Milling machine-types-operations..etc..from L.NARAYANAN,M.E.,AP.MECH

milling machine types-horizontal and vertical ....milling machine operation..

1. MAHA BARATHIO ENGINEERING COLLEGE, CHINASALEM TK.,VILLUPURAM DT., Pre pared by:- l.NARAYANAN,M.E ., ASST. PROFESSOR Dept. of mechanical Engg

2. unit-3 Milling machines l.NARAYANAN,M.E ., ASST. PROFESSOR Dept. of mechanical Engg .

3. CONTENTS Milling Milling Machines Milling Operations Specifications of Milling Machine Grinding Abrasives & Bonding Materials Grinding Machines

4. MILLING Milling: is a metal cutting operation in which the excess material from the work piece is removed by rotating multipoint cutting tool called milling cutter. Milling machine: is a power operated machine tool in which work piece mounted on a moving table is machined to various shapes when moved under a slow revolving serrated cutter.

5. CLASSIFICATION OF MILLING MACHINES 1. Column and knee milling machines a. Plain column & knee type milling machine - Horizontal spindle type - Vertical spindle type 2. Bed type milling machine 3. Planer type milling machine 4. Special purpose milling machine a. Tracer controlled milling machine b. Thread milling machine c. CNC milling machine

6. HORIZONTAL MILLING MACHINE FIG. HORIZONTAL MILLING MACHINE MAJOR PARTS : BASE COLUMN SPINDLE OVERARM KNEE SADDLE WORKTABLE Collar

7. VERTICAL MILLING MACHINE MAJOR PARTS : BASE COLUMN SPINDLE SPINDLE HEAD KNEE SADDLE WORKTABLE

8. DIFFERENCES BETWEEN HORIZONTAL & VERTICAL MILLING MACHINES SL. NO. HORIZONTAL MILLING MACHINE VERTICAL MILLING MACHINE 01 Spindle is horizontal & parallel to the worktable. Spindle is vertical & perpendicular to the worktable. 02 Cutter cannot be moved up & down. Cutter can be moved up & down. 03 Cutter is mounted on the arbor. Cutter is directly mounted on the spindle. 04 Spindle cannot be tilted. Spindle can be tilted for angular cutting. 05 Operations such as plain milling, gear cutting, form milling, straddle milling, gang milling etc., can be performed. Operations such as slot milling, T-slot milling, angular milling, flat milling etc., can be performed and also drilling, boring and reaming can be carried out.

9. PRINCIPLE OF MILLING

10. COMPARISON BETWEEN UP MILLING & DOWN MILLING SL. NO. UP MILLING (CONVENTIONAL MILLING) DOWN MILLING (CLIMB MILLING) 01 Work piece fed in the opposite direction that of the cutter. Work piece fed in the same direction that of the cutter. 02 Chips are progressively thicker. Chips are progressively thinner. 03 Strong clamping is required since the cutting force is directed upwards & tends to lift the work piece. Strong clamping is not required since the cutting force is directed downwards & keep the work piece pressed to the table. 04 Gives poor surface finish, since chips gets accumulated at the cutting zone. Gives good surface finish, since the chips are thrown away during cutting. 05 Used for hard materials. Used for soft materials and finishing operations.

11. MILLING OPERATIONS Plain or slab milling Face milling End milling Side milling Slot milling Angular milling Form milling Straddle milling Gang milling Slitting or saw milling Gear cutting

12. PLAIN/SURFACE/ SLAB MILLING FIG. PLAIN MILLING Plain Milling: Process to get the flat surface on the work piece in which the cutter axis and work piece axis are parallel. Cutter: Plain/ Slab milling cutter. Machine : Horizontal Milling m/c.

13. PLAIN/SURFACE/ SLAB MILLING FIG. PLAIN MILLING Work piece Plain mill cutter

14. FACE MILLING FIG. FACE MILLING Face Milling: Operation carried out for producing a flat surface, which is perpendicular to the axis of rotating cutter. Cutter: Face milling cutter. Machine : Vertical Milling Machine

15. END MILLING FIG. END MILLING End Milling: Operation performed for producing flat surfaces, slots, grooves or finishing the edges of the work piece. Cutter: End milling cutter. Machine: Vertical Milling Machine

16. SIDE MILLING FIG. END MILLING SIDE MILLING : Operation performed for producing flat surfaces, slots, grooves or finishing the edges of the work piece. Cutter: End milling cutter. Machine: Horizontal Milling Machine

17. SLOT MILLING FIG. T-SLOT MILLING SLOT Milling: Operation of producing slots like T-slots, plain slots, dovetail slots etc., Cutter : End milling cutter, T-slot cutter, dovetail cutter or side milling cutter Machine : Vertical Milling Machine

18. ANGULAR MILLING FIG. ANGULAR MILLING Angular Milling: Operation of producing all types of angular cuts like V-notches and grooves, serrations and angular surfaces. Cutter: Double angle cutter. Machine: Horizontal Milling Machine

19. FORM MILLING FIG. FORM MILLING End Milling: Operation of producing all types of angular cuts like V-notches and grooves, serrations and angular surfaces . Cutter: Double angle cutter . Machine: Horizontal Milling Machine

20. FIG. FORM MILLING

21. STRADDLE MILLING FIG. STRADDLE MILLING Straddle Milling: Operation of machining two parallel surfaces simultaneously on a work piece. Cutter : 2 or more side & face milling cutters Machine : Horizontal Milling Machine

22. STRADDLE MILLING

23. GANG MILLING FIG. GANG MILLING Gang Milling: Process to get different profiles on the work piece simultaneously with two or more cutters at one stretch. Cutter: Different cutters as required. Machine: Horizontal Milling Machine

24. GANG MILLING

25. CLASSIFICATION OF MILLING CUTTERS 1.Plain milling cutter 2.Face milling cutter 3. End milling cutter 4.Angle milling cutter 5.T-slot milling cutter 6.Slitting milling cutter 7.Form milling cutter 8.Fly cutter 9.Woodruff key slot milling cutter

26. 1.Plain milling cutter The most common milling cutter is known as a plain milling cutter. It is merely a metal cylinder having teeth cut on its periphery for producing a flat horizontal surface

27. 1(a).SLAB MILLING CUTTER Cutter width extends beyond the work piece on both sides Process where axis of cutting tool is parallel to the work piece surface to be machined U sed to create flat surfaces or slots C utter may have either straight or helical teeth

28. 1(a).SLAB MILLING CUTTER

29. 1.Plain milling cutter

30. 2.SIDE MILLING CUTTER Side milling cutters have teeth on its periphery and also on one or both of its sides. They are intended for removing metal from the sides of the work piece . There are different types of side milling cutters namely face and side milling cutter, half side milling cutter.

31. 2.SIDE MILLING CUTTER

32. 3.END MILLING CUTTERS These cutters have cutting teeth on the end as well as on the periphery of the cutter. It is made of two parts – body and shank. The shanks of the cutter may be straight or taper.

33. 3.END MILLING CUTTERS

34. 4.Metal slitting saw It is intended for cutting narrow, deep slots and for parting off operation. The teeth are cut on the circumference of the cutter. The width of the cutter is limited. The outside diameter of the cutter will be up to 200mm and width of the cutter ranges from 0.75mm to 7mm.

35. 4.Metal slitting saw

36. 5.Angle milling cutter The teeth of the angle milling cutter are not parallel to the axis but are at an angle to it. By using angle milling cutter, inclined surfaces, bevels and helical grooves are machined. There are two types of angle milling cutter 1 . Single angle milling cutter and 2.double angle milling cutter.

37. 5.Angle milling cutter

38. 6. ‘T ’ – Slot milling cutter. It is a special form of end mills intended for machining ‘T’- slots. It looks like a side milling cutter with a shank. The cutters have cutting teeth on the periphery as well as on both sides of the cutter.

39. 6. ‘T ’ – Slot milling cutter.

40. 7. Fly cutter Fly cutter is the simplest form of cutter. It consists of a single point cutting tool attached to the end of the arbor. The cutting edge may be formed to reproduce a contoured surface. They are used when standard cutters are not available. The work is done very slowly because of a single cutting edge.

41. Fly cutter

42. 8.Formed cutter Formed cutters have irregular profiles on their cutting edges to produce required outlines on the work. Concave and convex milling cutters are used to produce convex and concave surfaces respectively.

43. SPECIFICATIONS OF MILLING MACHINE Size of the work table: expressed in length x width Eg : 1500 x 30mm. Longitudinal movement: Total movement of table in mm(X-direction). Eg:800mm Transverse movement: Total movement of saddle along with table in mm(Y-direction). Eg:200mm Vertical movement: Total movement of table, saddle & knee in mm mm (Z-direction). Eg:380mm Range of the speed: Speed variation in the gear box in RPM. Eg : 45 to 200 rpm. Power capacity of the motor in HP. Eg : 2 HP

44. Thank You….!!!!!!!!!!!