1. Chapter4 - MILLING PROCESS

2. FIG. 1 Typical parts and shapes produced by various cutting processes

3. Fig. 2 Schematic illustration of milling machines

4. Fig. 3 Milling machines

6. Fig 4 Nomenclature of a common milling cutter

7. Left hand spiral
right hand spiral
Left hand cutter
right hand cutter
Fig. 5 Left and right hand cutters.
Helical
Plain
Fig. 6 Milling Cutters. a ) Helical b ) Plain

8. Fig. 7 Various types of milling cutters
Slab mill
Course tooth mill
Helical mill
Staggered tooth mill
Side mill
Interloching mill
Metal slitting saw
Fig. 7 Various types of milling cutters
Helical mill (arbor type)

9. Fig. 8 Various types of end mills
Woodruff Keyslot end mill
Double-end end mill
Two-lip end mill
Shell end mill
T-slot end mill

10. Fig. 9 Angle, concave, convex, corner and gear cutters
Corner rounding cutter
Covex formed cutter
Gear tooth cutter
Single angle cutter
Double angle cutter
Concave formed cutter

11. Fig. 10 Effect of milling cutter diameter on workpiece travel
Large diameter
cutter
Amount of travel using large diameter cutter
Direction of cut
Material being removed
workpiece
Small diameter
Amount of travel using small diameter cutter

12. Intermediate arbor support
Fig.11 Tapers used for Milling machine arborrs
Fig. 12The standard milling machine arbor
Arbor
Intermediate arbor support
Arbor support
Spindle
Draw in bolt
Milling cutter
Journal bearing
Arbor nut
Fig. 13 Arbor installation

13. Fig. 14 Typical milling arbors

14. Milling machine adapters
Chuck adapter
Fig. 16 Adapters
Fig. 15 Typical Collet types
Fig. 17 Quick change adapter and tool holder.

15. Standard machine table vise
Fig. 18 examples of various vises
swivel vise
Standard machine table vise
The universal vise
Fig. 19 The index head and footstock

16. Fig.22 Various mounting tools
Fig. 20 Rotary table
Fig. 21 Offset boring head
Angle plate V-Block and clamp V-clamp C- clamp
Step block Bent tail machine clamp Finger machine clamp Strap clamp C- clamp
Fig.22 Various mounting tools

17. Fig. 24 correct mounting of workpiece in a vise
Not correct
Correct
Workpiece
Parallel
Selection of Parallels
Vise
Centering of workpiece in vise
Locating the workpiece at end of vise
Fig. 24 correct mounting of workpiece in a vise
Strap block
Fig. 23 locating keys or tongues on the underside of the vise bases should be located correctly in relation to the T-slots on the milling machine table vise.

18. Brown and Sharpe type Plate I - 15, 16, 17, 18, 19, 20 holes
Fig. 25 using hold down straps
Fig. 26 The indexing plate
Brown and Sharpe type
Plate I - 15, 16, 17, 18, 19, 20 holes
Plate , 23, 27, 29, 31, 33 holes
Plate , 39, 41, 43, 47, 49 holes
Cincinnati type
First side - 24, 25, 28, 30, 34, 37, 38, 39, 41, 42, 43 holes
Second side - 46, 47, 49, 51, 53, 54, 57, 58, 59, 62, 66 holes

19. Fig. 27 Examples of Milling Cutters and Operations
a) Slab milling b) Face milling c) End milling
Arbor
Cutter
Spindle
Shank
End mill
Fig. 27 Examples of Milling Cutters and Operations d) e)

20. Fig. 28 Face-milling operation showing (a) action of an insert in face milling; (b) climb milling; (c) conventional milling; (d) dimensions in face milling. The width of cut, w, is not necessarily the same as the cutter radius.

21. f v
(a)
(b)
Fig. 29 (a) Slab milling operation, showing depth of cut, d, feed per tooth, f, chip depth of cut, tc, and workpiece speed, v. (b) Schematic illustration of cutter travel distance lc to reach full depth of cut.

22. TABLE 1 Typical capacities and maximum workpiece dimensions for milling machines
Machine tool
Maximum dimension
m (ft)
Power (kW)
Maximum speed
Milling machines (table travel)
Knee-and-column
1.4 (4.6) 20
4000 rpm
Bed
4.3 (14)
Numerical control
5 (16.5)
Note: Larger capacities are available for special applications.

23. TABLE 1 Parameters and formulae of the milling process=
Rotational speed of the milling cutter, rpm f
Feed, mm/tooth or in./tooth D
Cutter diameter, mm or in. n
Number of teeth on cutter v
Linear speed of the workpiece or feed rate, mm/min or in./min V
Surface speed of cutter, m/min or ft/min
=D N
Feed per tooth, mm/tooth or in/tooth
=v /N n l
Length of cut, mm or in. t
Cutting time, s or min
=( l+lc ) v , where lc =extent of the cutter’s first contact with workpiece
MRR
mm3/min or in.3/min
=w d v , where w is the width of cut
Torque
N-m or lb-ft
( Fc ) (D/2)
Power
kW or hp
(Torque) ( ), where  = 2 N radians/min
TABLE 1 Parameters and formulae of the milling process
Note: The units given are those that are commonly used; however, appropriate units must be used in the formulas.

24. Fig. 31 A typical setup for plain milling
Fig. 33 Straddel milling of a hexagon
Fig. 32 is a typical example of angular milling.
Fig. 34 Face milling

25. Fig. 35 Face milling of angular surfaces
Fig. 37 Form milling
Fig. 36 Gange milling.

26. Fig. 38 Fly cutting tools
Key is milled to required length
Cutter centered over the shaft
Fig. 40 Milling rounded end key slot waysKey is milled to required length
Fig. 39 The Woodruff key slot milling cutter

27. Fig. 41 T-slot milling cutter
Fig. 43 The splines are cut by straddle milling
Fig. 42 Parting of a solid stock