CLASS-1

Milling Machine
Milling is a method of removing material with a rotating multi point cutter.
Milling machines are used to machine flat or curved surfaces on the work piece. The
application of milling machine includes machining flat or angular surfaces, slots,
keyways, groves, machining cams, large pitch threads, etc. These machines are versatile
and accurate and can produce surface finish of 1.6 to 3.2 micro meter and 0.8 to 1.6
micro meter in finish.
Peripheral Milling- here finished surface is parallel to the axis of the cutter and is
machined by cutter teeth located on the periphery of the cutter. It is classified into
1. Up milling
2. Down milling.
Up milling/conventional milling

If the rotation of the cutter is close to the work feed and axis of the cutter does
not intersect the axis of the work piece, then it is called upmilling.
In upmilling chip thickness will progressively increase during the cut. During the
cut ie. Thickness of chip is minimum at the beginning of the cut and reaches
maximum when cut terminates.
Upmilling is preferred on work piece which are sandy, scaly, or flame cut work
surfaces. Since cutter enters below scale surface this avoids its damaging.
The direction of the rotation of the cutter tends to throw the chips in the air which
is hazardous to the operator and making the chip disposal difficult.
There is difficulty experienced in directing the coolant at the region when cutting
begins.
The initial rubbing of the cutting edge and consequently have lower tool life and
also surface generated is left with machining marks.

Down milling / climb milling

Rotation of the cutter is in the same direction as work piece feed and the cutter
axis does not intersect the work piece axis, then it is called down/climb milling
Chip thickness will progressively thinner during the cut that is the thickness of the
chip will be maximum at the beginning and minimum when cut terminates.
In down milling tangential force and thurst force acts in the same direction, thus
the feed force is low.
The direction of the rotation of the cutter is such that it tends to seat the work
firmly in the work holding device. This also minimizes the vibrations.
Feed drive power consumption is much lower.
Down milling tends to throw the chip on the table, rather than up in the air,
making chip disposal easy.
Difficulty is not encountered in directing coolant at the regions where the cut
begins. The coolant also carried along the direction of the cut and there is no
splashing.

Characteristics of milling process

Interrupted cut

It is cooler then turning

Small size chip

High MRR

Variation in the chip thickness

Face Milling
Here finished surface is at right angle to the axis of the cutter axis and is obtained by the
teeth on the periphery and flat end on the cutter. In face milling cutter axis and work
piece axis intersects and cutting teeth on the periphery does not do the cutting
End Milling
End mills have cutting edge both at end surfaces and periphery. Here both face and
peripheral teeth does the cutting.

CLASS-2
GENERAL CLASSIFICATION OF MILLING MACHINE
A.) General purpose
B.) Special purpose
General type milling machine- these are extremely versatile and are widely employed
for batch manufacture. These include:

Knee type

Bed type

Planar type

Rotary type
Special purpose milling machine are designed for machining a particular pattern in a
component which are to be produced in several thousands.
Column and knee type machines are further classified into:

Horizontal milling machine

Vertical milling machine

Universal milling machine

Ram type milling Machine

Bed type are further classified into:

Simplex milling machine

Duplex milling machine

Triplex milling machine

Plano type milling machine
Rotary type milling machine
Horizontal milling machine
1. BASE: It is the foundation of the milling machine and is that part upon which all other
parts are mounted. It gives the machine rigidity and strength. Sometimes it also serves as
a reservoir for cutting fluid.
2. COLUMN: It is the main supporting frame. The motor and other driving mechanisms
are contained within it. The front is a machined surface called the column surface. It
supports and guides the knee in its vertical travel.

3. KNEE: The knee projects from the column and slides up and down on its face. It
supports the saddle and the table and is partially supported by the elevating screw
which adjusts its height.
4. SADDLE: The saddle supports and carries the table and is adjustable transversely
on ways on top of the knee. It is provided with graduations for exact movement and
can be operated by hand or power.
5. TABLE: The table rests on ways on the saddle and travels longitudinally in a
horizontal plane. It supports the workpieces, fixture and all other equipments.
6. OVERARM: The over arm is mounted on and guided by the top of the column. It
is adjusted in and out by hand to the position of maximum support for the arbor and
then clamped.
7. SPINDLE: The spindle obtains its power from the motor through belt, gears and a
clutch and transmits it into an arbor or sub arbor. Cutters are mounted directly in the
spindle nose.
8. ARBOR: The arbor is an accurately machined shaft for holding and driving the
arbor type cutter. It is tapered at one end to fit the spindle nose and has two slots to fit
the nose keys for locating and driving it.
Vertical milling machine
Position of spindle is perpendicular to work table.
Spindle head maybe swiveled at an angle permitting to work on angular surfaces.
Machining groves, slots flat surfaces.
End milling and face milling.

Universal milling machine

Similar to horizontal milling machine but differ in table movement. Table can be
swiveled about vertical axis up to 45 degrees. The capacity of universal machine is
increased by the use of special attachments such as dividing head, vertical milling
attachment, rotary attachment. The machine can produce spur, spiral bevel gears, milling
cutter reamers etc.
Ram type milling machine
This is very versatile milling machine used in tool rooms. These machine have
movable rams on the top of the column this can be moved in the direction parallel to
saddle a swiveling tool head is mounted at the forward end of the ram.
CLASS-3
B) BED TYPE MILLING MACHINE
These are heavy and rigid in construction used for high volume production or
machining large parts. Table is directly mounted on the bed. The table will have
longitudinal and transfers movements. The spindle head moves up and down. Depending
upon the number of spindle they are classified as simplex duplex, triplex machines.

SIMPLEX

DUPLEX

C) PLANAR TYPE MILLING MACHINE

It resembles planer
In planer, the table moves to give the cutting speed but in plano-miller the
table movements gives the feed.
Hence table movement is slower in plano-miller.

D) ROTARY TYPE MILLING MACHINE

This is modification to vertical milling machine. It consists of two vertical spindles
mounted with face milling cutter on number of work pieces are clamped on a circular
table which rotates about a vertical axis. The cutter maybe set t different heights relative
from the work so that one of the cutter is for roughing operation the other for finishing
operation.

MILLING OPERATIONS
1. plain milling
2. face milling
3. straddle milling
4. angular milling
5. gang milling
6. form milling
7. gear milling
8. profile milling
9. helical milling
10. end milling
1) Plain milling:- It is the operation of production of plain, horizontal surface parallel
to the axis of the plain milling cutter. The operation is also called slab milling.
2) face milling : it is the process of milling flat surfaces using milling cutter such that
surface generated is at right angle to the axis of the cutter.

3)Stradle milling: It is the milling operation in which a pair of side milling cutter used
for machining for 2 parallel vertical surfaces of the work piece simultaneously.

4)Gang milling: It is the operation of machining several surfaces of a work

simultaneously by feeding the work against number of cutters having same or
different diameter on the machine. This method saves much of machining time.

5)Angular milling: it is the milling process which is used for machining flat surfaces
at an angle other than right angle to the axis of revolution.

CLASS-4
6)Form milling: It is the operation of production of irregular contours by using form
cutters. The irregular contour may be concave, convex or any other shape.

7)Profile milling: it is the process of reproduction of an out line of template or

complex shape of the master piece. Different cutters may be used for profile cutters
may be used for profile milling. An end mill is one of the most widely used milling
cutter in profile milling work.

8. End Milling: It is a operation of production of a flat surface which may be vertical,

horizontal or at angle in reference to table surface. The cutter used is an end milling
cutter. The end milling cutters are also used for production of slots, grooves or key ways.

9. Helical Milling: It is the operation of production of helical cuts or grooves, around the
periphery of the cylindrical or conical work-piece. The operation is performed by
swiveling the table to the required helix angle and thus by rotating and feeding it against
the rotary cutting edge of milling cutter. Production of helical gears and twisted drill pit
are some of the examples of helical milling.
10. Gear Cutting: Gear cutting operation is carried out in a milling machine by using a
formed cutter. The cutter may be of cylindrical type or end type. The cutter profile
corresponds exactly with the tooth space of the gear. Equally spaced gear teeth are cut in
a gear blank by holding the work or a Universal dividing head and then index it.

Milling Cutters

Milling cutter is a multipoint revolving tool. The teeth of milling cutters may be parallel
to the axis of the rotation or at an angle known as- Helix Angle. The helix angle may be
left or right handed. Further, milling cutters may be made of single piece (solid cutter) or
having removable cutting teeth inserted in the solid body.
1. Plain milling cutters: These cutters have straight or helical teeth cut on the
periphery of a cylindrical surface. These are used to machine flat surfaces and
mounted on horizontal milling machine.
2. Face milling cutters: It is also used for machining flat surfaces. It is mounted on
vertical milling machines.
3. Plain slitting saw: It resembles a plain milling cutter or slide milling cutter in
appearance but it is of very small width. It is used for cutting off and slotting
operations and some what similar to the circular saw blade.
4. Side milling cutters: They have teeth on its periphery and also on the side. It may
have plain helical or staggered teeth. These cutters are used for side milling and
slot cutting.

5. Angle milling cutters: This cutter will have thin cutting teeth at angle to the axis
of rotation. The angular cutters are classified into single angular cutters and
double angular cutters. Single angular cutters are used in cutting dovetail grooves.
6. T-Slot cutters: The T-slot milling cutters are spherical forms of end milling
cutters to T-slot.
7. End milling cutters: They have cutting teeth on the end as well as on the
periphery of the cutter. The teeth on the periphery may be straight or helical.
These are used for light milling operations like cutting slots, holes and profile
milling operations.
8. Form milling cutter: These cutters are designed to cut definite shapes. These
cutters can be classified according to their shape or convex or concave cutters,
gear cutters, etc.
Cutter material: (i) High speed alloy (ii)Non ferrous cast alloy.
CLASS-5
Elements of a plain milling cutter

Body of cutter: The main frame of the cutter on which the teeth rests forms an
integral part known as the body of the cutter.
Cutting edge: This is the edge formed by the intersection of face and land.
Face: The portion of the surface adjacent to the cutting edge on which chip impringes
as it is cut from the work.
Fillet: The curved surface at the bottom of the teeth.

Outside diameter: The diameter of circle passing through the peripheral cutting
body.
Root diameter: The diameter of circle passing through the bottom of the fillet.
Cutter angle: Like single point cutting tool milling cutter is also provided with rake,
clearance and other angles to remove metal efficiently.
1. Relief Angle: The angle between land of the teeth and the tangent to the outer
circle at the cutting edge.
2. Clearance Angle: Two types (i) Primary clearance (ii) Secondary clearance
Primary clearance angle: This is the angle between the surface of the back tooth to
the periphery at the cutting edge.
Secondary clearance angle: This is the angle formed by the secondary clearance
surface of the tooth and the tangent to the periphery at the cutting edge.
Lip Angle: The included angle between the land and face of the tooth.
Rake Angle (radial): The angle measured in the diametrical plane between the face
of the tooth and radial line passing through the cutting edge. It may be positive,
negative or zero.
Milling machine attachment
The range of work that milling machine can do is greatly increased by the use of
attachments. The following are the different types of attachments:
1. Vertical milling attachment: With the use of this attachment the horizontal and
universal machines can be made to set on vertical milling machine.
2. High speed milling attachment: This attachment consists of gearing attachments
to increase the spindle speed by 4-6 times.
3. Slotting attachment: This attachment converts the rotary motion of spindle into
reciprocating motion with the help of eccentric or crank arrangement. This is used for
key way cutting, grooving and internal gear cutting.
4. Dividing head attachment: This is a work holding device which is mounted on
the machine table. It is used for dividing the periphery of work piece into required
number of equal parts. There are three types of dividing heads.
Plain, Universal and Optical Dividing Head.
Universal Dividing Head
This consists of an index plate mounted on a housing at right angles to the work
piece. An index crank is provided to rotate the spindle through a desired angle. A
tailstock is used to support the mandrel in which the work piece is mounted. The

rotation of the spindle for indexing can precisely accomplished with the help of index
plate. Which has varying number of holes on different hole circles. An adjustable
sector is provided for convenience of containing the number of spaces on the selected
hole circle.
Milling Fixtures
1.Vice Jaws: Standard machine vice are very widely used for clamping the work
piece for most of the jobs.
2.Plain milling fixture.
CLASS-6
INDEXING
Definition: The indexing is the operation of dividing periphery of a piece of work into
any number of equal parts.
Uses: Spacing in cutting of spur gears.
For producing square & hexagonal headed bolts
Cutting spline on shafts and fluting drills etc.
Purpose of the Indexing Attachment
Many times a machinist is required to machine features into a part that are located
radially instead of linearly. Examples of such features are the flats on a nut, the teeth
on a gear or the splines on a shaft. The indexing attachment is a unique design that
provides a very economical means of accurately rotating a part so that these kinds of
features can be machined. The attachment consists of an indexing head and a tailstock
mounted on a 12-inch long dovetailed bed. Also included is a rack gear that is used to
measure radial movement.. The rack gear inserts into the indexing head and engages
an index gear. This converts the rotary motion of the spindle into linear motion that
can be measured with a Venire caliper. Simple calculations then permit accurate
indexing to an infinite number of positions

Using the Standard Dividing Head

A dividing head is a tool that is used to divide a circle into
equal divisions. In a nut shell, a dividing head is simply a spindle mounted with a
precision worm wheel and provided with a crank attached to the worm shaft.
The crank's handle is equipped with a spring loaded plunger that will drop an
indexing pin into equally spaced holes in a disk mounted behind the crank. The
spindle is provided with the means to mount a chuck or collet attachment for holding
a work piece. It is also provided with a lock for clamping the spindle in position for
increased rigidity. These units are usually mounted such that the spindle's axis can be
tilted through 90 degrees, to provide an additional axis of adjustment.

Most units are made with a 40:1 reduction in the worm, such that 40 turns of the
crank will rotate the spindle through one full turn. The indexing plate (the disk with
concentric circles of equally spaced holes behind the crank) provides a handy positive
index for positioning the crank at 1/n turns of the crank, where n equals the number of
holes in the disk. The plunger can be positioned along the arm of the crank to select
which circle of holes you wish the indexing pin to engage. These indexing plates are
usually interchangeable to provide a wide variety of choices for n, so that one turn of
the spindle can be divided into a great variety of equal parts.
The dividing head are of three types:(a) Plane or simple dividing head
(b) Universal dividing head
(c) Optical dividing head
Plane or simple dividing head
Plain dividing head consists of a cylindrical spindle housed in a frame and a base
bolted to the machine table. The indexing crank is connected to the tail end of the
spindle directly, and the crank and spindle rotate as one unit. The index plate mounted
on the spindle and rotate with it. The spindle can be rotated through the desired angle
and then clamped by inserting the clamping lever pin into any one of the slots of the
index plate. The job is held between two centers, one on the dividing head spindle
and the other on the tailstock as shown in figure.

Universal dividing head

The working mechanism of universal dividing head is shown in the figure. The
spindle carrying the worm heel meshes with the worm, which carries a crank at its
outer end. The worm wheel has 40 teeth and is single threaded. Thus 40 turn of crank
will rotate the spindle for one complete revolution or one turn of the crank will cause
the spindle to be rotated by 1/40 of a revolution. In order to turn the crank a fraction
of a revolution, an index plate is used

The following types of index plates having holes given against them are availableBrown and sharpPlate 1: 15, 16, 17, 18, 19 and 20
Plate 2: 21,23,27,29,31 and 33
Plate 3: 35,37,39,41,43,47 and 49
ParkinsonPlate 1: 24,25,27,31,34,37,3,39,41,42 and43
Plate 2: 46,47,49,51,53,54,57,58,59,62 and 63
CLASS-7
Indexing methods
1. Direct indexing
2. Simple indexing
3. Compound indexing
4. Angular indexing
5. Differential indexing
1. Direct indexing is performed on the plain dividing head and universal dividing
head. In this case the dividing head has an index plate, fitted directly on the spindle.
The index plate has 24 holes and the periphery of job can be divided into
2,3,4,6,8,12,24 teeth.
ExampleFind the indexing movement needed for milling the sides of hexagon nut using direct
indexing
Index movement- 24/6=4 holes
2. Simple indexing is performed on universal dividing head. The worm wheel carries
40 teeth and is single threaded. 40 turns are required to rotate the sphere for one
revolution. The method of simple indexing is used hen direct indexing cannot be
employed for obtaining required no. of divisions on the work. Universal dividing
head is used for this purpose. This method of indexing involves the use of crank,
worm, worm wheel and index plate as shown in figure. The worm wheel carries 40
teeth and the worm is single threaded. With this arrangement 40 turns of crank are
required to rotate the spindle for one revolution.
Rules of simple indexing: Suppose the work is to be divided into a number of parts,
the corresponding crank movement will be as follows:
Indexing crank movement= 40/N,
Where N= no. of divisions required.

CLASS-8

3. Compound indexing is used when the number of divisions are required outside the
range of simple indexing. It involves two stages:
This method is used when the number of divisions required is outside the
range of simple indexing. It involves two stages: by turning the crank a definite amount in one direction in the
same
ways as in simple indexing
by turning the index plate and the crank both in same
direction or
reverse direction ,thus adding further movement to or subtracting from that
obtained in two stages.

40/N=n1/N1 +(or -) n2/N2

N= no. of division required
N1= the hole circle used by crank pin
N2= the hole circle used by the lock pin
n1= hole spaces moved by the crank pin in N1 hole circle
n2= hole spaces moved by the plate and crank in N2 hole circle

Procedure involved in compound indexing

Factorize the number of divisions required.

Factorize the standard no. 40
Select for trial any two circles on the same plate and on same side. Factorize the
difference.
Factorize the number of holes of one circle.
Factorize the number of holes of the other circle.
After obtaining these factors place them as follows:-

Factors of division required* factors of difference of hole circles

----------------------------------------------------------------------------Factors of 40* factors of first circle*factors of second circle
CLASS-9
4. Differential Indexing: Differential indexing greatly resembles compound indexing.
This process is also carried in two stages. In the first operation a crank is moved in a
certain direction. In the second phase movement is added or subtracted by moving the
plate by means of a gear train.
Procedure involved in differential indexing.
1. Gear ratio = (A-N)*40
-------------A
A= selected no. which can be indexed by plain indexing and the number is
approximately equal to N
N= the required no. of divisions to be indexed.
2. In the gear ratio, the numerator indicates driving gears on the index head spindle
and the denominator indicates the driven gears on the index plate.
3. Index crank movement= 40/A
the index crank has to be moved for N no. of times for complete division of work.
If (A-N) is ve , the index plate must rotate in direction opposite to that of crank and
if (A-N) is +ve , the index plate must rotate in same direction.
To achieve this conditions, the following conditions are used: If gear train is simple and (A-N) is +ve, only one idler gear is used.
If the gear train is compound and (A-N) is +ve, no idler gear is used
If the gear train is simple and (A-N) is ve, two idle gear are used
If the gear train is compound and (A-N) is ve, only one idle gear is used

CLASS-10
5. Angular Indexing: The angular indexing is used to rotate the job through certain angle.
40 turns of crank makes the work rotate through one complete turn i.e., 40 turns of crank
make the work 360 degree.

Collets indexing fixtures offer a set number of angular positions which are very accurate.
The number of positions are usually governed by a row of precision ground holes or
notches in an indexing wheel that are engaged or disengaged with a set screw. The angle
of the holes or notches and the total number of them will always multiply to equal 360
degrees... one full rotation of arc. A common indexing fixture shown on the right has 24
notches and each notch is15 degrees apart.
Crank movement in angular indexing.
For each turn of the crank the crank will rotate by 360/40=9 degree.
Crank movement = angular displacement/140 (in degrees)
= angular displacement/ 240( in minutes)
= angular displacement of work/32400
(in seconds)

MACHINEING TIME CALCULATION IN MILLING