Chapter 3(d)
Milling Process
Ref: [Link]
Introduction
Machining operations can produce many other parts
with more complex shapes
Complex shapes need to be produced to very close
tolerances and a fine surface finish
Die casting and precision forging can achieve such
goals to some degree
Milling and Milling Machines
Milling is machining operation for a variety of
configurations with the use of a milling cutter
Milling Operations
Figure (a) Schematic illustration of conventional milling and climb milling. (b) lab-milling
operation showing depth-of-cut, d; feed per tooth, f; chip depth-of-cut, tc; and workpiece
speed, v. (c) Schematic illustration of cutter travel distance, lc, to reach full depth-of-cut.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R.
Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights
reserved.
Milling and Milling Machines:
Peripheral Milling
The axis of cutter rotation is parallel to the workpiece
surface
The cutter body has a number of teeth along its
circumference
When the cutter is longer than the width of the cut, the
process is called slab milling
Conventional Milling and Climb Milling
The cutter rotation can be clockwise
or counter-clockwise
Conventional vs Climb Milling
Conventional vs Climb Milling
Conventional Milling
• cutter rotates against the direction of feed of the work piece.
• chip is very thin at the beginning and increased along its
length.
• cutter tends to push the work along and lift it upwards from
the table.
Climb Milling
• cutter rotation is the same as the direction of feed
• maximum chip thickness is at the point of tooth contact with
the work piece
• work piece is pulled into the cutter
Peripheral Milling-Parameters
Cutting speed/surface speed of the cutter is
V DN
Feed per tooth is determined from v
f
Nn
The cutting time, t, is given by l lc
t
v
lwd
The material-removal rate (MRR) is MRR w.d .v
t
Milling and Milling Machines:
Peripheral Milling
Milling Parameters
Milling and Milling Machines:
Peripheral Milling
EXAMPLE
Material-removal Rate and Cutting Time in Slab Milling
A slab-milling operation is being carried out on a 300-mm-
long, 100-mm-wide annealed mild-steel block at a feed f
0.25 mm/tooth and a depth of cut d 3.0 mm. The cutter is
D=50 mm in diameter, has 20 straight teeth, rotates at
100rpm and, by definition, is wider than the block to be
machined. Calculate the material-removal rate
Milling and Milling Machines:
Peripheral Milling
Solution
Material-removal Rate and Cutting Time in Slab Milling
The linear speed of the workpiece is
v fNn 0.2510020 500 mm/min
Cutting time, t= 0.65 min
The material-removal rate is
MRR l.w.d / t 3001003 / 0.65 138,461 mm3 / min
Milling and Milling Machines:
Face Milling
In face milling, the cutter is mounted on a spindle
having an axis of rotation perpendicular to the
workpiece surface
As the relative motion between the cutter teeth and the
workpiece, face milling leaves feed marks on the
machined surface
Face-Milling Operation
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.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R.
Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights
reserved.
Milling and Milling Machines:
Face Milling
EXAMPLE
Material-removal Rate and Cutting Time in Face Milling
Assume that D = 150 mm, w = 60 mm, l = 500 mm, d = 3 mm, v = 0.6
m /min and N = 100 [Link] cutter has 10 inserts, and the workpiece
material is a high-strength aluminum alloy. Calculate the material-
removal rate, cutting time, and feed per tooth, and estimate the power
required.
Milling and Milling Machines:
Face Milling
Solution
Material-removal Rate, Power Required, and Cutting
Time in Face Milling
The cutting time is l 2lc 500 275
t 65 s 1.08 min
v 10
The material-removal rate is
MRR l.w.d / t 50060(3) / 1.08 83,333 mm3 / min
0.6 x1000
The feed per tooth is f 10010 0.6 mm/tooth
Milling and Milling Machines:
End Milling
End milling is versatile and capability to produce
various profiles and curved surfaces
An end mill has a straight shank or tapered shank
which is mounted into the spindle of the milling
machine
End milling can produce a variety of surfaces at any
depth, such as curved, stepped, and pocketed
Milling and Milling Machines:
Other Milling Operations and Milling Cutters
In straddle milling, two or more cutters are mounted
on an arbor and are used to machine two parallel
surfaces on the workpiece
Form milling produces curved profiles using cutters
that have specially shaped teeth
Slotting and slitting operations are performed with
circular cutters
Milling and Milling Machines:
Toolholders
Arbor cutters are mounted on an arbor for peripheral,
face, straddle and form milling
In shank-type cutters, the cutter and the shank are
made in one piece
Hydraulic toolholders and arbors are available
Stiffness of cutters and toolholders is important for
surface quality and in reducing vibration and chatter
during milling operations
arbor
collet
Milling and Milling Machines:
Milling Process Capabilities
Milling process capabilities include surface finish,
dimensional tolerances, production rate, and cost
considerations
Milling and Milling Machines:
Milling Process Capabilities
Milling and Milling Machines:
Milling Machines
Milling machines are among the most versatile and
useful machine tools
Standard milling machines are now being replaced with
computer controls and machining centers
Column-and-knee-type Machines
Column-and-knee-type machines are common milling
machines
Milling and Milling Machines:
Milling Machines
Bed-type Milling Machines
The worktable replaces the knee
and can move only longitudinally
Other Types of Milling Machines
Planer-type milling machines are
equipped with several heads and
cutters to mill different surfaces
Computer numerical-control (CNC)
machines are for low
production quantities
