Module IV

Milling machines – Types – Principal parts – Milling mechanism 1

Work holding devices – Milling machine attachments 1
Types of milling cutters – Elements of plain milling cutters 1
Nomenclature - Cutting forces in milling – Milling cutter materials 1
Up milling, down milling and face milling operations 1
Calculation of machining time 1
Indexing – Simple indexing – Differential indexing 1

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Cutting forces in milling process
In milling, cutting forces are exerted to shear away material in the form of a chip.
Knowledge of the cutting forces is essential for the following reasons:
1. Estimation of cutting power consumption,
2. Structural design of the machine – fixture – tool system
3. Evaluation of role of the various machining parameters (cutting speed, feed,
tool geometry, cutting fluid etc.) on cutting forces
4. Study of behaviour and machinability characterisation of the work materials

Let us consider the cutting forces due to the single tooth engagement of a plain milling cutter
1. Tangential force PT - force will be tangential force PT tangent to the work piece, this
is the most important force.
2. Radial or transverse force PR

Now resultant of these two is R - vector summation of this tangential force and the radial
force PR.So the main forces coming from the cutting process are the tangential force P T and
the radial force PR resultant of which is R

Tangential force PT generates the torque

D
Torque (T )  PT *
2
where PT  tan gential force
D  diameter of cutter
Power consumptio n for milling  2NT
whereN  rpm of cutter
The torque is necessary to be determined for design of the cutter cutting tool, design of the
milling arbor, drilling and design of the spindle design of the gear box and so on. This P T
gives the power consumption. The resultant force (R) of PT and PR can be again resolved into
PY and PZ will be utilized and important for design of the machine tool and cutting tool
holders and any fixtures and all these things
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Fundamental milling processes
The various milling processes may be grouped under two headings:
1. Peripheral milling
2. Face milling

Peripheral milling
The machining is performed by the cutting edges on the periphery of the milling cutter. It is
classified under two headings
1. Up milling
2. Down milling
Up milling
In this method, the work piece mounted on the table is fed against the direction of rotation of
the milling cutter. The cutting force is minimum during the beginning of the cut and
maximum at the end of cut. The thickness of chip is more at the end of the cut. As the cutting
force is directed upwards, it tends to lift the work piece from the fixtures. Application of
coolant on the cutting edge is also difficult. Due to these reasons the quality of the surface
obtained by this method is wavy. This processes being safer is commonly used and
sometimes called conventional milling.

Down milling
The work piece mounted on the table is moved in the same direction as that of the rotation of
the milling cutter. The cutting force is maximum at the beginning and minimum at the end of
cut. The chip thickness is more at the beginning of the cut. The work piece is not disturbed
because of the bite of the cutter on the work. The coolant directly reaches to the cutting point.
So the quality of surface finish obtained is high. Because of the backlash error between the
feed screw of the table and the nut, vibration is setup on the work piece
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 Up Milling Down Milling
1. Cutter rotates opposite direction of cutter rotates same direction of feed
feed which is also known as also known as climb milling
conventional milling.
2. chip width size is zero at initial chip size is maximum at start of cut
cut and maximum at the end of and decrease with the feed. It is zero at
feed. the end of feed.
3. In this process, heat is diffuse to In down milling most of heat diffuse
the work piece which causes the to the chip does not change the work
change in metal properties. piece properties.
4. In up milling, tool wear is more In this, tool wear is less compare to the
because the tool runs against the up milling, due to the cutter rotate with
feed. Tool rubs more at the the feed.
beginning of the cut causing faster
tool wear and decreases tool life

5. Chip length is large Chip length is small

6. The cutting chips fall down in The cutting chips fall down behind the
front of the cutting tool which tool and low vibration gives better
again cut the chips and high surface finish.
vibration cause less surface finish.
7. Due to upward force by tool, high In down milling, downward force act
fixture required to hold the work on work piece and low clamping is
piece. required

8. High quality cutting fluid is In this process heat does not diffuse in
required because heat diffuse in the work piece, so simple cutting fluid
the work piece. is required.
9. It required high cutting force It required low cutting force.
compare to down milling.

Climb milling is generally the best way to machine parts today since it reduces the load from
the cutting edge, leaves a better surface finish, and improves tool life. During conventional
milling, the cutter tends to dig into the work piece and may cause the part to be cut out of
tolerance.
Even though climb milling is the preferred way to machine parts, there are times when
conventional milling is the recommended choice. Backlash, which is typically found in older
and manual machines, is a huge concern with climb milling. If the machine does not
counteract backlash, conventional milling should be implemented. Conventional milling is
also suggested for use on casting or forgings or when the part is case hardened since the cut
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begins under the surface of the material.

Milling operations
1. Face milling and end milling
In the operation of face milling, axis of the milling cutter remains perpendicular to the
surface being milled. The surface obtained by the processes is perpendicular to the
axis of rotation of the cutter. Also, up and down types of milling are available,
depending on directions of the tool rotation and feed.
2. End Milling
In case of end milling thin (low diameter) cutter are used as compared to work piece
width. It is used to make slot in the work piece. End milling is a process of the
machining by milling cutters which have cutting edges both on the end face and on
the periphery.
3. Gang milling
4. Straddle milling
5. End milling
6. Saw milling
7. Angular milling
8. Form milling
9. Profile milling
10. Keyway milling
The operation of production of keyways, grooves and slots of different shapes and
sizes can be performed in a milling machine by using a plain milling cutter, a metal
slitting saw, an end mill or by a side milling cutter.
11. Drilling and reaming
The operation of drilling and reaming are performed in a milling machine by
mounting drills and reamers into the spindle of the machine.
12. Boring
A single point cutting tool is mounted on the arbor to perform boring. By adjusting
the single point cutting tool radially, different diameters of bores are machined.
13. Gear cutting
Gear cutting operation is performed in a milling machine by using a form cutter. The
work is held between centers on a universal dividing head. A proper gear cutter is
selected and the teeth are cut by DP, module method.
14. Thread milling
This operation is performed in a special thread milling machine by rotating both the
work and the cutter. Several cuts are made to cut the threads to their depth.
15. Cam milling
Cam milling is the operation of producing cams in a milling machine with the use of a
universal dividing head and a vertical milling attachment. It is performed by end mills
on the cam blank.
Specification of milling machine
1. Dimension of the table and the length of longitudinal, vertical and cross travel of
table.
2. Number of feeds available (specify their values).
3. Number of spindle speeds (specify their values).
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4. Total power available.

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5. Floor space require

Calculation of machining time
Cutting speed
It is the distance travelled by a point on the cutting edge of the milling cutter to remove metal
in time duration of one minute. It is expressed in meters per minute.
𝝅𝑫𝑵
Cutting Speed=𝟏𝟎𝟎𝟎 𝒎𝒆𝒕𝒆𝒓/𝒔𝒆𝒄

Where: D = The diameter of the milling cutter in mm N = Spindle speed in rpm

The cutting speed depends upon the material to be machined, the cutter material, depth of cut,
feed, type of operation and the coolant used.
Feed
The feed in a milling machine is defined as the distance the workpiece advances under the
cutter. The feed in a milling machine depends on the material to be machined, cutter material,
depth of cut, cutting speed, type of operation and the rigidity of the machine.Feed can be
expressed in three different methods:
1. Feed per tooth: It is the distance the work advances in the time between engagements by
the two successive teeth. It is expressed in mm per tooth.
2. Feed per cutter revolution: It is the distance the work advances in the time when the cutter
turns through one complete revolution. It is expressed in mm per revolution of the cutter.
3. Feed per minute: It is the distance the work advances in one minute. It is expressed in mm
per minute.
Depth of cut
The depth of cut is the thickness of the material removed in one pass of the work below the
cutter. It is expressed in mm.

Machining time for milling

The time required to mill a surface for any operations can be calculated from the formula
L
T
f *Z *N
where ,
T  time for machining in min ute
Z  number of teeth
f  table feed per tooth in mm
N  rpm
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Indexing
Indexing is the operation of dividing the periphery of a work piece into any number of equal
parts. An important use of milling machines is for cutting slots, teeth, grooves etc. which are
to be equally spaced around the circumference of a blank. This necessitates holding of the
blank (work piece) and rotating it the exact amount for each groove or slot to be cut. This
process is known as “indexing”. The indexing operations can also be adapted for producing
hexagonal and square bolts, splines etc.
Index head/dividing head of milling machine
The worm gear has 40 teeth and the worm has simple thread. Crank is directly attached with
the worm. Since the gear ratio of worm and worm wheel is 40:1, it takes 40 turns of the crank
to rotate the spindle and hence the work piece through one complete revolution. One
complete turn of the crank will revolve the spindle only by 1/40th revolution (turn).
In order to turn the crank precisely a fraction of a revolution, an indexing plate is used. An
indexing plate is a circular disc having concentric rings of different number of equally spaced
holes. Normally indexing plate is kept stationary by a lock pin. The work piece may also be
mounted on a mandrel between these centres or chuck.

Three indexing plates are used. These plates have concentric circles of holes with their
different numbers as described below:

If the pin is moved by one hole on the indexing plate in the circle of 20 holes, the spindle will
𝟏 𝟏 𝟏
revolve by 𝟒𝟎 ∗ 𝟐𝟎 = 𝟔𝟎𝟎 th turn of one rotation

Dividing heads are three types:

1. Simple dividing head
2. Universal dividing head
3. Optical dividing head
Plain indexing head
A plain dividing head has a fixed spindle axis and the spindle rotates only about a
horizontal axis.
Optical indexing head
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These models are used for high precision angular setting of the work piece with respect to the
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cutter. For reading the angles, an optical system is built into the dividing head.
Universal Dividing Head
In this, the spindle can be rotated at different angles in the vertical plane from horizontal to
vertical. As indicated by its name “universal”, it can be used to do all types of indexing on a
milling machine.
Universal dividing head is using for the following purposes
a) Universal dividing head can set the work piece in vertical, horizontal, or in inclined
position relative to the table surface.
b) To impart indexing movement.
c) For imparting a continuous rotary motion to the work piece for milling helical grooves

Indexing method
a. Direct indexing
b. Simple indexing
c. Compound indexing
d. Differential indexing

Plane/Simple Indexing
It is also named as plain indexing. It over comes the major limitation of direct indexing that is
possibility of dividing circumference of work piece into some fixed number of divisions. In
this case, worm and worm gear is first engaged. Since the gear ratio of worm and worm
wheel is 40:1, it takes 40 turns of the crank to rotate the spindle and hence the work piece
through one complete revolution. One complete turn of the crank will revolve the spindle
only by 1/40th revolution (turn). If the number of divisions on the job circumference (that is
number of indexing) needed is N, then the number of turns (n) that the crank must be rotated
for each indexing can be found from the formula:
40
Number of turns of crank 𝑛 = 𝑡𝑢𝑟𝑛𝑠
𝑁

Indexing Procedure
a) Divide 40 by the number of divisions to be done on the circumference of work piece.
40
Indexing crank movement= 𝑁
N is the number of divisions to be made on the circumference of work piece.
b) If the above number is a whole number, then crank is rotated by that much number of
revolutions after each milling operations, till the completion of the work.
For example, if we want to divide the circumference into 10 number of parts
40
Indexing crank movement 10 = 4 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛
That is the indexing crank is given 4 revolutions after each of milling operation
c) If indexing crank movement calculated by 40/N is not whole number, it is simplified and
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then expressed as a whole number and a fraction.

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d) The fractional part of the above number is further processed by multiplying its
denominator and numerator by a suitable common number so that the denominator will
turn to a number equal to any number of holes available on the any of indexing plates.
e) The numerator of the process fraction stands for the number of holes to be moved by the
indexing crank in the selected hole circle in addition to complete turns of indexing crank
equal to whole number part of 40/N.
Example 1
To cut 30 teeth on a spur gear blank
That means we need to divide the circumference of gear blank into 30 identical, parts.
40 40
Crank movement= = 30
𝑁
Here, N = 30
10 1
=1 =1
30 3
Let us multiply both numerator and denominator by 5.
5
=1
15
Denominator becomes “15” so we will select 15-hole circle of plate 1.
Action
After each milling operation we will rotate indexing crank by one complete turn and 5 holes
in 15 holes circle. This way we do milling total 30 times.
or
We can multiply numerator and denominator by 7 instead of 5 as above.

Action
We will select the hole circle of 21 holes. After each milling operation indexing crank will be
rotated by 1 complete circle and 7 holes in 21 holes’ circle. This way milling operation will
be done by total 30 times.
This method can use for indexing upto 50 for any number of divisions after 50 this method is
not capable for some numbers like 96, etc. Compound indexing overcomes the limitations.
Problem
Indexing 48 holes
40
Rotation of crank required = 𝑁
40
ie= 48 which means crank has to be rotated 40 holes in 48 holes circle after every cut for 48
times.

Since 48 holes are not available

40 20 5 5∗3 15
= 24=6 = 6∗3 = 18 so 15 holes in 18 holes circle after every cut (18 no holes are available)
48
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Differential indexing
This is an automatic way to carry out the compound indexing method. Differential indexing
has to be employed when the number of divisions to be achieved is not possible by simple
indexing where indexing holes are not available in any of index plate. In that case use the
nearest hole circle and give the index plate a definite amount of rotation to compensate for
the mismatch.
In this the required division is obtained by a combination of two movements
 The movement of the index crank similar to the simple indexing.
 The simultaneous movement of the index plate, when the crank is turned through the
back gears.
The spindle and index plate is connected by a trains of gears so that index plate will turn
either in the same direction or in the opposite direction as the crank is rotated
Procedure
1. Lock pin is disengage to permit rotation of index plate.
2. Select a nearst approximate number to that of number of divisions required
3. Find the gear ratio between spindle and gear mounted with index plate
40
𝑔𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜 = (𝐴 − 𝑁) ∗
𝐴
A = approximate number of divisions
N = required number of divisions to be indexed
4. Engage the gears as per the equation (numerator is gear on spindle and denominator is
gear on driven gear on the index plate
40
5. 𝑅𝑜𝑡𝑎𝑡𝑒 𝑡ℎ𝑒 𝑐𝑟𝑎𝑛𝑘 = 𝐴 𝑎𝑓𝑡𝑒𝑟 𝑒𝑣𝑒𝑟𝑦 𝑐𝑢𝑡 𝑓𝑜𝑟 𝑁 𝑡𝑖𝑚𝑒𝑠 𝑡𝑜 𝑐𝑜𝑚𝑝𝑙𝑒𝑡𝑒 𝑡ℎ𝑒 𝑐𝑢𝑡

 If A is greater than N, resulting fraction is positive and the index plate must move in
same direction as crank (clockwise). This positive rotation uses an idler gear.
 If N is greater than A, resulting fraction is negative and index plate must move
counterclockwise. This negative rotation required use of two idler gears.
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Example 1
Obtain the indexing for 87 divisions.
First of all, find out whether the number can be indexed by plain indexing or not
40 40
In plain indexing, crank movement = 𝑁 = 87 , cannot be indexed as 87 number holes are
not available

Procedure for differential indexing

1. Index plate is disengaged
2. Selected the nearest number to the required indexing number---- ie A=90
40
3. Then gear ratio (𝐴 − 𝑁) ∗ 𝐴
40 40 120 24
(90 − 87) ∗ =3∗ = =
90 90 90 18

4. Engage the gears of driver shaft with 24 gears and driven shaft 18 gears ratio (index
plate rotation in the same direction of rotation of crank)
40 8
5. Rotate the crank = 90 = 18 (moving 8 holes in 18 number hole circle)
6. After the every cut, rotate the crank 8 holes in 18 number hole circle for 87 times to
get 87 divisions on the surface

Example 2
Index the given surface to 209 divisions
The required indexing is 40/209 which cannot be obtained with any of the index plate
available. Choose the nearest possible divisions.

1. Selected the nearest number to the required indexing number---- ie A=200

40
2. Then gear ratio (𝐴 − 𝑁) ∗ 𝐴
40 40 360 36
(209 − 200) ∗ =9∗ = =
200 200 200 20
𝑔𝑒𝑎𝑟 𝑜𝑛 𝑡ℎ𝑒 𝑠𝑝𝑖𝑛𝑑𝑙𝑒 36
3. Change of gear = 𝑔𝑒𝑎𝑟 𝑜𝑛 𝑡ℎ𝑒 𝑖𝑛𝑑𝑒𝑥 𝑝𝑙𝑎𝑡𝑒 = 20 with opposite index plate rotation
40 4
4. Rotate the crank = 200 = 20 (moving 4 holes in 20 number hole circle)
5. After the every cut, rotate the crank 8 holes in 18 number hole circle for 87 times to
get 87 divisions on the surface
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Differences between a plain milling machine and a universal milling machine

CONVENTIONAL MILLING
In conventional milling, also called up milling, the maximum chip thickness is at the end of the cut.
The feed movement is opposite to the tool rotation.
Pros:
1. Tooth engagement is not a function of work piece surface characteristics.
2. Contamination or scale on the surface does not affect tool life.
3. The cutting process is smooth, provided that the cutter teeth are sharp.
4. The width of the chip starts from zero and increases as the cutter finishes slicing.
5. The tooth meets the work piece at the bottom of the cut.
6. Upward forces are created that tend to lift the work piece during face milling.
7. More power is required to conventional mill than climb mill.
8. Surface finish is worse because chips are carried upward by teeth and dropped in front
of cutter. There’s a lot of chip re-cutting. Flood cooling can help!
9. Tools wear faster than with climb milling.
10. Conventional milling is preferred for rough surfaces.

Cons:
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1. The tool has the tendency to chatter.

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2. The workpiece has the tendency to be pulled up, thus proper clamping is important.
 3. Faster wear on tool than climb milling.
4. Chips fall in front of the cutter – chip disposal difficult.
5. Upward force tends to lift up workpiece.
6. More power required due to increased friction caused by the chip beginning at the minimum
width.
7. Surface finish marred due to the chips being carried upward by tooth.

In climb milling, also called down milling, cutting starts with the chip at its thickest location. The
feed movement and the tool rotation have the same direction.
Pros:
1. The downward component of cutting forces holds the work piece in place, particularly for
slender parts.
2. Easier chip disposal - chips removed behind cutter.
3. Less wear - increases tool life up to 50%.
4. Improved surface finish - chips less likely to be carried by the tooth.
5. Less power required - cutter with high rake angle can be used.
6. Climb milling exerts a downward force on work piece - fixtures simple and less costly.
Cons:
1. Because of the resulting high impact forces when the teeth engage the work piece, this
operation must have a rigid setup, and backlash must be eliminated in the table feed
mechanism.
2. Climb milling is not suitable for machining work pieces having surface scale, such as hot-
worked metals, forgings and castings. The scale is hard and abrasive and causes excessive
wear and damage to the cutter teeth, thus reducing tool life

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 QUESTIONS
Answer the following questions in one or two words
1. What is the base of a milling machine made of?
2. Name the part which holds the other end of the arbor in a milling machine.
II. Answer the following questions in one or two sentences
1. What is milling?
2. What are the types of milling machines?
3. How is the size of a milling machine specified?
4. Name the fundamental milling processes.
5. What are the types of peripheral milling?
6. Name four work holding devices in a milling machine.
7. What is indexing?
8. What is the use of indexing head?
9. What are the types of indexing head?
10. What are the methods of indexing?
III. Answer the following questions in about a page
1. List out various milling machine attachments.
2. What are the different milling machine operations?
IV. Answer the following questions in detail
1. Draw a neat diagram of a milling machine and explain its construction.
2. Explain – Up milling, Down milling.
3. Explain any four cutter holding devices with diagrams.
4. Draw a neat diagram of a plain milling cutter and explain its nomenculature.
5. What are the differences between a plain milling machine and a universal milling
machine?
6. List out various milling machine attachments.
7. Name the milling cutters.
8. What are the different milling machine operations?

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 General
Types of milling cutter in detail
Milling cutters are classified into different categories depending on different criteria as
described below :
According to the Construction of Milling Cutter
(a) Solid milling cutter
(b) Inserted teeth cutter
(c) Tipped solid cutter
Solid cutter consists of teeth integral with the cutter body, in tipped cutter, teeth are made of
cemented carbide or satellite, teeth are brazed to steel cutter body called shank. Inserted teeth
cutter are larger in diameter, teeth of hard material are inserted and secured in the shank.
According to Relief Characteristics of the Cutter Teeth
(a) Profile relieved cutter
(b) Form relieved cutter
In case of profile relieved cutter, a relief to cutting edges is provided by grinding a narrow
land at their back. In case of form relieved cutters a curved relief is provided at the back of
the cutting edges.
According to Method of Mounting the Cutters
(a) Arbor type
(b) Facing cutter
(c) Shank cutter
Arbor type cutters have a central hole and keyways for their mounting on arbor. Milling
Shank type cutters are provided with straight or tapered shanks inserted into the spindle nose
and clamped there. Facing type milling cutter are used to produce flat surfaces. These are
balled or attached to the spindle nose or the face of a short arbor.
According to Direction of Rotation of the Cutter
(a) Right hand rotational cutter
(b) Left hand rotational cutter
A right hand rotational cutter rotates in an anticlockwise direction when viewed from end of
the spindle while left hand rotational cutter rotates in a clockwise direction.
According to the Direction of Helix of the Cutter Teeth
(a) Parallel straight teeth
(b) Right hand helical
(c) Left hand helical
(d) Alternate helical teeth
Parallel or straight teeth cutter consists of teeth parallel to axis of rotation of the cutter with
zero helix angle. In case of right hand and left hand helical teeth cutters, teeth cut at an angle
to the axis of rotation of the cutter. Teeth have opposite inclination in both the cutters.
Alternate helical teeth cutter has alternate teeth of right hand and left hand helical teeth
cutters.
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Direct Indexing
It is also named as rapid indexing. In this case first of all worm and worm wheel is
disengaged. Direct indexing is accomplished by an additional index plate fastened to the
index head spindle. It offers a quick means of milling squares, hexagons, taps, etc. Direct
indexing plate usually contains three sets of hole circles or slots: 24, 30, and 36. The number
of divisions possible to be indexed is limited to numbers that are factors of 24, 30, 36.
By using 24 number index plate, any number of divisions which is a factor of 24 can be
indexed quickly. It is possible to divide the surface of work piece into any number of equal
divisions out of 2, 3, 4, 6, 8, 12, 24 parts.

Slots Direct indexing divisions

24 2 3 4 6 8 12 24
30 2 3 5 6 10 15 30
36 2 3 4 6 9 12 18 36

Example: Problems
If we want to cut a hexagonal bolt by direct indexing, using a 24 number index plate
24
No: of holes to be moved =4
6
After completing one pair of milling whole surface of work piece, we have to move the pin
by 4 holes before next milling operation, that is to be done for 5 number of times for making
hexagonal bolt.

*****************************************
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I.B. Answer the following questions in one or two words
1. What is the base of a milling machine made of ?
2. Name the part which holds the other end of the arbor in a milling machine.
II. Answer the following questions in one or two sentences
1. What is milling?
2. What are the types of milling machines?
3. How is the size of a milling machine specified?
4. Name the fundamental milling processes.
5. What are the types of peripheral milling?
6. Name four work holding devices in a milling machine.
7. What is indexing?
8. What is the use of indexing head?
9. What are the types of indexing head?
10. What are the methods of indexing?
III. Answer the following questions in about a page
1. What are the differences between a plain milling machine and a universal milling
machine?
2. List out various milling machine attachments.
3. Name the milling cutters.
4. What are the different milling machine operations?
IV. Answer the following questions in detail
1. Draw a neat diagram of a milling machine and explain its construction.
2. Explain - Upmilling, Down milling.
3. Explain any four cutter holding devices with diagrams.
4. Draw a neat diagram of a plain milling cutter and explain its nomenculature.
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