Material Removal Processes

Machining Operations
and Machine Tools
Material Removal Processes

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 Milling Machine
 Milling is a metal cutting operation
in which the operating tool is a
slow revolving cutter having
cutting teeth formed on its
periphery (edge, border).

 The milling cutter is a multipoint

cutting tool. The work piece is
mounted on a movable worktable
which will be fed against the
revolving milling cutter to perform
the cutting operation.
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 Milling Machine
 Milling machine is the most
versatile and widely used machine
tool after lathe.

 Milling machines exist in two basic

forms: horizontal and vertical,
which terms refer to the orientation
of the cutting tool spindle.

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 Horizontal and Vertical Millers
 Horizontal Milling  Vertical Milling
Machine: Machine:
 Here, a spindle axis is  In vertical milling
placed in horizontal machine, a spindle axis
direction. is aligned vertically.

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 Parts of the Milling Machine
 The base gives support and
rigidity to the machine

 The column is a precision-

machined section used to
support and guide the knee
when it is moved vertically

 The knee is attached to the

column face and may be
moved vertically on the
column face either manually
or automatically. It houses the
feed mechanism Asad
 Parts of the Milling Machine
 The saddle is fitted on the top
of the knee and may be moved
in or out either manually by
means of the crossfeed
handwheel or automaticaly by
the means of crossfeed
engaging lever

 The swivel table housing,

fastened to the table on a
universal milling machine,
enable the table to be swiveled
45° to either side
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 Parts of the Milling Machine
 The table rests on the guideways in
the saddle and travels longitudinally
in a horizontal plane. It supports the
vise and the work

 The crossfeed handwheel is used

to move the table toward or away
from column

 The table handwheel is used to

move the table horizontally left and
right in front of the column

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 Parts of the Milling Machine
 The spindle provides the drive
for arbor and cutters
 The overarm provides correct
alignment and support for the
arbor. It can be adjusted and
locked in various positions
 The arbor support is fitted to
the overarm and can be clamped
at any location on the overarm
 The elevating screw gives an
upward or downward movement
to the knee and the table
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 Rotation of spindle

Y- axis o

Z-axis or Vertical
r
Transve
rse
axis

axis
d in al
on git u
is or L
X- ax
axis

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 Difference b/w Climb & Conventional
Milling
 Up(Conventional) Milling:  Down(climb) Milling:
 In up milling, cutter rotates  In down milling, cutter rotates
against the direction of table along the direction of table
feed. feed.
 If the workpiece or cutter  Down milling is not a good
material is brittle (such as choice if the workpiece
ceramic), up milling is always material is brittle.
preferred.  Chances of distortion of thin
 Thin workpiece samples, if workpiece samples are less
machined using up milling with down milling mode if
mode, may get distorted due to proper support in bottom is
upward cutting force. provided.

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Difference b/w Climb & Conventional
Milling

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 Difference b/w Climb & Conventional
Milling
 Up(Conventional) Milling:  Down(Climb) Milling:
 With horizontal axis milling  In down milling mode, the
machine, cutting force in up cutting force is directed
milling mode is directed upward, downward, and thus it tends
and thus it tends to lift off the to press the workpiece rather
workpiece from the worktable. than lift off. So cheaper
Accordingly, rigid and fixture can be employed.
expensive fixture is required for
firmly mounting the workpiece.

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Direction of Feed

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 Types of Milling Operation
 Peripheral milling
 Face milling

 Difference b/w Peripheral and Face

milling
 In peripheral milling, also called plain milling,
the axis of the tool is parallel to the
surface being machined, and the operation
is performed by cutting edges on the outside
periphery of the cutter.
 In face milling, the axis of the cutter is
perpendicular to the surface being milled,
and machining is performed by cutting edges
on both the end and outside periphery of the
cutter
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 Types of Peripheral Milling

 Slab Milling

 Slotting

 Side Milling

 Straddle Milling

 Form milling

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 Types of Peripheral Milling

Slab Milling

Basic form of peripheral milling

in which the cutter width extends
beyond the work-piece on both
sides

Width of cutter larger than

width of workpiece

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 Types of Peripheral Milling

Slotting

Width of cutter is less than width

of workpiece, creating a slot in the
work
If width of cutter is too small, the
tool will become a saw and the
operations will be called sawing

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 Types of Peripheral Milling
Side Milling

In which the cutter machines

the side of the workpiece
(a) plain (b) staggered tooth (c)
half-side

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 Types of Peripheral Milling
Straddle Milling

 The same as side milling, only

it involves the use of two side
milling cutters to machine the
opposite sides of a workpiece in
one cut

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 Types of Peripheral Milling
 Form milling
 In which the milling teeth
have a special profile that
determines the shape of the
slot that is cut in the work

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 Types of Face milling

 Conventional face milling

 Partial face milling

 End milling

 profile milling

 Pocket milling

 Surface contouring

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 Types of Face milling

Conventional face milling

In which the diameter of the

cutter is greater than the work
part width, so the cutter
overhangs the work on both
sides;

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 Types of Face milling

Partial face milling

where the cutter overhangs the

work on only one side

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 Types of Face milling

End milling

In which the cutter diameter is

less than the work width, so a slot is
cut into the part

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 Types of Face milling

Profile milling

A form of end milling in which the

outside periphery of a flat part is cut

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 Types of Face milling

Pocket milling
Another form of end milling to cut
shallow pockets into flat parts

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 Types of Face milling

Surface Contouring

In which a ball-nose cutter (rather

than square-end cutter) is fed back
and forth across the work along a
curved path at close intervals to
create a three-dimensional surface
form

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 Example 14.1.
 A peripheral milling operation is performed on a rectangular workpiece
that is 320 mm wide by 60 mm wide by 56 mm thick. The 65-mm-
diameter milling cutter has 4 teeth, is 80 mm wide, and overhangs the
work on either side by 10 mm. The operation reduces the thickness of
the piece to 50 mm. Cutting speed = 0.50 m/s and chip load = 0.24
mm/tooth. Determine the (a) machining time and (b) metal removal rate
once the cutter reaches full depth.

where fr = feed rate, mm/min (in/min); N = spindle speed, rev/min; nt = number of teeth on the cutter; f = chip
load in mm/tooth (in/tooth) d = depth of cut, mm (in); w = width and D = diameter of the milling cutter, mm
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 Shaping and Planing
 Shaping and Planing Similar operations
 Both use a single point cutting tool moved linearly relative to the workpart
 Shaping is performed on a machine tool called a shaper. The components
of the shaper include a ram, which moves relative to a column to provide the
cutting motion, and a worktable that holds the part and accomplishes the
feed motion.
 The machine tool for planing is a planer. Cutting speed is achieved by a
reciprocating worktable that moves the part past the single-point cutting tool.

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 BROACHING
 Broaching uses a multiple-tooth tool to take multiple cuts by moving the
tool linearly relative to the work in the direction of the tool axis

Broaching Advantages:

 Good surface finish

 Close tolerances
 Variety of work shapes possible
 High material removal rate
 Cutting tool called a broach
 Owing to complicated and often custom‑shaped geometry, tooling is
expensive

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 External and Internal Broaching
 Internal Broaching Performed on internal surface of a hole
 A starting hole must be present in the part to insert broach
at beginning of stroke
 Work shapes that can be cut by internal broaching;
cross‑hatching indicates the surfaces broached.

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 GEARS
Gears are machine components used to transmit motion and power
between rotating shafts.
 GEARS

GEAR HOBBING
Gear hobbing is also a milling
operation, but the specialized cutter,
called a hob, is much more complex
and therefore much more expensive
than a form milling cutter. In addition,
special milling machines (called
hobbing machines) are required to
accomplish the relative speed and feed
motions between the cutter and the
gear blank.