1. The Vertical Milling Machine
Turret type vertical milling machine.

2. The Horizontal Milling Machine
Horizontal milling machine with arbour steady between spindle nose and arbour support.

3. Example of a horizontal milling operation with multiple cutters used on a long arbour, i.e. gang milling

4. Milling Cutters
Example of:
A ball nosed slot drill
A slot drill
An end mill
The gold colouring is a titanium nitride coating which has a lower coefficient of friction compared to the parent material HSS. As a result less heat is generated and tool life increased.

5. Milling Cutters
A selection of milling cutters for both vertical and horizontal milling operations.

6. Aspects of End Milling
The radial depth of cut should be less than 0.1 of the diameter of the mill: ar <0.1 D.

7. Aspects of End Milling
The radial depth of cut should be no more than 0.9 D: ar = to or <0.9 D.

8. Producing an open ended slot
The radial depth of cut is equal to the diameter of the mill: ar = D.

9. Up-Cut & Down-Cut Milling
In conventional milling, the cutter revolves opposite to the direction of table feed. Therefore the width of the chip starts at zero and increases to a maximum at the end of the cut. This can lead to accelerated tool wear under some conditions. Conventional milling may be advantageous when milling hot rolled steel, surface hardened and steels with a surface scale.
In climb milling, the cutter revolves in the same direction as the table feed. The tooth meets the work at the top of the cut, producing the thickest part of the chip first. In horizontal applications the resultant force created by climb milling can act as a clamping force, acting towards the machine table.
It is important to make sure that the machine tool has no leadscrew backlash. Normally climb milling improves product surface finish and increases tool life.

10. Tipped Milling Cutters
A tipped End Mill

11. Tipped Milling Cutters
Tipped cutters for high removal rates.

12. Workholding
The Machine Vice

13. Workholding The magnetic table.
Can be used to hold magnetic materials quickly and effectively.

14. Workholding
Cylindrical workpieces can be held in a chuck which is mounted directly to the machine table

15. Milling Operations A ripping cutter being used to rough out.
The serrated edges break the chip improving swarf evacuation and reducing the risk of tool breakage.

16. Workholding
Angle Plates can be used for holding workpieces during milling operations.
The angle bracket may need to be trued first using a DTI.

17. Workholding The rotary table.
Used for producing radii, PCDs or circular features on workpieces.
The photograph shows the rotary table being set-up in-line with the machine spindle.

18. Use of a Rotary Table
Clocking up the workpiece in-line with the machine spindle.

19. Rotary Table - Further Applications
Aligning the workpiece with the machine spindle.

20. Rotary Table - Further Applications
Using the rotary table to machining a radius on the workpiece.
Note: a four jaw chuck is being used with some jaws reversed.

21. Rotary Table - Further Applications
Production of radius.

22. Rotary Table - Further Applications
Production of radius.

23. Rotary Table - Further Applications
Using a rotary table to index hole positions and machine a PCD.

24. Rotary Table – Further Applications
Use of a rotary table to mill the diameter of workpiece.

25. Rotary Table with Additional Workholding
Workpieces can be mounted directly to the table of the rotary table or other workholding devices such as vices, angle plates etc can be mounted on the table for work holding.

26. The Dividing Head

27. The Dividing Head
A dividing head with corresponding tail stock for supporting longer workpieces.

28. The Dividing Head
Workpiece held in a three jaw chuck for machining.

29. The Dividing Head
Gear teeth are being cut individually. The dividing head allows accurate indexing for each tooth position.

30. The Dividing Head – Production of Gears
Typical components produced using a dividing head.

31. The Dividing Head
Further applications of the dividing head.

32. The Sine Table
The sine table allows accurate angles to be set using slip gauges (gauge blocks).
The distance between the two rollers is known and forms the hypoteneuse.
The slip gauges are positioned to form the opposite of the triangle, i.e.
Sine θ = Opp / Hyp
Opp = Sine θ × Hyp

33. Sine Table

34. The Sine Bar
The sine bar used in the same way as the sine table as the distance between the rollers is known.

35. Slip Gauges (also known as Gauge Blocks)
Sets are graded:
A for calibration.
B for inspection.
C for workshop.
Slips are wrung together.
Surface are such that molecular attraction occurs allowing slips to be built up to a specific size.

37. Vee Blocks
A range of vee blocks which can be used to hold round workpieces.

38. Adjustable Vee Block
An adjustable vee block can be used to set workpieces to required angular position.

39. 30˚/60˚ & 45˚ Set-up Plates

40. A Set of Angled Set-up Plates

41. Collets

42. Collets

43. Collets for Square Bar

44. Quick Release Milling Fixture using Collets

45. The Electronic Edge Finder
Electronic edge finder with a ¾" shank.
The 0.400" diameter ball tip is spring-loaded to prevent damage from over travel.
When the edge is detected, zero the DRO, retract the quill then move the axis ½ the distance of the ball's radius (0.200") & then zero the DRO, again.

46. Edge/Centre Finders
A variety of edge detectors & center finders with ¾". ½", & ⅜" shanks.
The wiggle-type (right) works best at about 1000 RPM.