1. Subject :- Manufacturing Processes-1
Prepared by:- Mangukiya Ketan ( )
Guided By :Harshal Sir
Bipin Sir

2. Milling
Machine

3. Introduction
Milling is the machining operation in which work is fed past a rotating tool with multiple cutting edges
Axis of tool rotation is perpendicular to feed direction
Usually creates a planar surface; other geometries possible
either by cutter path or cutter shape
Other considerations and terms:
Milling is an interrupted cutting operation
Cutting tool called a milling cutter, cutting edges called "teeth"
Machine tool called a milling machine

4. Construction of milling machine
The basic components of these machines are as follows:
Worktable: on which the work piece is clamped using T-slots. The table moves longitudinally relative to the saddle.
Saddle: supports the table and can move in the transverse direction.
Knee: supports the saddle and gives the table vertical movement so that the depth of cut can be adjusted and work pieces with various heights can be accommodated.

5. Overerarm: used on horizontal machines; it is adjustable to
accommodate different arbor lengths.
Head: contains the spindle and cutter holders. In vertical machines,
the head may be fixed or can be adjusted vertically, and it
can be swiveled in a vertical plane on the column for cutting
tapered surfaces.
Typical parts and shapes that can be produced with the milling operations

6. Types of milling machine
Column-and-Knee type milling machines
--- Vertical type
--- Horizontal type
Bed type milling machines
Five-axes profile milling machines
The Horizontal
Milling
Machine

7. The Vertical Milling Machine

8. Bed-type Milling Machine

9. Five-Axis Profile Milling Machine
There are three principal linear and two angular movements of machine components in these types of milling machine.

10. Types of milling operations
Conventional Milling (Up Milling)
Max chip thickness is at the end of the cut
Advantage: tooth engagement is not a function of work piece surface characteristics, and contamination or scale on the surface does not affect tool life.
Cutting process is smooth
The work piece has a tendency to be pulled upward, necessitating proper clamping.

11. Climb Milling (Down Milling)
Cutting starts at the surface of the work piece.
Downward compression of cutting forces hold work piece in place
Because of the resulting high impact forces when the teeth engage the work piece, this operation must have a rigid setup, and backlash must be eliminated in the table feed mechanism
Not suitable for machining work piece having surface scale.

12. Types of milling cutters
Side and slot
milling cutters :-
These arbour mounted disc
type cutters have a large number
of cutting teeth at equal spacing
on the periphery.
These types of cutters are used
for the operation like Straddle
milling, Form milling, Slotting,
Slitting as shown in figure

13. T-slot cutter :- Slab or Plain milling cutters :-
Plain milling cutters are hollow straight
HSS cylinder of 40 to 80 mm outer
diameter having 4 to 6 straight or
helical equi-spaced flutes or
cutting edges and are used in
horizontal arbour to machine flat
surface as shown in figure.
T-slot cutter :-
Width of cutter is less than work piece
width, creating a slot in the work

14. Face milling cutters :-
The main features of these cutters are :
- Large in diameter and heavy
- Used only for flat surface
- Coated or uncoated carbide inserts a clamped at the
outer edge of the carbon steel body
- Generally used for high production machining of
larger jobs.

15. All types of milling cutters
Ball Nose End milling cutters
These cutters are able to produce
elaborate contours and are often
used in the machining of dies and
molds.
All types
of milling
cutters

16. Work holdings The Dividing Head :-
A dividing head with corresponding tail stock for supporting longer work pieces.
Work piece held in a three jaw chuck for machining.
Gear teeth are being cut individually. The dividing head allows accurate indexing for each tooth position.

17. Angle Plates :-
Angle Plates can be used for holding work pieces during milling operations.
The angle bracket may need to be trued first using a DTI.

18. THANKS !!!