MILLING
PRESENTED BY
SUBMITTED TO
ANUJ KUMAR SRIVASTAVA
ME-1 3 rd YEAR
ROLL NO- 1214340035
Mr. DEEPAK SHARMA
COORDINATOR AND FACCULTY
IMSEC
CONTENT
DEFINITION
MILLING CUTTING MECHANISM
MILLING OPERATION
TOOL NOMENCLATURE
TYPES OF MILLING MACHINES
WORK HOLDING DEVICES
INDEXING
MILLING
 MILLING IS DEFINED AS THE PROCESS OF
CUTTING ,SHAPING &FINISHING A PIECE OF
METAL BY USING A ROTATING MULTIPOINT
CUTTING TOOL CALLED CUTTER
 THE CUTTERS ARE GENERALLY MADE OF
“HSS”
 THE CUTTING ACTION ARE GENERALLY FAST.
 USED TO PRODUCED COMPLEX SHAPES.
MILLING CUTTING
MECHANISM
 Peripheral milling
a) Up milling
b) Down milling
 Face milling
 End milling
PERIPHERAL MILLING
 Milled surfaces is generated by teeth
located on the periphery of cutter body.
 Axis of cutter rotation is parallel to
workpiece.
Two types
a) Up milling
b) Down milling
UP MILLING
 Known as conventional
Milling.
 Direction of cutter opposes
feed motion.
 Chip thickness minimum at
beginning and max.at end
UP MILLING
ADVANTAGE
the process is
smooth
DISADVANTAGE
 The workpiece has
tendency to pulled up
so proper clamping is
required.
Contamination
on surface does
 The tool has
tendency to chatter.
not affect tool life
DOWN MILLING
Known as climb
milling.
The direction of
cutter is opposite
to feed motion
ADVANTAGE
Better surface
finish.
There is less
radial pressure
on arbour.
DISADVANTAGE
Not suitable for
machining
workpiece
having scale
Presence of
scale reduces
tool life.
FACE MILLING
Cutter is mounted on spindle having an axis of
rotation perpendicular to workpiece
Used to mill flat faces
END MILLING
 Cutter rotates on an axis perpendicular to
workpiece
 Used to mill end surfaces.
MILLING OPERATIONS
a) Slab milling ( peripheral milling)
b) Face milling
c) End milling
d) Straddle milling
e) Form milling
SLAB MILLING
 Milled surfaces is generated by teeth located on
the periphery of cutter body
 Cutter generally made of HSS.
FACE MILLING
Cutter is mounted on spindle having an axis of
rotation perpendicular to workpiece
Used to mill flat faces
STRADDLE MILLING
 Two or more cutter are mounted on an
arbour.
 Used to machine two parallel surface.
FORM MILLING
 Cutter of specially shaped teeth are used for milling
 Shapes of teeth is same as the form required on
surface
 Used for cutting gear teeth.
TOOL NOMENCLATURE
TYPES OF MILLIN G
MACHINES
 Column & knee type milling machine
a) Horizontal milling machine
b) Vertical milling machine
 Fixed bed type milling machine
 CNC milling machine
COMPONENTS
Worktable- on which workpiece is mounted
Saddle – supports table & can move transversly
Knee – supports saddle &give vertical
movement to table.
Over arm – used in horizontal machine which is
adjustable to accommodate different length.
Head – contains spindle &cutter holder.
HORIZONTAL MILLING MACHINE
 In this machine ,axis of cutter is parallel to workpiece.
 Suitable for short production run.
VERTICAL MILLING MACHINE
MACHINE HAVING CUTTING TOOL SPINDLE
VERTICAL TO WORKPIECE.
HAVE HEAVY OVERARM.
BED TYPE MILLING MACHINE
 Used to mill flat surface having large bed which
only moves in horizontal axis.
 Work table is mounted on bed which replaces the
knee
CNC MILLING MACHINE
 This machine is operated by computer numerical
controls
 Feed is given automatically.
WORK HOLDING
DEVICES
BENCH VICES
Used for holding workpiece commonly in workshop .
Good for quick loading and unloading.
CLAMPS AND ANGLE PLATE
 Made of mild steel in which Used for checking straightness
slot is made in centre and Tand for holding
bolt passes through slot.
four types
two types
• Plain slot clamp
 Fixed
• Goose neck clamp
 Tilted type
• Adjustable clamp
INDEXING
 INDEXING MEANS THE
PROCESS OF DIVIDING THE
PERIPHERY OF THE WORK INTO
NUMBER OF EQUAL OR
UNEQUAL DIVISIONS BY USING
INDEX PLATE .
In indexing a plate
consisting of number of
holes at equally spaced
distance is used .
INDEXING METHOD
There are four types
 Direct indexing
 Simple indexing
 Compound indexing
 Differential indexing
DIRECT INDEXING
 Direct indexing is
simplest method of
indexing.
 It requires that the
worm & worm wheel
should be disengaged
so that it move by
hand.
Continue……
 In direct indexing a plate of 24,30,36 hole plate is used
 For choosing the correct plate , we choose it on basis of no.
of division required.
 There are several known indexing plates are available
15,16,17,18,19,20,21,23,27,29,31,33,37,39,41,43,47,49.
 These number represent number of holes on the plate.
Continue……
Let us take an example
 If we have to make a round shaft into square at
end then no of sides =4
 Now choose among three 24,30,36. the one
which is divisible by 4 is chosen .
 24 &36 both are divisible by 4 but least will be
taken
 Divide 24/4=6
 Mark the indexing plate consisting of 24 holes at
equal interval of 6 holes.
 The number obtained should be whole number.
Continue……
 Thus for making a 4 square hole the indexing plate
consisting of 24 holes must moved for 6 holes at one
time.
 Then a pin is attached on the plate is fixed on holes
diameter.
 Thus rotating a direct indexing plate by 6 holes in
simultaneous 4 operation gives a full rotation to the
work piece.
SIMPLE INDEXING
 In simple indexing the worm is engaged with
the rotating hole plate .
 This worm and worm wheel arrangement have
40:1 gear reduction ratio.
 It is used when division is not possible by three
hole plate ,24,30,36.
 It may be fraction.
 The 40 rotation of the plate by pin cause one
rotation to work piece.
Continue……
 Suppose we have to make 7 faces specimen on a round
work piece.
 Then it is given by 40/N ( where N denotes no of
division required).
 Here
 But plate does not contain 7 holes
 Then
Continue……
This means
 Thus 5 full turn of the pin and 5/7 th turn of next
Turn i.e. in a plate of 49 holes 35 will be moved by
help of a guide and then making the milling at there.
 This will be repeated by 7 times.
 Finally we got desired shapes.
THANK
YOU