complete description on introduction on milling

1. Milling Machine

2. Contents
• Basic functions & purposes
• Classifications
• Kinematic system & working principle
• Applications

3. Functions of Milling M/c
• Producing flat surfaces at any orientation
• Inclined surfaces
• Special contours on m/c elements

4. Principles
• Up milling:
– More clamping forces
– No effect with back
clash in screw-nut
systems
• Down milling
– Proper clamping is
ensured
– back clash affects the
process & product

5. Major uses
• Making flat surfaces (diff. orientations)
• Slots and steps
• Slitting
• Rotary turning
• Threads
• Helical surfaces
• Gushing in drills

6. Classifications
• Purpose
• Configuration
• Spindle orientation
• Automation
• CNC

7. According to purpose
– General purpose :
• most versatile, non-automated
• Low vol. of production
– Single purpose :
• specific operation , automated to some degree
• Lot production
– Special purpose :
• Making special features using attachments
• Batch production (automatic)

8. According to configuration
• Knee type :
– Non-automated
– Piece production
– Small size m/c

9. -contd.
• Bed type :
– Rigid & robust
– Vertical spindle
– Depth is given to
cutter
– Batch wise
production

10. - contd.
• Plano miller:
– Many cutters
simultaneously
can work
– (for large jobs
having many
plane surfaces)
– Fast production

11. Contd.
• Rotary table type:
– Open / closed
type
– Work table rotates
– High productivity
– More than 1
spindle

12. According to spindle orientation-
Contd.
horizontal Vertical spindle Universal head

13. Base
Ram
Arbour
Speed chain
Feed chain
Over running
clutch

14. Milling cutters

15. classifications
• Profile sharpened cutters – surface geometry
doesn’t depend on tool shape
– Slab or plain milling cutter
– Side milling cutter
– Slitting cutters
– End milling cutter
– Face milling cutter

16. Plain or slab milling cutter
• Hollow straight HSS cylinders
• 4 to 16 straight or helical flutes
Feed

17. Side milling cutters
• Large cutting teeth on periphery
• Each tooth has peripheral cutting edge
– Single sided milling cutter
– Double sided milling cutter

18. Slitting cutters
• Only one peripheral cutting edge
• Cutter is larger in φ & thin
• Large nos. but smaller in size
• Only for slitting

19. End mills & shell mill

20. Face milling cutter
• Larger φ:80 to 800 mm
• Coated or uncoated
carbide inserts
• For larger jobs like
lathe bed, planer beds

21. Contd.
• Form relieved cutters – surface generated is
the replica of the tool shape
– Form cutters
– Gear milling cutter
– Spline shaft cutter
– T-slot cutter
– Thread milling cutter

22. characteristics
• Flank surface is Archimedean spiral shape
• Tooth are sharpened by grinding the rake face
• To make 2D or 3D contours

23. Form cutters
• Made of HSS or carbides

24. Gear teeth milling cutter
Disc type cutter End mill type
form cutter

25. Spline cutter
• To make spline shaft
• The cutter has the same shape to be produced
• Indexing helps to generate the spline over the
circumference

26. Thread milling
• Short thread
• Long thread