MILLING MACHINE
Milling Machine: Overview & Types
A milling machine is a power-driven tool used to remove material from a workpiece using rotating multi-point cutting tools. It can produce a variety of shapes, including flat surfaces, grooves, slots, and complex 3D profiles.
Types of Milling Machines
1️⃣ Column and Knee Type Milling Machine (Most Common)
- Horizontal Milling Machine: The spindle is horizontal, suitable for heavy-duty milling.
- Vertical Milling Machine: The spindle is vertical, used for precise cutting and shaping.
- Universal Milling Machine: Can perform both horizontal and vertical milling.
2️⃣ Bed Type Milling Machine
- Heavy-duty, designed for large workpieces.
- Table moves only in the longitudinal direction.
3️⃣ Planer Type Milling Machine
- Similar to a planer machine, but with a milling tool.
- Used for heavy and large workpieces.
4️⃣ CNC Milling Machine
- Fully automated, controlled via computer programs.
- Used for high-precision and complex machining.
5️⃣ Special Milling Machines
- Rotary Table Milling Machine: For circular workpieces.
- Drum Milling Machine: For mass production.
- Tracer Controlled Milling Machine: Used for duplicating profiles.
Up Milling vs. Down Milling
1. Up Milling (Conventional Milling)
✅ Cutter rotates opposite to the feed direction.
✅ Chips start thin and become thicker.
✅ Requires more cutting force, leading to tool wear.
✅ Used for hard materials (e.g., cast iron).
2. Down Milling (Climb Milling)
✅ Cutter rotates in the same direction as the feed.
✅ Chips start thick and become thinner.
✅ Produces a better surface finish.
✅ Less tool wear, but requires a rigid machine setup.
✅ Used for soft materials (e.g., aluminum).
Milling Operations
1️⃣ Plain Milling (Slab Milling): Producing flat surfaces parallel to the axis.
2️⃣ Face Milling: Cutting flat surfaces perpendicular to the spindle.
3️⃣ End Milling: Producing pockets, slots, and keyways using an end mill cutter.
4️⃣ Angular Milling: Cutting at an angle (e.g., dovetail or chamfer).
5️⃣ Form Milling: Producing irregular contours using a shaped cutter.
6️⃣ Gang Milling: Using multiple cutters at once for high productivity.
7️⃣ Straddle Milling: Cutting on both sides of a workpiece simultaneously.
8️⃣ Slot Milling: Creating slots and grooves.
9️⃣ Gear Cutting: Using specialized cutters to cut gears.
🔟 Thread Milling: Creating threads with a thread mill cutter.
