Study and Demonstration of Milling machine

Milling Machine Definition

The milling machine is defined as perhaps most widely used in manufacturing
industries after the lathe machine. 

However, In the case of lathe machine tools, the tools used there single-point cutting tools
but In the case of this machine, the tool used is multi-point cutting tools.

The milling is a process of metal-removing by feeding the workpiece passes through the
rotating multipoint cutter.

The diagram of the cutting operation is shown below:

This machine can hold one or more cutters

at a time and rotates at high speed to
remove the metal at a faster rate.

The metal removal rate is faster as

compared to a lathe machine.

This machine is used to make gears like

Spur gears, and also drill the workpiece
bore, and produce slots.
Milling machine cutter and workpiece position

Milling Machine Parts

A milling machine consists of the following parts:

Base
Column
Knee
Saddle
Table
Overhanging Arm
Spindle
Arbor
Arbor Supports
Milling Head
Ram

So let discuss all of these parts in detail.

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Base:

It is the foundation part of a machine and all other parts are joined on it.

The base carries the entire load so it should have high compressive strength and it is
made up of cast iron.

Column:

Column is mounted vertically on the base.

It supports the knee, table, etc., and works as housing for all the other driving members.

The column is a hollow member which contains driving gears and sometimes a motor for
the spindle and the table.

Knee:

It is a casting that supports the saddle and table. All gearing mechanism is enclosed
within the knee.

It is fastened to the column by dovetail ways.

The knee is supported and adjusted by a vertical positioning screw (elevating screw).

The elevating screw is used to adjust the knee up and down by raising or lowering the
lever either with the help of a hand or power feed.

Saddle:

This is placed between the table and the knee and works as an intermediate part
between them.

This can moves transversally to the column face.

This slides over the guideways provided situated on the knee which is perpendicular to
the column face.

The main function is to provide motion in a horizontal direction to the workpiece. This is
also made of cast iron.

Table:
This is a rectangular casting that is present on the top of the saddle and is situated over
the knee.

It is the part of a machine that holds the workpiece while machining.

This is made of cast iron and has T-slot cut over it. 

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This provides vertical motion by moving the knee up and down.

It provides horizontal motion by the feed screw.

This provides a horizontal (transverse) motion by moving the saddle.

Overhanging arm:

The overarm is used to fastened arbor support.

It may consist of one or two cylindrical bars that slide through the holes in the column.

It is made of cast iron.

Spindle:
The spindle is the main part of the machine which holds the tool in the right place.

This spindle provides the drive for arbors, cutters, and attachments used on a machine.

Arbor:
This is a mechanical part, which is used as an extension part of the spindle in a horizontal
mill machine.

It is fitted on the spindle whenever it's required.

This holds the tool and moves it in the correct direction.

Arbor Supports:

There are generally two types of arbor supports used in the mill machine.

The first one has a small diameter bearing hole, 1-inch in maximum diameter, and the
other one has a large diameter bearing hole, usually up to 23/4 inches.

The arbor support has an oil reservoir that lubricates the bearing surfaces.

It can be clamped anywhere on the overarm.

The arbor support is used only in the horizontal types of milling machines.

Milling head:
It is the upper section of a vertical mill machine.

It consists of a spindle, a driving motor, and other controlling mechanisms.

Ram:

One end of the arm is attached to the column and the other ends to the milling head.

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The ram can be moved transversally ( in and out) on the column by a hand lever.

Milling Machine Types

The types of milling machines are the following:

Column and Knee Type Milling

Vertical Milling
Horizontal Milling
Universal milling
Fixed Bed Milling
Simplex Milling
Duplex Milling
Triple Milling
Planer Milling
CNC Milling
Tracer Milling

Column and knee type milling machine:

It is a very common machine type.

In this machine, a vertical column is attached to the bed which consists of all gear drives
which rotate the knee and saddle.

A knee is situated on the base which provides vertical motion to the workpiece or which
moves up and down.

A saddle is attached to the upper section of the knee which can move in the transverse
direction.

The table is placed over the which can hold the workpiece by use of climbing bolts.

Column and knee type milling machine: diagram

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Vertical milling machine:

The spindle of this machine is in a vertical position.

No arbor is required in this machine.

The cutter tool has the cylindrical shape and the cutting edges are situated at the
circumference of the cylindrical face.

Verticle milling machine (Source: IndiaMart)

Horizontal milling machine:

As the name implies, the spindle is situated horizontally.

The spindle rotates horizontally.

An arbor is attached to the machine which holds the cylindrical disk shape cutter which
cuts the metal workpiece.

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 Horizontal milling machine (Source: IndiaMart)

Universal milling machine:

It is the same as the horizontal mill machine, except there is an arrangement of swings up
the table to 45 degrees in either direction.

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 Universal milling machine (Source: IndiaMart)

Operations that can be performed in a Milling Machine:

There are several types of operation that can be performed in a milling machine, and
those are:

Plain Milling Operation

Face Milling Operation
End Milling Operation
For Milling Operation
T-slot Milling Operation
Side Milling Operation
Gear Milling Operation
Straddle Milling Operation
Grooves Milling Operation
Gang Milling Operation

Plain Milling Operation:

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It is the operation of producing a plain, flat, horizontal surface, parallel to the axis of
rotation.

This operation is also known as slab milling.

This operation is very common and done in almost all jobs.

This can be carried out on every mill machine.

Plain milling operation diagram

Face milling Operation:

This machining operation is done on the surfaces which are perpendicular to the axis of
the cutter.

The operation is performed by the face milling cutter mounted on the stub arbor of the
machine.

Face milling operation diagram

End milling operation:

It is the process of producing flat surfaces which may be horizontal, vertical, and at an
angle taking worktable as a reference.

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 Diagram of End milling operation

Form milling Operation:

It is the process of machining a special contour (outline) composed of curves, straight

lines, or entirely of curves, at a single cut.

This operation is accomplished by using convex, concave, and corner rounding milling
cutters.

Form milling operation diagram

T-slot milling Operation:

It is the operation of producing the T-slots on the workpiece by using the T-slots milling
cutter.

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 T-slot milling operation diagram

Side milling Operation:

It is the operation of producing the flat vertical surface on the sides of the workpiece by
using a side milling cutter.

You can read the Milling cutter here in detail.

The cutter is having teeth on its face as well as its side.

Gear cutting Operation:

It is the operation of producing gear tooth on the gear blank by using a form-relieved
cutter in a milling machine.

The cutter profile is exactly matched with the tooth space of the gear.

Straddle milling Operation:

It is the operation of producing the flat vertical surface on both sides of the workpiece by
using two side milling cutters mounted on the same arbor.

The distance between the two cutters is adjusted by using a spacing collar.

This is commonly used to produce a hexagonal or square surface.

Grooves milling Operation:

It is the operation of producing the groove on the surface of the workpiece by using a
saw-milling cutter or end milling cutter.

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The workpiece is fixed firmly on a milling machine and fixing the end milling cutter on an
arbor, by adjusting the depth of cut, the work is fed against the cutter to cut the groove on
the work surface.

Gang milling Operation:

It is the machining process in which two or more milling cutters are used together to
perform different milling operations simultaneously.

In gang milling, the cutters are mounted on the arbor.

The advantages of the Milling machine:

In the milling machine there are the following advantages, those are:

Ideal for the production of individual pieces and small batches.

Capable of producing complex shapes with the use of multitooth, as well as a single
point, cutting tools.
Operation cost can be very modest given general-purpose equipment and cutters
are used.

Milling Machine Disadvantages:

These are the following disadvantages of a milling machine:

It is more costly than casting, cold forming, extrusion, etc. If these processes can
provide the flatness, surface finish and dimensional accuracy required for the part.
For mass production, it becomes economically necessary to use special-purpose
machines.
They may cost millions of dollars but the cost is justifiable when handling labor
which is virtually eliminated and machining accuracy and repeatability is ensured.

The applications of Milling Machine:

These are the following applications of the milling machine:

This machines used to making gears.

Usually used to a machined flat surface but can also produce irregular surfaces.
Used to produce the groove or slot.
Modern mill machine cut superalloys, titanium, tensile steel to closer tolerance, a
greater accuracy, and faster rate.
This machine is used to design of metal and other materials.

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