The document provides information about milling machines. It discusses the principle of milling where material is removed from the workpiece by a rotating multi-point cutting tool called a milling cutter. It describes the main types of milling machines including column and knee mills, fixed-bed mills, planer mills, and special types like CNC mills. It also outlines various milling operations like face milling, end milling, slot milling, and angular milling.
The document provides information about milling machines. It discusses the principle of milling where material is removed from the workpiece by a rotating multi-point cutting tool called a milling cutter. It describes the main types of milling machines including column and knee mills, fixed-bed mills, planer mills, and special types like CNC mills. It also outlines various milling operations like face milling, end milling, slot milling, and angular milling.
The document provides information about milling machines. It discusses the principle of milling where material is removed from the workpiece by a rotating multi-point cutting tool called a milling cutter. It describes the main types of milling machines including column and knee mills, fixed-bed mills, planer mills, and special types like CNC mills. It also outlines various milling operations like face milling, end milling, slot milling, and angular milling.
The document provides information about milling machines. It discusses the principle of milling where material is removed from the workpiece by a rotating multi-point cutting tool called a milling cutter. It describes the main types of milling machines including column and knee mills, fixed-bed mills, planer mills, and special types like CNC mills. It also outlines various milling operations like face milling, end milling, slot milling, and angular milling.
Presented By Dr. Jawad Sarwar Prepared By Dr. Awais A. Khan Associate Professor, MED, UET Lahore CONTENT: Introduction of milling machine Principle of milling machine
Types of milling machine
Milling machine operation
Milling Milling machine Milling: is a metal cutting operation in which the excess material from the work piece is removed by rotating multipoint cutting tool called milling cutter. A milling machine is a machine tool that removes metal as the work is fed against a rotating multipoint cutter. The milling cutter rotates at high speed and it removes metal at a very fast rate with the help of multiple cutting edges. One or more number of cutters can be mounted simultaneously on the milling machine. This is the reason that a milling machine finds wide application in production work. Used for machining flat surfaces, contoured surfaces, external and internal threads. Milling machine As the workpiece moves against the cutting edges of milling cutter, metal is removed in form chips Machined surface is formed in one or more passes of the work. The work to be machined is held in a vice, a rotary table, a three jaw chuck, an index head, in a special fixture or bolted to machine table. In many applications, due to its higher production rate and accuracy, milling machine has even replaced shapers and slotters. Milling machine applications MILLING METHODS Two basic methods of milling 1. Up-milling or conventional milling 2.Down-milling or climb milling 1.Up-milling or conventional milling Metal is removed by cutter rotating against the direction of travel of the workpiece. Needs stronger holding of the job.
Chip thickness is minimum at the start of cut and
maximum at the end of the cut. Disadvantage- tendency to lift work from the fixtures and poor surface finish. 1.CONVENTIONAL MILLING MILLING METHODS 2.down-milling or climb milling Metal is removed by cutter rotating in the same direction of travel of the workpiece. teeth cut downward instead of upwards.
Chip thickness is maximum at the start of cut and
minimum at the end of cut. Less friction involved
Better surface finish.
Less power consumption.
2.CLIMB MILLING PRINCIPLE OF MILLING TYPES OF MILLING MACHINE The milling machine may be classified in several forms, but the choice of any particular machine is determined primarily by the size of the workpiece. According to general design, the distinctive types of milling machines are: 1. Column and knee type milling machines
2. Planer milling machine
3. Fixed-bed type milling machine
4. Special types of milling machines
PRINCIPLE PARTS Base Column
Knee
Saddle
Table
Spindle COLUMN AND KNEE TYPE
It is the most commonly used
milling machine used for general shop work. The table is mounted on the knee which in turn is mounted on the vertical slides of the main column. The knee is vertically adjustable on the column so that the table can be moved up and down to accommodate work of various heights. CLASSIFIACTION OF COLUMN & KNEE TYPE MILLING MACHINE
spindle that is parallel to the shop floor and an overarm that extends over the workpiece. • The overarm supports the arbor, which holds the milling cutter. • On the horizontal mill, the arbor is the component that rotates the milling cutter. ACTUAL HORIZONTAL MILLING MACHINE ARBORS
Fig : Mounting a milling cutter on an arbor for use on a horizontal
milling machine. (B) VERTICAL MILLING MACHINE Spindle is vertical or perpendicular to the work table. It has all the movements of the table for proper setting and feeding the work. Spindle head may be swiveled at an angle, permitting the milling cutter mounted on the spindle to work on angular surfaces. In some machines, spindle can also be adjusted up or down relative to the work. Adopted for machining grooves, slots and flat surfaces. VERTICAL MILLING MACHINE
MAJOR PARTS : 1. BASE 2. COLUMN 3. SPINDLE 4. SPINDLE HEAD 5. KNEE 6. SADDLE 7. WORKTABLE DIFFERENCES BETWEEN HORIZONTAL & VERTICAL MILLING MACHINES SL. NO. HORIZONTAL MILLING VERTICAL MILLING MACHINE MACHINE Spindle is horizontal & parallel to Spindle is vertical & perpendicular to 01 the worktable. the worktable.
Cutter cannot be moved up &
02 Cutter can be moved up & down. down.
Cutter is directly mounted on the
03 Cutter is mounted on the arbor. spindle.
Spindle can be tilted for angular
04 Spindle cannot be tilted. cutting.
Operations such as slot milling, T-slot
Operations such as plain milling, milling, angular milling, flat milling gear cutting, form milling, straddle 05 etc., can be performed and also milling, gang milling etc., can be drilling, boring and reaming can be performed. carried out. (C) UNIVERSAL MILLING MACHINE Difference from plain horizontal machine is addition of table swivel housing Permits table to be swiveled 45º in either direction in a horizontal plane Used for milling of helical grooves in twist drills, milling cutters, and gears 2. Fixed-bed type milling machine
•Comparatively large, heavy and rigid and differ from column
and knee type milling machines. •Table is directly mounted on fixed bed. •No provision is provided for cross or vertical adjustment of the table. •The cutter mounted on the spindle head may be moved vertically on the column and the spindle may be adjusted horizontally to provide cross adjustment. •Three types 1. Simplex 2. duplex 3. triplex FIXED BED MILLING MACHINE 3. PLANER MILLING MACHINE Looks like double column planer machine. Milling heads mounted in various planes, vertical heads on the cross-rail and horizontal heads at the sides (on column) This arrangement enables it to machine a workpiece on several sides simultaneously Used for producing long straight surfaces on large and heavy machine parts. 5. SPECIAL-TYPE MACHINES
Designed for individual milling operations
Used for only one particular type of job Completely automatic Employed when hundreds or thousands of similar pieces are to be machined
➢ Tracer mills (Profiling milling machines):
- Also called duplicators -Designed to reproduce an irregular part geometry that can be created on an template - In two dimensions- tracer - In three dimensions- duplicator SPECIAL-TYPE MACHINES CNC milling machines: - Cutter path controlled by numerical data
- Suited to profile, pocket, surface contouring.
MILLING OPERATIONS ❖ Plain or slab milling ❖ Face milling
❖ Cam milling PLAIN/SURFACE/ SLAB MILLING Plain Milling: Process to get the flat surface on the work piece in which the cutter axis and work piece axis are parallel. The primary motion is the rotation of the cutter. The feed is imparted to the work piece. Cutter: Plain milling cutter. Machine:Horizontal Milling m/c. PLAIN/SURFACE/ SLAB MILLING Plain mill cutter
Work piece FACE MILLING
Face Milling: Operation carried out for producing a flat surface, which is perpendicular to the axis of rotating cutter.
Cutter: Face milling
cutter.
Machine: Vertical Milling
Machine FACE MILLING MANUFACTURING TECHNOLOGY END MILLING End Milling: Operation performed for producing flat surfaces, key slots, grooves or finishing the edges of the work piece.
Cutter: End milling cutter.
Machine: Vertical Milling
Machine FIG. END MILLING SIDE MILLING
SIDE MILLING : Operation
performed for producing flat surfaces, slots, grooves or finishing the edges of the work piece.
Cutter: End milling cutter.
Machine: Horizontal Milling
Machine SLOT MILLING
Slot Milling: Operation
of producing slots like T-slots, plain slots etc.,
Angular Milling: Operation of producing all types of angular cuts like V- notches and grooves, serrations and angular surfaces.
Cutter: Double angle cutter.
Machine:Horizontal Milling FIG. ANGULAR MILLING Machine FORM MILLING Form Milling: Operation of producing all types of angular cuts like V-notches grooves, and serrations and angular surfaces. Cutter: Double angle cutter. Machine: Horizontal Milling Machine FORM MILLING STRADDLE MILLING
Straddle Milling: Operation of machining two parallel surfaces simultaneously on a work piece.
Cutter: 2 or more side &
face milling cutters
FIG. STRADDLE MILLING Machine: Horizontal
Milling Machine GANG MILLING Gang Milling: Process to get different profiles on the work piece simultaneously with two or more cutters at one stretch.
Cutter: Different cutters
FIG. GANG MILLING as required.
Machine: Horizontal Milling Machine Profile milling • Outside periphery of flat part is cut. • Conventional end mill is used to cut the outside or inside periphery of a flat part. Pocket Milling
Another form of end milling used to mill shallow pockets into flat parts SURFACE CONTOURING
Ball - nose cutter is
fed back and forth across the work along a curvilinear path at close intervals to create a three dimensional surface.
