Outline of the presentation:

 Types of milling process:

1. Peripheral milling 2. Face milling

 Types of milling cutters:

1. Profile relieved cutters 2. Form relieved cutters

 Plain milling cutter Nomenclature

 Design of milling cutters

size, teeth, flutes, relief, and material

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Classification of Milling Cutter:
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.

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Milling cutters are multipoint
cylindrical cutting tools with
cutting teeth spaced around
the periphery. Cutters are
classified into 2 main
categories.
1. Profile Relieved Cutters

2. Form Relieved Cutters

Milling Process is divided into 2

main types:
1.Peripheral Milling: Finished
Surface is parallel to the axis of
the cutter
2.Face Milling: Finished
Surface is perpendicular to the
axis of the cutter
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Milling cutters are often identified
according to the type of
construction, such as inserted –
tooth cutters, solid cutters and
carbide –tipped solid cutters. On the
other hand, the same cutters may
be referred to by the method of
mounting, arbour type, shank type
and spindle – mounted milling
cutters.
The two basic cutter types
according to relief are the form and
profile relieved cutters. The profile
relieved cutter is obtained by
sharpening the narrow land behind
the cutting edge. The land is
resharpened when the cutter
becomes dull. Form relieved cutters
have a curved relief behind the
cutting edge and are sharpened by
grinding the face of the tooth.
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A cutting tool having its edge shaped to the profile to be imparted to the work.
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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
(stub 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.

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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.

According to Purpose of Use of the Cutter

(a) Standard milling cutter
(b) Special milling cutter
Special milling cutters are designed to perform special operations
which may be combination of several conventional operations.

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Milling cutters are made in various forms to perform certain classes
of work, and they may be classified as:

(1) Plain milling cutters,

(2) Side milling cutters,
(3) Face milling cutter,
(4) Angle milling cutters,
(5) End milling cutter,
(6) Fly cutter,
(7) T-slot milling cutter,
(8) Formed cutters,
(9) Metal slitting saw

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9
End milling cutter

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Nomenclature:
Side milling cutter

1. Body: It is the part of the solid or tipped cutter exclusive of the teeth
or shank.
2. Arbor: It is the shaft on which the arbor type cutters are mounted or
driven.
3. Shank: It is a cylindrical or tapered extension along the axis of the
cutter employed for holding and driving shank type cutters.
4. Cutting edge: It is the edge formed by the intersection of the face
and the circular land or the surface left by the provision of primary
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clearance.
Nomenclature:

5. Land: The narrow surface of a cutter tooth immediately behind the

cutting edge.
6. Flute or Gash: The chip and coolant space between the back of one
tooth and the face of the following tooth.
7. Face: It is the portion of the flute adjacent to the cutting edge.
8. Fillet: It is the bottom surface of the flute.

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Nomenclature:

9. Helix angle: The cutting edge angle which a helical cutting edge
makes with a plane containing the axis of a cylindrical cutter.
10. Diameter: Cutter diameter or the outside diameter of the cutter is
the diameter of the circle passing through the peripheral cutting edge.
11. Relief: The result of the removal of tool material behind or adjacent
to the cutting edge to provide clearance and prevent rubbing.
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Nomenclature:

12. Primary relief: It is the relief immediately behind the cutting edge.
13. Secondary relief or clearance: The additional space provided
behind the relieved land (prinmry relief) of a cutter to eliminate
undesirable contact between the cutter and the workpiece.

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Nomenclature:

14. Relief angle: The angle formed between a relieved surface and a
given plane tangent to a cutting edge or a point on a cutting edge.
15. Radial rake angle: It is the angle in a plane perpendicular to the
axis of the cutter, between the face of the tooth and a radial line
passing through the cutting edge.
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Design:

Size:
The face width of the cutter must be wide enough to provide
adequate support behind the cutting edges.

The cutter diameter should be kept as small as possible because

small diameter cutters require less torque and deflect less.

A larger cutter diameter will give more flute depth (chip space)
resulting in better heat removal, longer tool life and higher cutting
rates. However, a larger diameter cutter will require more torque
and deflect more.

Larger diameter cutters may be required when interference

between the outer arbor support and workpiece occurs.

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Design:

Size:
The diameter will depend upon the depth of the flute and the
diameter of the hole in the cutter. A general rule diameter is to
provide a minimum ratio of 3: 1 between cutter diameter and hole
diameter.
Or

Generally the cutter diameter, D, is taken to be about (2.5 to 3)

times the arbor diameter.
Or

The outside diameter of the cutter, D, depends upon the arbor

diameter “d”, thickness of the cutter ring “t”, and the height of the
cutting tooth “h”, or the depth of the flute.

It is given as : D = d + 2t + 2h

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Design:
Tool angles: 1. Radial rake angle 2. Relief angle 3. Helix angle

Regarding the tool angles, the same general principles apply for
multi-point tools as for single point tools. A compromise has to be
made between the efficient cutting action (greater tool angles) and
tool strength (smaller tool angles).

The radial rake angle varies from 10° to 20°, larger values for
cutting softer materials and smaller values for cutting harder
materials. Carbide tipped cutters have negative rake angles, - 10°
to - 15°.

Relief angle is provided to eliminate heel drag, i.e., to reduce

friction between the tooth land and the cutting surface. Relief
angles should be small to ensure greater strength of the cutting
edge. Larger relief angles reduce the strength of cutting edge
leading to its failure and also increase the tendency of chatter.

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Design:
Tool angles: 1. Radial rake angle 2. Relief angle 3. Helix angle
Larger values of relief angles are used for smaller-diameter
cutters and vice-versa. The relief on side or end cutting edges is
much smaller as compared to peripheral teeth, because the
problem of heel drag does not exist for these teeth.

Due to repeated sharpening, the land width will go on increasing,

leading to increased tendency of heel drag on the workpiece. To
control the land width, a clearance angle (or secondary relief) is
ground on the tooth. This secondary relief is approximately twice
the relief angle. To give strength to the cutting point, a narrow land
is provided immediately behind the cutting edge.

Plain milling cutters may have either straight or helical teeth.

Helix angle = 20° to 30° for plain helical cutters
= 10° to 15° for side and end milling cutters

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Design:
Width of Land:
To give strength to the cutting point , a narrow land is provided.
Width of land = 0.127 to 0.254 mm for small end mills
= upto 3.2 mm on large diameter cutters
= 0.8 to 1.6 mm for average diameter cutters

Flutes: The flutes of a milling cutter can be straight, helical, or

angular.

When milling cutter teeth are cut on a helix, the entire cutting edge
does not come into contact with the workpiece at one time. The
helix causes more than one tooth to be in contact with the
workpiece along a single contact line parallel to the cutter axis.
Each individual tooth picks up the chip gradually until a maximum
chip load is attained. The maximum chip load continues for a
considerable part of the tooth travel and then decreases gradually
as the tooth leaves the workpiece. This action provides smooth
and continuous cutting and greatly decreases the tendency to
chatter.
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Flutes:
When milling-cutter teeth are cut on a helix, the entire cutting edge
does not come into contact with the workpiece at one time. The
helix causes more than one tooth to be in contact with the
workpiece along a single contact line parallel to the cutter axis.
Each individual tooth picks up the chip gradually until a maximum
chip load is attained. The maximum chip load continues for a
considerable part of the tooth travel and then decreases gradually
as the tooth leaves the workpiece. This action provides smooth
and continuous cutting and greatly decreases the tendency to
chatter.

The cutting action of a tooth formed by a straight flute is

intermittent. When the tooth enters the workpiece, the whole length
of the tooth takes the full load and the cutting forces increase
rapidly. The forces continue to increase until the tooth leaves the
cut and then suddenly drop. The shock load produced by this type
of cutting generally reacts through the drive mechanism of the
machine to produce chatter.

Angular flutes on milling cutters are a compromise between helical

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and straight flutes.
Design:
Number of teeth:
The solution of the correct number of teeth in a milling cutter is a
compromise depending upon working material, type of milling
cutter and the surface finish required.

A milling cutter with a relatively large number of small teeth

around its periphery promote smoother cutting because more
teeth are in the cut. When other cutting conditions are constant, a
cutter of many teeth will also have a finer feed per tooth which
results in a better surface finish. However, a cutter of many teeth
may not have adequate chip space to prevent chip interference.

A soft material that allows a heavy feed rate and produces long
continuous chips requires a greater chip space.

An effective way of providing chip space is by reducing the

number of teeth in the cutter and increasing the size of the
individual tooth. This provides a stronger tooth and is therefore
suitable for heavy roughing cuts when a large volume of material
is being removed.
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Design:
A milling cutter should have enough teeth to ensure uninterupted
contact with the workpiece and yet not so many that there is too little
space between the teeth for chip disposal. The thumb rule is to select
a cutter so that a minimum of one tooth will always be in the cut. This
will ensure that one tooth will not leave the workpiece before another
enters and will promote a smooth cutting operation.

Number of teeth:

The number of teeth in a milling cutter is given as:

n = [f/(ft * N)]
where f = feed rate, mm/min, ft = feed rate per tooth, mm
N = cutter speed, rpm

For H.S.S. plain milling cutters,

ft = 0.05 to 0.6 mm/tooth for milling steel
= 0.1 to 0.8 mm/tooth for mil1ing C.I.

Metal removal rate, MRR = w x h x f, mm3/min

where w = width of cut, mm & h = depth of cut, mm 23
To prevent the overloading of the machine, following condition is given:
n = Power/[ft *N*h*w]

Power = depth of cut ‘h’ * width of cut ‘w’ * feed * specific cutting force
mm * mm * mm/min* N/ mm2

n = [k*hpc] / [ft *N*h*w]

K = machinability factor [units: mm3 / min. / hpc]

A suitable formula for calculating horsepower (HPC) at the cutter is:

HPC = MRR/K

For horsepower at the motor (HPm), use formula:

HPm = HPC/E

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The feed of an 8-tooth face mill is 0.033 cm per tooth at 200 RPM.
The material cut is 300 BHN steel. Depth of cut is 0.32 cm and the
width is 10 cm. Calculate the (a) horsepower at the cutter (b)
horsepower at the motor if the efficiency of the machine is 60%.
hpc = MRR/KThe feed of an 8-tooth face mill is 0.033 cm per tooth
at 200 RPM. The material cut is 300 BHN steel. Depth of cut is 0.32
cm and the width is 10 cm. Calculate the (a) horsepower at the
cutter (b) horsepower at the motor if the efficiency of the machine
is 60%.
MRR = w*h*f
w = width of cut = 10 cm
h = depth of cut = 0.32 cm
f = feed rate, cm/min = n * ft * N
n=8
ft = 0.033cm and N = 200 RPM
MRR = ?
K =8.2
hpc = MRR/K
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hpm = hpc/efficiency