Milling Machine Definition:

The milling machine is a type of machine which removes the material from the
workpiece by feeding the work past a rotating multipoint cutter. The metal removal
rate is higher very high as the cutter has a high speed and many cutting edges.

It is the most important machine in the tool room as nearly all the operations can be
performed on it with high accuracy.

Milling Machine Application or Uses:

Milling Machine is used for Machining flat surfaces, Slotting, Contoured
surfaces. It is also useful for making Complex and irregular areas, Revolution
surface, Gear cutting, Machining external and internal threads. Machining helical
surfaces of various cross-sections and many more.

Milling Machine Parts:

The Milling Machine consists of Base, Column, Knee, Saddle, Table, Over-Arm,
Spindle or Arbor, Arbor supports, Ram, and Milling Head.

We will study one by one in detail.

Here in this Milling machine diagram, you can easily see Its parts

#1 base : The base is the part upon which the whole machine parts are being mounted. It
is a type of foundation for the machine.
The base is mostly made up of cast iron, so it has good strength and rigidity. It also helps in
the absorption of shocks. Cutting fluid can also be stored in the base.

#2. Column:
The main supporting frame which consists of all the driving mechanisms and the motor
is called the column.

The driving mechanism usually consists of a cone pulley mechanism in which the v-belt
is being used to connect it to the motor.

Further by using this driving mechanism the speed of the machine can control as per
our requirement.

#3. Knee:
The knee shape is quite similar to that of the human body knee. This is an important
part of this machine that supports the other parts like the saddle and table.

It is attached to the column and has guideways by which it can move up and down with
the help of the elevating screw for adjusting its height.

#4. Saddle:
The saddle is present on the top of the knee which further carries the table. Its basic
function is to support the table.

A saddle can slide on the guideways which are exactly at 90 degrees to the column
face. Saddle moves crosswise(in or out) on guideways provided on the knee.

#5. Table:
The table is present on the top of the saddle. The table consists of T-slots or
sometimes fixtures are used for holding up the workpiece on the table. A table can
travel longitudinally in a horizontal plane.

#6. Over-arm:
It is also called the over-hanging arm. Overarm is present at the top of the column. The
basic function of the over-arm is to support the arbor and spindle.

It is attached to the column and has guideways by which it can move up and down with
the help of the elevating screw for adjusting its height.

#4. Saddle:
The saddle is present on the top of the knee which further carries the table. Its basic
function is to support the table.

A saddle can slide on the guideways which are exactly at 90 degrees to the column
face. Saddle moves crosswise(in or out) on guideways provided on the knee.
#5. Table:
The table is present on the top of the saddle. The table consists of T-slots or
sometimes fixtures are used for holding up the workpiece on the table. A table can
travel longitudinally in a horizontal plane.

#6. Over-arm:
It is also called the over-hanging arm. Overarm is present at the top of the column. The
basic function of the over-arm is to support the arbor and spindle.

#7. Spindle or Arbor:

The top portion of the column contains the spindle. The spindle is also an important part
of the machine as it is the part where the multipoint cutter is attached.

Power required for the rotation of the spindle is obtained from the motor through the
belt, gear, and clutch assembly.

Milling Machine Working Principle:

 Milling machine employed in the metal removing operation in which the work is rigidly
clamped on the table of the machine and the revolving cutter which has multiple teeth is
mounted on the arbor.
 The cutter revolves at high speed and the work is fed slowly past the cutter.
 The work can be fed in a vertical, longitudinal, or cross direction depending upon the type of
milling machine being used.
 As the work proceeds, the cutter-teeth removes the metal from the surface of the
job(workpiece) to produce the desired shape.

Milling Machine Operations:

The following Operation is performed by the Milling Machine:

 Plain or Slab Milling Operation

 UP and DOWN Milling Operation
 Face Milling Operation
 End Milling Operation
 Gang Milling Operation
 Straddle Milling Operation
 Groove Milling Operation
 Gear Milling Operation
 Side Milling Operation and
 T-Slot Milling Operation
The milling machine does not give a continuous cut like in the case of the Lathe
Machine.

First, the wheel of the cutter slides on the surface followed by the crushing movement,
and then the cutting movement by which the unwanted material is removed from the
workpiece.

#1. Plain Milling or Slab Milling Operation:

Plain or slab milling is a process in which the plain, horizontal or flat surfaces are
produced, which are parallel to the axis of the rotation of the cutter. A peripheral mill
cuter is used for performing the slab milling operation.

#2. Up Milling and Down Milling:

Up milling is a method of milling operation in which the cutter and the workpiece both
move in the opposite direction.

Down Milling is a method of milling operation in which the direction of the rotation of
the cutter coincides with the direction of the work feed.
 UP and Down
Milling Operation

Chip Thicknesswill be minimum in the beginning and maximum at the end in the case of
up-milling. Whereas, the chip thickness will be greater at the beginning and lesser at the
end in the case of down-milling.

Tool Life will is more in the case of down-milling as compared with the up-milling.

The surface finish will be more in the case of the down-milling as compared with the up-
milling method due to which down-milling method is used for the finishing operations in
the industries.

Accuracy will be more in the case of up-milling as compared with the down-milling
process since in up-milling the workpiece is pulled against the table so the fasteners will
be under tension and we know that under tension the backlash error will not have any
effect which ultimately results in the better accuracy in up-milling.

#3. Face Milling Operation:

It is a type of milling operation in which the layer of material is removed from the face of
the material. The end milling cutter is preferred for performing face milling
operations.

In Face Milling operation the teeth for cutting are present on both the periphery and the
face of the cutter.

The axis of rotation of the cutter is perpendicular to the work surface. In face milling
most of the cutting is done by the periphery portions of the teeth, the face portion
provides finishing the action.
 Face Milling
Operation

#4. End Milling Operation:

This type of operation is the combination of the slab milling and face-milling operation
used for creating slots in the workpiece and is mostly used for handling the complicated
profile.
 End Milling
Operation

#5. Gang Milling Operation:

This is a type of milling operation in which multiple cutters are being mounted on the
same arbor to produce the desired shape on the workpiece.
 Gang Milling
Operation

#6. Straddle Milling Operation:

The straddle is the type of milling process in which milling is performed on two surfaces
simultaneously. T-slot milling is a unique example of straddle Milling.

Straddle Milling
Operation

Advantages of Milling Machine:

The various advantages of Milling are:
High speed: In Milling, the rate of metal removal is very high as the cutter rotates at a
high speed and has multiple cutting edges.

Better surface finish: The surface finish of the materials machined on the milling
machine is better because of the multi-cutting edges.

Increased Productivity: CNC Milling Machines are the machines in which the milling
operation is being controlled by software. It has increased the overall production with
better finish and accuracy.

High Accuracy: In the milling machine, the products machined are of high accuracy,
especially in the case of the most advanced form of milling machine which is the CNC
Machine.

Huge Application: The indexing head makes it suitable for so many applications as the
exact rotation of the job is possible by the use of it. Milling can be used for machining
flat surfaces, irregular surfaces, contoured surfaces, slotting, gear cutting, and many
more.

Milling Machine disadvantages with remedies:

The disadvantages of the milling machine are as follows:

High Flank wear: It has a high flank wear rate which can be prevented by reducing
speed and increasing the feed rate. Further to avoid it one should use harder carbide
with proper geometry and sharpened cutting edges.

High crater wear: High crater wear is found which can be tackled by reducing speed
and using harder carbide.

Breaking of carbide: Sometimes the production process gets hindered because of the
breaking of the carbide. The remedy for this problem can be the use of tougher carbide,
and rigidity of the cutter, machine, and arbor should be ensured.

High Chatter: This happens due to poor rigidity of cutter, machine, loose arbor, and
improper geometry. This situation can be improved by increasing feed, reducing speed,
and using unequal pitch cutters.

Chip clogging: The milling machine also suffers from the problem of chip clogging
which can be reduced by using reducing the number of teeth on the cutter and
increasing speed and chip pockets.
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