Milling Machine Operations Using Milling Cutters With Diagrams

Milling machines are mostly general purpose and have wide range of applications requiring various types and size of milling cutters.
Intermittent cutting nature and usually complex geometry necessitate making the milling cutters mostly by HSS which is unique for high tensile and transverse rupture strength, fracture toughness and formability almost in al respects i.e. forging, rolling, powdering, welding, heat treatment, machining (in annealed condition) and grinding. Tougher grade cemented carbides are also used without or with coating, where feasible, for high productivity and product quality.
OPERATIONS PERFORMED ON MILLING MACHINE
Unlike a lathe, a milling cutter does not give a continuous cut, but begins with a sliding motion between the cutter and the work. Then follows a crushing movement, and then a cutting operation by which the chip is removed. Many different kinds of operations can be performed on a milling machine but a few of the more common operations will now be explained.
These are:
1) Plain milling or slab milling
Fig.illustrates the plain and slab milling operation. It is a method of producing a plain, flat, horizontal surface parallel to the axis of rotation of the cutter.
Plain Milling Or Slab Milling Operation 
Plain Milling Or Slab Milling Operation
2) Face milling
Fig.  illustrates the face milling operation. It is a method of producing a flat surface at right angles to the axis of the cutter.
Face Milling Operation 
Face Milling Operation


3) Side milling

Fig. illustrates the side milling operation. It is the operation of production of a flat vertical surface on the side of a work-piece by using a side milling cutter.
Side milling operation 
Side milling operation


4) Angular milling

Fig.  illustrates angular milling operation. It is a method of producing a flat surface making an angle to the axis of the cutter.
Angular Milling Operation 
Angular Milling Operation


5) Gang-milling

Fig.  illustrates the gang milling operation. It is a method of milling by means of two or more cutters simultaneously having same or different diameters mounted on the arbor of the milling machine.
Gang Milling Operation
Gang Milling Operation


6) Form milling

Fig.  illustrates the form milling operation. It is, a method of producing a surface having an irregular outline.
milling operation form milling
milling operation form milling


7) End milling

Fig. illustrates end milling operation. It is a method of milling slots, flat surfaces, and profiles by end mills.
End Milling Operations 
End Milling Operations


8) Profile milling

Fig.  illustrates profile milling operation. It is the operation of reproduction of an outline of a template or complex shape of a master die on a workpiece.
Profile Milling operations 
Profile Milling operations


9) Saw milling

Fig.  illustrates saw milling operation. It is a method of producing deep slots and cutting materials into the required length by slitting saws.
Saw Milling Operations 
Saw Milling Operations


10) T-slot milling

Fig. illustrates T-slot milling operation.
T-Slot Milling Operation 
T-Slot Milling Operation
11) Keyway milling
Fig.  illustrates keyway milling operation. keyways for shaft or hub is produced by this operations .
Keyway Milling Operation 
Keyway Milling Operation


12) Gear cutting milling

Fig.  illustrates gear cutting milling operation. Spur ,helical gears are cut on milling machine with help of indexing mechanism .
Gear cutting Milling Operation 
Gear cutting Milling Operation


13) Flute milling

It is a method of grooving or cutting of flutes on drills, reamers, taps, etc,
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