1. Milling machines

2. Milling Machines
Can be used as a highly accurate drilling machine when drilling many holes.
Can perform sideways cutting operations that a drill cannot.
Use many cutting tools that are similar to the drill, but more rigid and designed to cut sideways and/or vertically (like the drill).

3. The Vertical Milling machine

5. Uses of the Vertical Mill
Rough and finish machining.
Complex shapes.
Pockets.
Holes (drilling and boring).
Profiles.
Surfaces.
Keyways and slots.

6. Vertical Milling operations
End Mill
Shell Mill
Slot Drill
Dovetail Cutter

8. Vertical Milling machine cutting tools
Cutting edges
Uses
Fly-cutter 1
Large surfaces, low metal removal
Shell mill
6-8 or more
Large surfaces, rapid metal removal
End mill
4 or more
General cutting
Slot drill
2 or 3
Slots, pockets, flat bottomed holes
Ripper
3 or more
Hard materials, rapid metal removal
Centre-cutting end mill
All cutting, with minimal tool changes
All drilling tools
Various
Boring head
Accurately sized holes, good surface finish

9. Problems with Vertical Mills
The size of the cutter is limited. Although small diameter cutters (< 5mm) are available, they break easily.
The depth of a feature is limited by the length of the cutting tool (usually short).
Some shapes cannot be cut (e.g sharp notches)
Special holders are required for cutting tools, increasing the costs.
Large diameter cutting tools are not generally suitable.
High speeds are used (small diameter cutters) and the risk of vibration is increased.

10. The Horizontal Milling machine

12. Other Milling Machines
Universal Milling Machine

13. Uses of the Horizontal Mill
Narrow and deep slots and channels (Slitting saw).
Large surfaces.
Complex translated surfaces (gang milling).
Rough milling.
Gear teeth.
Profiles (limited).
Notching.
Slitting (cutting like a saw, but with high accuracy).

14. Horizontal Milling operations #1

15. Horizontal Milling Operations #2

16. Gang Milling of Charpy Specimens

17. The Horizontal Milling machine arbor

18. Problems with Horizontal Mills
Work requiring long, thin, deep slots and channels is minimal.
The arbor (spindle) can be accidentally bent.
Large amount of cutting tool material required.
Cutting tools are more prone to fracture.
Cannot machine holes, pockets or any feature that is not translated along one axis.

20. Climb Milling
The cutter pulls the work piece towards it, and the table also pushes the work piece into the cutter.

21. Result of Climb Milling
The cutter shatters due to overloading, unless the machine can withstand the cutting forces.

22. ‘Up Cut’ Milling
The cutter pushes the work piece away, whilst the table pushes the work piece towards the cutter.