MILLING

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 MILLING

Directi
In MILLING, a rotating tool with multiple cutting edges is fed
on of
slowly across the work material to generate a plane or straight Rotati
surface on

The axis of rotation of the cutting tool is perpendicular to the

direction of feed.( In drilling, the cutting tool is fed in a direction
Feed
parallel to its axis of rotation)

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

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.

Different types of peripheral milling are shown in the next slides. 4

 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
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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2. SLOTTING/ SLOT 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
• 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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5. FORM MILLING

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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 13

(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 (Note that in PERIPHERAL MILLING the axis of the tool is parallel to the
surface being machined), 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 which15are

 1. 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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 2. 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

• 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. 19
 (C) END MILLING : Remarks
• 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 is called an end mill.

• 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. 20
 (C) END MILLING : Remarks
• 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.

• 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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(C) END MILLING

Types of End milling

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 1. 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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Construction of Milling machine and
Parts

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HORIZONTAL MILLING MACHINE

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VERTICAL MILLING MACHINE

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 Specifications of Milling machine
• Maximum longitudinal travel of the work table
• Orientation of spindle axis
– Horizontal milling machine
– Vertical milling machine
• Spindle speed ‘rpm’
• Floor area requirement
• Motor power
 Classification of Milling machines
• According to the orientation of spindle axis
– Horizontal spindle milling machine
– Vertical spindle milling machine
• According to machine design
– Column and knee type
– Fixed bed type
– Special purpose machine
• According to power drive
– Belt drive
– Individual motor drive
– Geared drive
 Horizontal Milling machine
• Spindle is horizontally aligned and work-piece can be moved in
three directions
– Longitudinal direction
– Transverse direction
– Vertical direction
• Classification of horizontal milling machine
– Belt drive, individual motor drive, geared head drive
• Modern machines are equipped with geared drive which
enables larger variation of speed by simple lever control
• Main components
– Base
– Column
– Table
– Spindle
– Over hanging arm
Shaper Machine
SHAPER tool post

vice

Shaper is Machine tool which produces flat surfaces in horizontal,

vertical or inclined planes depending upon the orientation of the cutting
tool.
Features:
Single point cutting tool is used for machining.
Tool is clamped in the tool post mounted on the ram of the machine.
The ram reciprocates to and fro,
Tool cuts the material in the forward stroke,
No cutting during return stroke. 35
Major parts of shaper
RAM

BASE - made of cast iron provides support for other parts of machine
COLUMN- box type of casting vertically mounted on the top of base.
It has 2 guide ways.
• Vertical guide way in the front over which a cross slide moves up and down.
• Horizontal guide way on the top over which ram reciprocate. The reciprocating
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mechanism is housed inside the column
 Main parts of a shaper
machine

Crank and
Slotter
Mechanism
Forward stroke is the cutting stroke i.e. tool cuts the metal.
Return stroke is the Idle stroke i.e. tool does not cut metal
Double stroke = cutting stroke + return stroke

Stroke starts slightly before the work piece (a) and ends after the work piece
(b)
Total stroke length = l + a + b
L = length of work piece, a = length of start before w/p, b = length after w/p
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 Other parts of shaper

Cross rail- it is mounted on the front vertical guide ways.The table can be
lowered or raised by adjusting the cross rail

Table- mounted on a saddle which is located above the cross rail. Top and
sides are accurately machined and have T slots.

RAM- supports tool head on its front. It reciprocates on accurately machined

horizontal guide ways on top of column

Tool head fitted on the face of ram. It holds the tool rigidly.
- Provide vertical and angular feeds for the tool
-Tool head can be positioned at any angle

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Classification of shapers

Position of ram travel

▪ Horizontal Shaper- Ram holding the cutting tool moves in horizontal plane

▪ Vertical Shaper-The cutting tool moves in vertical plane

▪ Traveling head Shaper-Cutting tool reciprocates & moves cross wise simultaneously

According to Cutting Stroke action

Push Type Shaper- Standard Shaper. Metal is removed when the ram moves away from column

Draw Type Shaper-Metal is removed when the tool is drawn towards the column. Allows heavier cuts to be

made. Less vibration during cutting

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 Rack & Pinion mechanism

According to driving mechanism

Crank type - Driving mechanism is by crank & gear
Geared type - Driven by Rack & Pinion mechanism
Hydraulic Shaper - Driven by oil pressure developed by a pump, which is
run by an electric motor

According to the Table Design:

Standard shaper- Work Table can be moved
1. Vertically & 2. Horizontally

Universal Shaper- Table can be moved

1.Horizontally 2. Vertically
3. Swivelled and 4. Tilted - This is mostly used in Tool Rooms 41
SHAPER - crank and slotter mechanism

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 Specifications of Shaper Machine

• Max. Stroke length of Ram

• Type of Drive
• Power input, kW
• Floor Space required, sq ft
• Weight of the Machine, kg
• Cutting to Return Stroke ratio
• Feed, depth of cut and speed

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Cutting Horizontal & Vertical Surface on Shaper

Tool cutting Horizontal Tool cutting Vertical

Surface Surface
 Operations done using a shaper

• Machining horizontal surfaces

• Machining vertical surfaces
• Machining angular surfaces
• Cutting slots, grooves & key ways
• Machining irregular surfaces
• Machining splines/ cutting gears

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Milling m/c

Can produce gears, different slots and

plain surfaces

Can handle small and medium size jobs

Work is help in vise

Cutter is mounted on arbor

Uses multi point cutting tool

It is a multi purpose mc

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Thank you
 Making of Dovetail

Dovetai
 Making of rack

Rack
(teeth on flat
surface)
 Making of an internal keyway

Internal
keyway
Machining a contour surface

contour
surface
Thank you

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Milling machine: https://www.youtube.com/watch?v=LDxq9AkxYfk

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