Milling: ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Milling
Machining operation in which work is fed past a

rotating tool with multiple cutting edges
 Axis of tool rotation is perpendicular to feed
 Creates a planar surface
 Other geometries possible either by cutter
path or shape
 Other factors and terms:
 Interrupted cutting operation
 Cutting tool called a milling cutter, cutting
edges called "teeth"
 Machine tool called a milling machine
©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Two Forms of Milling
Figure 21.3 Two forms of milling: (a) peripheral milling, and (b)
face milling.
Peripheral Milling vs. Face Milling
 Peripheral milling
 Cutter axis parallel to surface being
machined
 Cutting edges on outside periphery of cutter
 Face milling
 Cutter axis perpendicular to surface being
milled
 Cutting edges on both the end and outside
periphery of the cutter
Slab Milling
 Basic form of peripheral milling in which the
cutter width extends beyond the workpiece
on both sides
Figure 22.18 (a) slab

milling
Slotting
 Width of cutter is less than workpiece
width, creating a slot in the work
Figure 22.18 (b) slotting
Conventional Face Milling
Cutter overhangs work
on both sides
Figure 22.20 (a) conventional face milling
High speed face
milling using
indexable inserts
(photo courtesy
of Kennametal
Inc.).
End Milling
 Cutter diameter is
less than work
width, so a slot is
cut into part
Figure 22.20 (c) end milling
Profile Milling
Form of end milling
in which the
outside periphery
of a flat part is cut
Figure 22.20 (d) profile milling
Pocket Milling
 Another form of
end milling used
to mill shallow
pockets into flat
parts
Figure 22.20 (e) pocket

milling
Surface Contouring
 Ball-nose cutter fed
back and forth
across work along a
curvilinear path at
close intervals to
create a three
dimensional surface
form
Figure 22.20 (f) surface

contouring
Horizontal Milling Machine
Figure 22.23 (a) horizontal knee-and-column milling machine.
Vertical Milling Machine
Figure 22.23 (b) vertical knee-and-column milling machine
Basic movements
 Of a horizontal milling machine:
 The movements and alignment required are the location and
movement of workpiece by the worktable in a plane beneath the
cutter, parallel to the spindle axis.
 The spindle must have a horizontal axis.
 The work table must move in a direction at right angles to the
longitudinal traverse.
 The work table should be able to able to be raised or lowered in
order to feed the work into the cutter and to compensate for
different thicknesses of work.
 Table movements are controlled by lead screws fitted with
micrometer dials for accurate positioning of the table and
workpiece under the cutter.
Basic movements
 Of a vertical milling machine:
 Table movements are controlled by lead screws fitted with
micrometer dials for accurate positioning of the table and
workpiece under the cutter.
Milling cutters
 A milling cutter is a cutting tool that is used on a milling
machine.
 Milling cutters are available in many standard and special
types, forms, diameters, and widths.
 The teeth maybe straight (parallel to the axis of rotation)
or at a helix angle.
 The helix angle helps a
slow engagement of the
tool distributing the forces .
Milling cutters
 The cutter may be right-hand (to turn clockwise) or left-
hand (to turn counterclockwise).The figure shows a
typical end milling cutter.
Milling cutters
 Milling cutters have a secondary clearance angle to

prevent the heel of the tooth interfering with the
machined surface of the workpiece.
 The tooth can be made up of a series of straight lines, or
it can be a curved profile.
Milling cutters
Cutting Action
 Up-cut milling
 Traditional method – great
advantage of not tending to drag the
work into the cutter – can be used
on worn and cheap machines.
 Disadvantages:
1. Tends to rub before biting into the
metal, resulting in cutter wear and
poor finish
2. Cutting forces at maximum as the
chip leaves the workpiece –
resulting in transmission bounce
(ramble).
Cutting Action
 Up-cut milling
3. Cutting forces tend to lift the
component off the work table.
4. The feed mechanism drives the
workpiece against the full thrust of
the cutter.
Cutting Action
Down-cut milling
 This process has a number of
advantages:
1. The cutter bites into the workpiece
immediately and the load is eased off the
tooth gradually – thus smoother
operating conditions; longer cutter and
machine life, and good surface finish.
2. Cutting forces press the workpiece down
on to the table – maximum rigidity
3. Feed mechanism controls the feed rate
only, as the cutter tends to draw the
work through.
Cutting Action
Down-cut milling
 The major disadvantage is, it can only be
used on modern machine in good
condition and fitted with a backlash
eliminator.
Standard milling vs. climb milling
Plain milling and End milling
Milling Machine Cutting Parameters
 The cutting speed, V, in milling operation is the

peripheral speed of the cutter, or
V = πDN
 where D is the cutter diameter, and N is the
rotational speed.
where f is the feed per tooth of the cutter in mm/tooth,

and d is the depth of cut.
v is the linear speed (or feed rate) of the
workpiece, and n is the number of teeth per
cutter.
 The cutting time, t, is given by the expression
t = (l + lc)/v
l is the length of the workpiece and lc is the

extent of the cutter’s first contact with the
workpiece. Based on the assumption
that l << lc,
the material removal rate, MRR, is
MRR = lwd/t = wdv
 W is the width of the cut, which for a workpiece

narrower that the length of the cutter is the
same as the workpiece.
Worked example
Figure below indicates the final shape of a part that is to be made using an end mill. A 25 mm
wide and 5 mm deep slot is to be produced in a cast iron block with a 25 mm diameter high-speed
cutter. The cutter has four teeth. The combined total length of pretravel and overtravel is 5 mm.
The cut is to be made at a feed rate of 0.13 mm/tooth and a cutting speed of 40 m/min. Determine
the following
(a) the RPM used [6 marks]

(b) the length of the lead [6 marks]
(c) the cutting time, and [7 marks]
(d) the material removal rate (MRR) [6 marks]
Worked example
Ans:
1000V
(a) N 
D
1000  40
N
3.14  25
N  510 RPM
(b) 1 =D
= 25.0 mm
L
(c) T =
F
Where
L = piece length + lead + pre travel and over travel
= 100 mm + 25.0 mm + 5.0 mm
=130 mm
F = ftntrN
=0.130 mm/tooth  4 teeth  510 rev/min
=265 mm/min
Therefore, the cutting time is:
T =L/F
=130 mm/265mm/min
= 0.46 min
(d) MMR = WcDF

= 25mm  5mm  265mm/min
= 33,125mm3/min
Example
(a) A face milling operation is used to machine 6.0 mm in a single pass from the top
surface of a rectangular piece of aluminum 300 mm long by 125 mm wide. The cutter
has four teeth (cemented carbide inserts) and is 150 mm in diameter. The cutting
speed is 2.8 m/s and the chip load is 0.27 mm/tooth. Determine:
i. time to make one pass across the surface and [5 marks]

ii. the maximum metal removal rate during cutting. [3 marks]
Answer:
i. Spindle speed,
N = v/πD = (2800 mm/s)/150π = 5.94 rev/s
Feed rate in mm/s, f = Nn f = 5.94(4)(0.27) = 6.42 mm/s

r t
Extent of the cutter, A = D/2 = 150/2 = 75 mm
Time taken to make one pass, Tm

Tm = (L + 2A)/fr = (300 + 2(75))/6.42 = 70 s = 1.17 min
3
ii. MRR = wdf = 125(6)(6.42) = 4813 mm /s
r

Milling: ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Milling: ©2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e

Încărcat de

Drepturi de autor:

Formate disponibile

Milling

Machining operation in which work is fed past a

Figure 22.18 (a) slab

Figure 22.18 (b) slotting

Figure 22.20 (a) conventional face milling

Figure 22.20 (c) end milling

Figure 22.20 (d) profile milling

Figure 22.20 (e) pocket

Figure 22.20 (f) surface

Figure 22.23 (a) horizontal knee-and-column milling machine.

Figure 22.23 (b) vertical knee-and-column milling machine

 Milling cutters have a secondary clearance angle to

 The cutting speed, V, in milling operation is the

where f is the feed per tooth of the cutter in mm/tooth,

 The cutting time, t, is given by the expression

l is the length of the workpiece and lc is the

MRR = lwd/t = wdv

 W is the width of the cut, which for a workpiece

(a) the RPM used [6 marks]

(d) MMR = WcDF

i. time to make one pass across the surface and [5 marks]

Feed rate in mm/s, f = Nn f = 5.94(4)(0.27) = 6.42 mm/s

Time taken to make one pass, Tm

S-ar putea să vă placă și