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.
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.
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.
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.
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.
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.
6) Form milling
Fig. illustrates the form milling operation. It is, a method of producing a surface having an irregular outline.
7) End milling
Fig. illustrates end milling operation. It is a method of milling slots, flat surfaces, and profiles by end mills.
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.
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.
10) T-slot milling
Fig. illustrates T-slot milling operation.
11) Keyway milling
Fig. illustrates keyway milling operation. keyways for shaft or hub is produced by this operations .
12) Gear cutting milling
Fig. illustrates gear cutting milling operation. Spur ,helical gears are cut on milling machine with help of indexing mechanism .
13) Flute milling
It is a method of grooving or cutting of flutes on drills, reamers, taps, etc,