HOUSING PLANER MACHINE
Most workshop use a double
housing planer machine.
Two vertical housings are
mounted one housing: One on
each side and these are
connected at the top by a cross
member. It has a horizontal cross
rail that carries two tool heads
slides over the vertical faces of
the machine housing.
PIT PLANER MACHINE
Pit planer has a massive
construction in which the table is
kept in a pit and kept stationary.
The crosses rail reciprocates on a
horizontal rail mounted on both
sides of the table.
The table of the planer is leveled
with the floor, so heavy work can
be loaded. It has two tool heads
and these can be moved
horizontally and vertically to have
the feed. By means of a motor, a
driving screw is used for driving
the column.
ONE SIDE PLANER MACHINE
One housing on one side of the
base is attached or clamped on
which a cross rail on a table
moves.
The open side planer machine
has three tool heads mounted on
the machine. Single housing will
bear the entire load, Therefore it
should be rigid and robust to
face the forces.
It can slide along the guideways
of the housing in the vertical
direction which carries the tool
heads.
EDGE PLANER MACHINE
Edge planer is also called plate
planer and is used for beveling
and squaring the edges of steel
plates used for pressure vessels
in different applications and in
the ship buildings industry.
The table holds the work that
remains in a stationary position.
The workpiece can be attached
by air-operated clamps. The tool-
head that mounts on the carriage
moves along two horizontal
guideways.
DIVIDED TABLE PLANER MACHINE
Divided table Planer Machine has
two tables on the bed that can
reciprocate separately or jointly.
This will saves the idle time when
you set the work.
Divided type planer is mostly
suitable for mass production
work that can Machine is to be
done identically, the work on one
of the tables is loaded, the other
part can reciprocate the cutting
tool for the finishing process.
 PLANER MACHINE
ADVANTAGE DISADVANTAGE
It has Greater accuracy, The cost of the machine is on
Good surface finish, the higher side.
More than one tool can The power consumption is
perform on the workpiece at a quite more.
time and The skilled worker required.
Low maintenance is required. Only tool single point is used.
PLANER MACHINE APPLICATION
The Planer machine is used for
Flat surfaces on the workpiece.
Cutting angular surfaces is one
of the major applications.
Cutting slots and grooves.
MACHINE WORKING VIDEO
SPECIAL TYPE MILLING MACHINE
OTARY-TYPE MILLING MACHINE
This type of milling machine
features a circular table that rotates
about a vertical axis. The workpiece
is mounted on the table and can be
rotated to different positions,
allowing for milling operations at
various angles. The rotary table is
powered by a motor and can be
operated manually or automatically
DRUM MILLING MACHINE
This type of milling machine is
designed for milling cylindrical
workpieces, such as drums or pipes.
The workpiece is held in place by a
series of clamps, and the milling
cutter rotates around the
workpiece to remove material.
Drum milling machines are often
used in the manufacturing of
automotive parts.
PROFILE MILLING MACHINE
A profile milling machine is used to
mill complex shapes and profiles
into a workpiece. It features a
specialized milling cutter that can
follow the contours of the
workpiece to create precise
profiles. Profile milling machines are
commonly used in the production
of aircraft and aerospace parts.
PLANETARY TYPE MILLING MACHINE
This type of milling machine features
multiple milling heads mounted on a
single spindle. The heads rotate around
the workpiece to remove material from
multiple angles simultaneously,
resulting in faster and more efficient
milling. Planetary milling machines are
often used in the manufacturing of
automotive parts and aerospace
components.
TRACER CONTROL MILLING MACHINE

A tracer control milling machine

uses a stylus to trace the outline of a
pattern or template, which is then
duplicated in the workpiece by the
milling cutter. This type of machine
is often used in the production of
dies and molds.
PENTOGRAPH MILLING MACHINE
A pantograph milling machine is a type
of milling machine used to produce
highly accurate and intricate patterns
or designs on metal, plastic or wood
surfaces. It works on the principle of a
pantograph mechanism, which is a
mechanical linkage that allows a set of
connected rods to move in a parallel
manner.
NC/CNC MILLING MACHINE
An NC/CNC milling machine is a
computer-controlled milling machine that
allows for precise and automated control
of the milling process. The operator inputs
a program that specifies the desired
milling operations, and the machine
executes those operations automatically.
This type of machine is commonly used in
the production of complex parts for a
variety of industries.
MILLING MACHINE OPERATIONS
PLAIN MILLING OPERATION

A.K.A. SLAB
MILLING
OPERATION
FACE MILLING OPERATION

SIMPLEST
MILLING
OPERATION
SIDE MILLING OPERATION

PRODUCING
FLAT VERTICAL
SURFACE ON THE
SIDE OF THE
WORKPIECE
STRADDLE MILLING OPERATION

PRODUCING
FLAT VERTICAL
SURFACE ON
BOTH SIDES OF
THE WORKPIECE
ANGULAR MILLING OPERATION

PRODUCING
ANGULAR SURFACE
ON THE
WORKPIECE AT
RIGHTANGLES ON
AXIS OF THE
SPINDLE
GANG MILLING OPERATION

OPERATION IF
MACHINE WITH
SEVERAL
SURFACES
SIMULTANEOUSLY
FORM MILLING OPERATION

PRODUCING
IRREGULAR
CONTOURS BY
USING FORM
CUTTERS
PROFILE MILLING OPERATION

OPERATION OF REPRODUCTION , AN OUTLINE OF A

TEMPLATE, OR COMPLEX SHAPE OF A MASTER DIES ON A
WORKPIECE
OTHER MILLING OPERATIONS
END MILLING
SAW MILLING
KEYWAYS, GRROVES, AND SLOT
GEAR MILLING
HELICAL MILLING
CAM MILLING
THREAD MILLING OPERATIONS