MANUFACTURING PROCESSES

MILLING & DRILLING

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 MILLING
• In MILLING, a rotating tool with multiple cutting
edges is fed slowly across the work material to
generate a plane or straight surface.
• The axis of rotation of the cutting tool is
perpendicular to the direction of feed.
• This orientation between the tool axis and the
feed direction is one of the features that
distinguishes milling from drilling.
• In drilling, the cutting tool is fed in a direction
parallel to its axis of rotation.
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 MILLING
• The cutting tool in milling is called a milling
cutter and the cutting edges are called teeth.
• The conventional machine tool that performs
this operation is a milling machine .

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 TYPES OF MILLING OPERATIONS
• There are three basic types of milling operations.

– (A) peripheral milling

– (B) face milling.

– (C) end milling

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(A) PERIPHERAL MILLING

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(A) PERIPHERAL MILLING

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(A) PERIPHERAL MILLING

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 (A) PERIPHERAL MILLING
• In PERIPHERAL MILLING, also called plain
milling, the axis of the tool is parallel to the
surface being machined, and the operation is
performed by cutting edges on the outside
periphery of the cutter.
• Several types of peripheral milling are shown in
the next slides.

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1. SLAB MILLING

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 1. SLAB MILLING
• SLAB MILLING , the basic form of peripheral
milling in which the cutter width extends beyond
the workpiece on both sides.

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2. SLOTTING/ SLOT MILLING

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2. SLOTTING/ SLOT MILLING

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 2. SLOTTING/ SLOT MILLING
• SLOTTING , also called SLOT MILLING ,in which the
width of the cutter is less than the workpiece
width, creating a slot in the work—when the cutter
is very thin, this operation can be used to mill
narrow slots or cut a workpart in two, called saw
milling.

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 3. SIDE MILLING
• SIDE MILLING , in which the cutter machines the
side of the workpiece

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 4. STRADDLE MILLING
• STRADDLE MILLING , the same as side milling,
only cutting takes place on both sides of the
work.

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5. FORM MILLING

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 5. FORM MILLING
• FORM MILLING , in which the milling teeth have
a special profile that determines the shape of the
slot that is cut in the work.

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More Examples

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 UP/DOWN MILLING
• In peripheral milling, the direction of cutter rotation
distinguishes two forms of milling:

UP MILLING DOWN MILLING 19

 UP/Conventional MILLING
• In UP MILLING , also called conventional milling ,
the direction of motion of the cutter teeth is
opposite the feed direction when the teeth cut
into the work.
• It is milling ‘‘ against the feed.’’
• The maximum chip thickness is at the end of the
cut as the tooth leaves the workpiece surface.
• The cutter tends to push the work along and lift
it upward from the table.
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 UP/Conventional MILLING
• The action tends to loosen the work from the
fixture.
• Therefore, greater clamping forces must be
employed, with the danger of deflecting the part.
• More power required due to increased friction
caused by the chip beginning at the minimum
width.
• There may be a tendency for the tool to chatter.

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 UP/Conventional MILLING
• In up milling, chips can be carried into the newly
machined surface, causing the surface finish to
be poorer (rougher) than in down milling and
causing damage to the insert.

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 DOWN/Climb MILLING
• In DOWN MILLING ,also called climb milling , the
direction of cutter motion is the same as the feed
direction when the teeth cut the work.
• It is milling ‘‘ with the feed.’’
• Chips are cut to maximum thickness at initial
engagement of cutter teeth with the work, and
decrease to zero at the end of its engagement.

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 DOWN/Climb MILLING
• The cutting force tends to hold the work against
the machine table, permitting lower clamping
forces.
• Slightly lower power consumption is obtainable
by climb milling, since there is no need to drive
the table against the cutter.
• Down-milling is characterized by fewer
tendencies of chattering and vibration, which
leads to improved surface finish.
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 DOWN/Climb MILLING
• Easier chip disposal - chips removed behind
cutter.

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(B) FACE MILLING

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TYPES OF MILLING OPERATIONS

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(B) FACE MILLING

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 (B) FACE MILLING
• In FACE MILLING, the axis of the cutter is
perpendicular to the surface being milled, and
machining is performed by cutting edges on both
the end and outside periphery of the cutter.
• As in peripheral milling, various forms of face
milling exist, several of which are shown in the
next slides.

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 CONVENTIONAL FACE MILLING
• CONVENTIONAL FACE MILLING , in which the
diameter of the cutter is greater than the workpart
width, so the cutter overhangs the work on both
sides.

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 PARTIAL FACE MILLING
• PARTIAL FACE MILLING , where the cutter
overhangs the work on only one side.

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(C) END MILLING

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(C) END MILLING

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 (C) END MILLING
• In case of end milling thin (low diameter) cutter
are used as compared to workpiece width. It is
used to make slot in the workpiece.
• A milling cutter that performs a mix of
peripheral and face milling.

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 (C) END MILLING
• End milling, in which a rotating cutter travels
along a certain depth in the workpiece and
produces a cavity.
• End milling is an important and common
machining operation because of its versatility
and capability to produce various profiles and
curved surfaces.
• The cutter, called an end mill.

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 (C) END MILLING
• The cutter usually rotates on an axis
perpendicular to the workpiece surface, and it
also can be tilted to conform to machine-tapered
or curved surfaces.
• Machining can also be carried out in areas not
accessible to other types of cutters.
• However, the length-to-diameter ratio of end
mills is high and they can be supported only at
one end, so they are less rigid than cutters for
other milling methods.
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 (C) END MILLING
• Lighter feeds may be required to reduce cutter
deflection.
• Material removal rates are less than with other
milling methods and accuracy may not be as
great.

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 PROFILE MILLING
• PROFILE MILLING ,a form of end milling in which
the outside periphery of a flat part is cut.

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 POCKET MILLING
• POCKET MILLING , another form of end milling
used to mill shallow pockets into flat parts.

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 SURFACE CONTOURING
• SURFACE CONTOURING , in which a ball-nose cutter
(rather than square-end cutter) is fed back and forth
across the work along a curvilinear path at close
intervals to create a three-dimensional surface form.

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HORIZONTAL MILLING MACHINE

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VERTICAL MILLING MACHINE

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 DRILLING
• DRILLING is a machining operation used to
create a round hole in a workpart.
• Drilling is usually performed with a rotating
cylindrical tool that has two cutting edges on its
working end.
• The tool is called a drill or drill bit.
• The tool is fed in a direction parallel to its axis of
rotation into the workpart to form the round
hole.
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DRILLING

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DRILL BIT
Cone angle 118°-135°

Cutting
edge

10°-45°

Land

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DRILL BIT

10°-45°

Land

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 DRILLING
• The most common types of drills are twist drills .
• These have three basic parts: the body, the
point, and the shank.
• The body contains two or more spiral or helical
grooves, called flutes, separated by lands .
• The lands terminate in the point, with the
leading edge of each land forming a cutting
edge.

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 DRILLING
• The flutes serve as channels through which the
chips are withdrawn from the hole and coolant gets
to the cutting edges.
• The cone-shaped point on a drill contains the
cutting edges and the various clearance angles.
• The rotating drill feeds into the stationary workpart
to form a hole whose diameter is equal to the drill
diameter.
• Drilling is customarily performed on a drill press ,
although other machine tools also perform this
operation.
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DRILL PRESS

Drill bit

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