Machining Processes for Various

Shapes: Milling, Broaching and Sawing

Milling and Milling Machines

Planing and Shaping
Broaching
Sawing
Filing
 Machining Shapes

Fig 24.1 Typical parts and shapes that can be

produced with the machining processes
described in this chapter.
Machining Shapes - Milling

Fig 24.2 Some basic types of milling cutters and milling operations. (a) Face milling; (b)
end or shoulder milling.
Machining Shapes
- Milling

(c) Profile milling

Fig 24.2 Some basic types of milling cutters and milling operations. (c) profile milling;
(d) slot milling.
Machining Shapes - Milling

Fig 24.2 Some basic types of milling cutters and milling operations. (e) slot and groove
milling; (f) thread milling and tapping.
Machining Shapes - Milling
Peripheral milling

cutter axis //
workpiece surface

Fig 24.4 Schematic illustration of peripheral milling.

 Peripheral
Machining Shapes - Milling milling
(a)

(b)

(c)

Fig 24.5 (a) Schematic illustration of

conventional milling and climb milling. (b)
Slab-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.
Machining Shapes - Milling

Peripheral milling

Table 24.1 Summary of Peripheral Milling Parameters and Formulas.

 Machining Shapes - Milling Peripheral milling
Given: A slab-milling operation is being carried out on a 300 mm-
long, 100 mm-wide annealed mild-steel block at a feed 𝑓𝑓 =
0.25 mm/tooth and a dept of cut 𝑑𝑑 = 3 mm. The cutter is 𝐷𝐷 =
50 mm in diameter, has 20 straight teeth, rotates at 𝑁𝑁 = 100 rpm
and is wider than the block to be machined.
Calculate the material-removal rate, estimate the power and
torque, and calculate the cutting time.
Soln:
Lin speed of workpiece 𝑣𝑣 = 𝑓𝑓𝑓𝑓𝑓𝑓 = 0.25 × 100 × 20 = 500 mm/min
MMR= 𝑤𝑤𝑤𝑤𝑤𝑤 = 100 × 3 × 500⁄60 = 2500 mm3 ⁄s
(From Table 21.2 specify energy for steel estimated as 5.5W � s⁄mm3 )
Power= 5.5 × 2500 = 13.75 kW
Power 13.75kW
Torque = = = 1.32 kNm
Rot speed 100 2𝜋𝜋⁄60 rad/s
300+12.24
𝑙𝑙𝑐𝑐 = 𝐷𝐷𝐷𝐷 = 50 × 3 = 12.24 mm; 𝑡𝑡 = = 37.5 s
500/60
 (b)
Machining Shapes - Milling
(a) Face milling
cutter axis ⊥
workpiece surface

(c)

(d)

Fig 24.6 (a) Face-milling operation with cutter removed, showing the action of a single
insert; (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.
Machining Shapes - Milling
Face milling

Fig 24.7 A face-milling cutter with indexable inserts. Source: Courtesy of Ingersoll Cutting
Tool Company.
 Machining Shapes - Milling
Face milling

Fig 24.8 Schematic illustration of the

effect of insert shape on feed marks on a
face-milled surface: (a) small corner
radius; (b) corner flat on insert; (c) wiper,
consisting of a small radius followed by a
large radius, resulting in smoother feed
marks.
Machining Shapes - Milling
Face milling

Corner
radius

wiper
 Machining Shapes - Milling Face milling

Fig 24.8 Schematic illustration of the effect of

insert shape on feed marks on a face-milled
surface: (d) Feed marks due to various insert
shapes.
Machining Shapes - Milling
Face milling

Fig 24.9 Terminology for a face-milling cutter.

 Machining Shapes - Milling Face milling

Fig 24.10 The effect of the lead angle on the undeformed chip thickness, t in face milling.
Note that as the lead angle increases, the chip thickness decreases, but the length of contact
(i.e., chip width) increases. The edges of the insert must be sufficiently large to
accommodate the contact length increase.
 Machining Shapes - Milling
(a) Face milling
(b)

(c)

Fig 24.11 (a) Relative position of the cutter and insert as they first engage the workpiece in
face milling. (b) Insert positions towards the end of cut. (c) Examples of exit angles of the
insert, showing desirable (positive or negative angle) and undesirable (zero angle) positions.
In all figures, the cutter spindle is perpendicular to the page and rotates clockwise.
 Machining Shapes - Milling Face milling
Example. Face Milling. Refer to Fig 24.6 and assume that 𝐷𝐷 = 150mm,
𝑤𝑤 = 60mm, 𝑙𝑙 = 500mm, 𝑑𝑑 = 3mm, 𝑣𝑣 = 0.6m/min,and 𝑁𝑁 = 100rpm.
The 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.
Soln.
MMR= 𝑤𝑤𝑤𝑤𝑤𝑤 = 60 × 3 × 0.6 × 1000 = 108000 mm3 /min
𝑙𝑙𝑐𝑐 = 𝐷𝐷⁄2 = 75 mm
Cutting time 𝑡𝑡 = 𝑙𝑙 + 2𝑙𝑙𝑐𝑐 ⁄𝑣𝑣 = 500 + 2 × 75 ⁄10 = 1.08 min
Feed per tooth 𝑓𝑓 = 𝑣𝑣⁄ 𝑁𝑁𝑁𝑁 =
10 mm/s ⁄ 1.67 rev/s 10 tooth/rev = 0.6 mm/tooth
Unit power estimated at 1.1 𝑊𝑊𝑊𝑊/mm3 (Table 21.2)
108000
Power= 1.1 × = 1980 W
60
 Machining Shapes - Milling End milling
cut with the tool end

Fig 24.12 A selection of end mills. The flute depth and helix angle are selected based on
whether it is a roughing or finishing cut. Note the variety of geometries of the end of the
mill; with the proper cutter, a radius, chamfer, or flat surface can be machined. Source:
Courtesy of Kennametal, Inc.
 Machining Shapes - Milling End milling

Fig 24.13 Ball nose end mills. These cutters are can produce complex contours and are often
used in machining dies and molds (see also Fig. 24.2d). Source: Courtesy of Dijet, Inc.
Machining Shapes - Milling

Fig 24.14 Cutters for (a) straddle milling; (b) form milling; (c) slotting; (d) slitting with a
milling cutter.
Machining Shapes - Milling

(b)

Fig 24.15 (a) T-slot cutting with a milling cutter. (b) A shell mill.
 Machining Shapes - Milling
Milling machines

Base

Worktable

Fig 24.18 Schematic illustration of (a) a horizontal-spindle column-and-knee-type milling

machine; (b) vertical-spindle column-and-knee-type milling machine. Source: After G. Boothroyd.
 Machining Shapes
- Milling

Milling
machines

Fig 24.19 Schematic illustration of a

bed-type milling machine.

Fig 24.20 A computer numerical-

control (CNC) vertical-spindle milling
machine. This is one of the most
versatile machine tools.
Machining Shapes - Planing and Shaping
tool cutting edge moves linearly
relative to workpiece

planing: workpiece moves

shaping: tool moves
Fig 24.22 Typical parts that can be made on a planer.
 Machining Shapes - Broaching
(c)

(a)

(b)

Fig 24.23 (a) Typical parts made by internal broaching. (b) Parts made by surface broaching.
(c) Vertical broaching machine. Source: (a, b) Courtesy of General Broach and Engineering
Company; (c) Courtesy of Ty Miles, Inc.
 Machining Shapes - Broaching
(a)
total removal =
combined
removal from all
the teeth
(b)

Fig 24.24 (a) Cutting action

of a broach, showing
various features. (b)
Terminology for a broach.
Machining Shapes - Broaching

Fig 24.26 Terminology for a pull-type internal broach used for enlarging long holes.
Machining Shapes - Broaching

Fig 24.27 Example of a part with internal

splines that were produced by broaching.
 Machining Shapes - Sawing
(a) (c) (e)

(d)
(f)
(b)

Fig 24.28 Examples of various sawing operations: (a) ripping; (b) internal cuts: (c) angular
cuts; (d) contouring cutting; (e) stack cutting; (f) wafer slicing.
 Machining Shapes - Sawing
(a)

(b)
Tooth rake
angle
(positive)

Fig 24.29 (a) Terminology for saw teeth. (b)

Types of tooth sets on saw teeth staggered
to provide clearance for the saw blade to
prevent binding during sawing.
Machining Shapes - Filing

Fig 24.31 Types of burs used in burring operations.