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Milling Machine

Milling Machine. Milling is the process of removing excess metal from a workpiece by using a rotating multipoint cutter called milling cutter. It differs from lathe & drilling machine in that here, the workpiece is fed against the rotating cutter.

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Milling Machine

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  1. Milling Machine • Milling is the process of removing excess metal from a workpiece by using a rotating multipoint cutter called milling cutter. • It differs from lathe & drilling machine in that here, the workpiece is fed against the rotating cutter. • Milling operation can be broadly classified as; • Peripheral milling: Here, the surface generated is parallel to the axis of rotation of the cutter. Ex: Horizontal milling machines (ii) Face milling: Here,the surface generated is perpendicular to the cutter axis. Ex: Vertical milling machines P R Venkatesh, Mech Dept, RVCE, B'lore

  2. Milling Cutters P R Venkatesh, Mech Dept, RVCE, B'lore

  3. Milling Machine • According to the relative motion between the cutter & the work, peripheral milling operations may be classified as; • Up milling or conventional milling • Down milling or climb milling. In up milling, the workpiece is fed in a direction opposite to the direction of cutter rotation. In down milling, the workpiece is fed in the samedirection as that of the rotating cutter. P R Venkatesh, Mech Dept, RVCE, B'lore

  4. Up Milling & Down Milling Down or Climb Milling Up or Conventional Milling P R Venkatesh, Mech Dept, RVCE, B'lore

  5. Up Milling Animation P R Venkatesh, Mech Dept, RVCE, B'lore

  6. Comparison between Up & Down Milling P R Venkatesh, Mech Dept, RVCE, B'lore

  7. Classification of Milling Machines Milling machines may be classified as; • Plain or Horizontal milling machine • Vertical Milling Machine • Universal Milling machine • Planer type milling machine • Profile cutting milling machine P R Venkatesh, Mech Dept, RVCE, B'lore

  8. Horizontal Milling Machine P R Venkatesh, Mech Dept, RVCE, B'lore

  9. Horizontal Milling Machine(Or) Knee & Column milling machine The principal parts of a milling machine are; • Base • Column • Knee • Saddle • Table • Spindle • Arbor • Over arm P R Venkatesh, Mech Dept, RVCE, B'lore

  10. Horizontal Milling Machine • Base: The lower part of the machine is the base and upon all other parts are mounted. • Column: The column is a vertical hollow casting which houses the driving mechanism. Its front face provides an accurate guide for vertical travel of the knee. P R Venkatesh, Mech Dept, RVCE, B'lore

  11. Horizontal Milling Machine 3. Knee: The upper surface of the knee is provided with guideways to mount the saddle. It can be moved up or down by an elevating screw. 4. Saddle: The saddle supports the table and provides transverse movement. It is guided by accurately machined surfaces of the knee. P R Venkatesh, Mech Dept, RVCE, B'lore

  12. Horizontal Milling Machine 5. Table: It is supported and guided by saddle ways and can travel longitudinally in a horizontal plane. T-slots are provided on the table to hold the work piece or vice. 6. Spindle: The spindle is a hollow shaft mounted on the bearings supported by column. The spindle is driven by an electric motor through a gear train. The front end of the spindle has a tapered bore to receive the arbor. P R Venkatesh, Mech Dept, RVCE, B'lore

  13. Horizontal Milling Machine 7. Arbor: It is a shaft with a straight body & a tapered shank which fits in the tapered hole of the spindle. The milling cutters are mounted on the arbor & the other end is mounted in a bearing housed in a projecting overarm. 8. Overarm: It is located on the top face of the column. It supports and guides the bracket housing the arbor. P R Venkatesh, Mech Dept, RVCE, B'lore

  14. Horizontal Milling Machine Horizontal milling machines may be used for operations such as cutting keyways, gear teeth, splines, etc. P R Venkatesh, Mech Dept, RVCE, B'lore

  15. Assembling arbor into spindle P R Venkatesh, Mech Dept, RVCE, B'lore

  16. Arbor for horizontal milling machine P R Venkatesh, Mech Dept, RVCE, B'lore

  17. Horizontal Milling Machine Animation P R Venkatesh, Mech Dept, RVCE, B'lore

  18. Vertical Milling Machine P R Venkatesh, Mech Dept, RVCE, B'lore

  19. Vertical Milling Machine P R Venkatesh, Mech Dept, RVCE, B'lore

  20. Vertical Milling Machine • In a vertical milling machine, the spindle is mounted with its axis vertical and hence perpendicular to the work table. • The column & the base are formed into an integral casting. • The knee supporting the saddle & the table moves up & down over the guideways with the help of elevating screw. • The upper part of the column is machined to receive the spindle head & motor. • The spindle head may be moved up & down to perform operations like grooving, slotting, facing, etc. P R Venkatesh, Mech Dept, RVCE, B'lore

  21. Universal Milling Machine P R Venkatesh, Mech Dept, RVCE, B'lore

  22. Milling Machine Opeartions The most common operations performed on a milling machine are as follows; • Plain or Slab milling • Angular milling • Form milling • Slot milling • Face milling • End milling P R Venkatesh, Mech Dept, RVCE, B'lore

  23. Slab Milling: It is a method of producing flat surfaces parallel to the cutter axis as shown in fig. The cutter has straight or helical teeth cut on the periphery of a cylindrical surface. P R Venkatesh, Mech Dept, RVCE, B'lore

  24. SLAB MILLING P R Venkatesh, Mech Dept, RVCE, B'lore

  25. Angular Milling: • It is used to produce tapered surfaces with various angles. • The cutter has teeth inclined to axis. • These are used to cut V-grooves, dovetail grooves, etc. P R Venkatesh, Mech Dept, RVCE, B'lore

  26. Form Milling: • It is a method of producing special profiles by using cutters having the shape corresponding the desired profile. • Used to produce concave, convex slots & gear teeth profiles. P R Venkatesh, Mech Dept, RVCE, B'lore

  27. Slot Milling: • It is a method of cutting grooves or slots in the workpiece. • It is done with a side milling cutter having cutting edges both on both the sides as well as on the periphery. P R Venkatesh, Mech Dept, RVCE, B'lore

  28. Face Milling: • It is a method of milling flat surfaces by cutters whose axes are perpendicular to milled surfaces. • It is carried out on a vertical milling machine. P R Venkatesh, Mech Dept, RVCE, B'lore

  29. End Milling: • It is a method similar to face milling but a smaller diameter cutter is used. • It is carried out on a vertical milling machine. • The end mill cutters will have cutting teeth both on the end & the periphery. P R Venkatesh, Mech Dept, RVCE, B'lore

  30. Straddle Milling: • In straddle milling, two parallel surfaces of a work piece can be milled simultaneously. • The two side milling cutters are spaced apart with collar to give the required space between them. P R Venkatesh, Mech Dept, RVCE, B'lore

  31. Gang Milling: • The operation of milling several faces at one pass of the cutters is called gang milling. • Two or more cutters are used on the same arbor to produce the desired shape as shown in fig. P R Venkatesh, Mech Dept, RVCE, B'lore

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