11

MILLING MACHINES

1.1 INTRODUCTION

Amilling machine is a machine tool that removes metal as the work is fed
inst a rotating multipoint cutter. The cutter rotates at a high speed and
hecause
be
of the multiple cutting edges it removes metal at a very fast rate.
The machine can also hold one or more number of cutters at a time. This is
in
whya milling machine finds wide application production work. This is
superior to other machines as regards accuracy and better surface finish,
andis designed for machining a varicty of tool room work.
Thefirst milling machine came into existence in about 1770 and
de
was of French origin. The milling cutler was first developed by Jacques
machine
Vaucanson in the year 1782. The first successful plain milling member
R Brown a
was designed by Eli Whitney in the year 1818. Joseph
the first universal milling
ofBrown and Sharpe Company invented
machine in the year 1861.

112 TYPES OF MILLING MACHINE

covering a wide
may be classified
in several form
ne milling machine machine is
the choice of any particular
Tange of work and capacities, but undertaken both in
the of the work to be
nature
etemined primarily by The usual classifications
and operation to be performed.
iallon to the size machine are
dccordingto the general design of the milling

1. Column and knee type.

machine.
(a) Hand milling
(b) Plain milling machine.
machine.
() Universal milling machine.
(d) Omniversal milling
(e) Vertical milling machine.
 TECHNOLOGY

WORKSHOP

ELEMENTS
OF

398
398
bed type.
of fixed
Manufacturing
machine.

2. milling
Simplex
(a) milling
machine.
Duplex
(b) milling
machine.

(c) Triplex
3. Planer type.
4 . Special type. machine.
table milling
(a) Rotary machinc.

Drum milling
((b)
c ) P l a n e t a r ym i l l i n g m a c h i n e .

& tracer controlled milling machi.

chine.
(d) Pantograph, profiling

shopwork the most

commonlu
: For general used
Column and
knee type
where the table
is mounted on the
and knee type nee
is the column
mounted on the
vertical slides of the main n. columa
which in turn is the
casting column so that table can he
knee is vertically adjustable on the be
The work of various heights. The columa
to accommodate
moved up and down to the varios
machines are classified according
and knee type milling
different movements of the table
methods of supplying power to the table,
and different axis of
rotation of the main spindle. Fig.11.1 illustrates a

column and knee type milling machine.

0 12

-14

16

3/
15

Figure 11.1 Column and knee

1.
Base, 2. Elevating serew, 3. Knee, 4. Kneetype milling machine ssfeed
elevating handle, 5. Cr
handle,6. Saddle, Table, 8. Front brace, 9. Arbor
support, 10. Conepu
Telescopic feed shaft.
 MILLING MACHINES 399

ing m
Head milling machine: The simplest of all types of milling machine is
hand niller in which the feeding movement of the table is supplied by
the
tne control. The cutter is mounted on a horizontal arbor and is rotated by
h a n dcontrol.

power, The
The machine is relatively smaller in size than that of other types
po is particularly
and is particu suitable light and simple milling operations such as
for
machining slots, grooves and keyways.

atain milling machine: The plain milling machines are much more rigid
and sturdy than hand millers for accommodating heavy workpieces. The
and sturdy
milling machine table may be fed by hand or power rotating
against a

cutter
ut mounted on a horizontal arbor. A plain milling machine, having
horizontal spindle, spindle milling machine: In a
is also called horizontal
machine, the table may be fed in a longitudinal, cross or
plain milling when the table is moved at
vertical directions. The feed is longitudinal is moved parallel to
rightangles spindle, it is cross when the table
to the
is adjusted in the
the spindle, and the feed is vertical when the table
vertical plane.
named
universal milling machine is
so

Universal milling machine:A A

to a very wide range of miliing operations.
because it may be adapted
can be distinguished
from a plain milling
machine
universal milling machine is mounted on a
of universal milling
machine in that the table
a
graduations, and the tale can be
base which has degree
circular swivelling 45° on either side of the
normal position. The
swivelled to any angle upto axis and set an angle
other than
about a vertical
table can be swivelled Thus in a universal milling machine, in addition
rightangles to the spindle. in a plain milling
machine, the table
movements as incorporated
to the millingg
to three movement when it is fed at an angle
fourth
may have a feature enables it to perform
helical milling
cutter. This additional done on a
machine unless a spiral
plain milling
which cannot be machine is
operation of a universal milling
is used. The capacity
milling attachment the use of special
attachments such dividing
as

considerably increased by attachment, rotary

attachment, slotting

index head, vertical milling twist

heador machine can produce spur, spiral, bevel gears,
attachment, etc. The conventional milling
cutters, etc. besides doing all
dills, reamers, milling with advantage for any and every type
also be employed A
operations.. It may on a shaper or on
a drill press.
can be perfomed
of operations that a tool room
machine designed
therefore, essentially
universal machine is,
accurate work.
to produce a very
 400 ELEMENTS OF WORKSHOP TECHNOLOGY

Comparison between plain and universal milling :

1. The plain milling machine is provided with three table

movements: longitudinal, cross and vertical, whereasa universal
milling machine has a fourth movement of the table in addition
to the above three. The table can be swivelled
can be fed at an angle to the
horizontally
and
milling machine spindle.
2. The universal milling machine is
provided with auxiliaries such
as dividing head
equipment, vertical milling attachment, rotary
table, etc. These extras and the special of the
design machine
itself make it possible to produce
spur, spiral bevel gears, twist
drills, reamers, milling cutters and all types of
and shaping operations. milling, drilling
3. The plain milling machine is more rigid and heavier in
construction than a universal machine of the same
intended for heavier milling size, and is
operations. The plain type is
particularly adapted for manufacturing operations, whereas the
universal machine is intended more for tool room work and for
special machining operations.
Omniversal milling machine In this machine, the table
:
besides having
allthe movements of a universal milling machine, can be tilted in a vertical
plane by providing a, swivel arrangement at the knee.
Also the entire knee
assembly is mounted in such a way that it may be fed in a.
direction horizontally. The additional longitudinal
enables it to machine swivelling arrangement of the table
taper spiral grooves in reamers, bevel
essentially a tool room and experimental shop machine.
gears, etc. It is

Vertical milling machine A

vertical milling machine
distinguished from a horizontal milling machine
can be
spindle which is vertical or by the position of its
may be of plain or universal perpendicular to the work table. The
machine
for proper type and has all the movements of
setting and feedingg the work. The the table
clamped to the vertical column may be spindle head which is
the milling cutter swivelled at an
angle,
mounted on the permitting
some machines, the spindle can spindle work on angular surfaces.
to
In
work. The machine is also be
adjusted up or down relative to the
Surfaces. The end millsadapted for machining grooves, slots, and
and face flat
mounted on the
spindle. The Fig.11.2 milling cutters are
illustrates a vertical
the usual
tools
milling machine.
 Manufacturing or ING N
LNG MACHINES
Manulactunng
The fixed bed
or Dxed
type
bed type ACHINES 401
type
machines are
comparativelymilling
heavy, and rigid and large
radically from column and differ
type milling machines
knee
by the
construction of its table
The table is mounted mounting.
the ways of fixed [Link] on
The table
movement is
restricted to
reciprocation at
right angles to the
spindle axXis with no
provision
for
cross or vertical
adjustment. The
cutter mounted on the spindle head Figure 112 Vertical milling
may be moved vertically on the machine
column, and the spindle may be 1. Base, 2.
Saddle, 3. Table, 4.4.
Spindle
adjusted horizontally to
provide
heed, 5. Column.
cross adjustment. The name
simplex, duplex and triplex indicates that
machine is provided with single, double and triple
the
spindle heads
respectively. In a duplex machine, the spindle heads are arranged one on
each side of the table. In triplex
type the third spindle is mounted on a
cross rail. The usual feature of these machines is
the automatic cycleThe
of
operation for feeding the table, that is repeated in a regular sequence.
feed cycle of the table includes the following: start,
rapid approach, slow
feed for cutting, rapid traverse to the next workpiece, quick retum and
stop. This automatic control of the machine enables it to be used with
advantage in repetitive type of work. Fig.11.3 illustrates a bed type milling
machine.

Figure 1 1 4 Plano-miller
machine
Figure 113 Bed type milling
 TECHNOLOGY
402 ELEMENTS OF WORKSHOP

Planer type: The plano-miller, as it is called, is a massive machine buit

work, having spindle heads adjustable in vertical in

up for heavy duty
transverse directions. It resembles a planer and like a planing machine,

has a cross rail

capable of being raised or lowered carrying the cutters theie
heads, and the saddles, all supported by rigid uprights. There may be a
number of independent spindles carrying cutters on the rail as well as two
heads on the uprights. This arrangement of independently driving multiple
cutter spindles enables number of work surfaces to be machined
simultaneously, thereby obtaining great reduction in production time. The
essential difference between a planer and a plano-miller lies in the table
movement. In a plancr, the table moves to give the cutting speed, but in a
plano-milling machine the table movement gives the feed. Hence the table
movement in a plano-milling machine is much slower than that of a
planing machine. Modern plano-millers are provided with high power
driven spindles powered to the extent of 100 h.p. and the rate of metal
moval is tremendous. The use of the machine is limited to production
work only and isconsidered ultimate in metal removing capacity. Fig.11.4
illustrates a plano-miller.

Special type Milling machines of non-conventional design have been

developed to suit special purposes. The features that they have in common
are the spindle for rotating the cutter and provision for moving the tool or
the work in different directions. The following special types of machines
of interest are described below:
Rotary table machine: The construction of the machine is a
modification to a vertical milling machine and is
flat surfaces at
adapted for machining
production rate. The face milling cutters are mounted on
two or more vertical spindles and a number of workpieces are
clamped on
the horizontal surface of a circular table which
rotates about a vertical
The cutters may be set at different axis.
one of the cutter is
heights relative to the work so that when
roughing the pieces, the other is finishing
them. A
continuous loading and unloading of
workpieces
operator while the milling is in progress. may be carried out by the
Drum milling machine: The drum
rotary table milling machine in that its milling machine is similar to isa
called a drum, Rotates in a
horizontal
work-supporting table, which
mounted on axis. The face milling cutters
three or four spindle heads rotate in a horizontal axis and
remove
The
metal from
workpieces supported on both the faces of the drum.
finished machined
parts are removed after
drum, and then the new ones one
complete turn ot the
are
clamped to it.
 MILLING MACHINES 403

Planetary milling machine: In a planetary milling

work is held stationary while the revolving cutter or cuttersmachine, the
move in a
planetary path to finish a cylindrical surface on the work either
or externally or simultaneously. The machine is
internally
particularly adapted for
milling internal or extenal threads of different pitches.
Pantograph milling machine A pantograph machine can
duplicate a job by using a pantograph mechanism which permits the size of
the workpiece reproduced to be smaller than, equal to or greater than the
size of a template or model used for the purpose. A pantograph is a
mechanism that is generally constructed of four bars or kinks which are
joined in the form of a parallelogram. Pantograph machines are available
in two dimensional or three dimensional models. Two dimensional
for engraving letters
pantographs are
used other designs, whereas three
or
dimensional models are employed for copying any shape and contour of
the workpiece. The tracing stylus is moved manually on the contour of the
model to be duplicated and the milling cutter mounted on the spindle
moves in a similar path on the workpiece. reproducing the shape of the
model.
machine duplicates the full size of
Profiling machine : A profiling
the template attached to the machine. This is practically a vertical milling
in which the spindle be adjusted vertically and
machine of bed type can

the cutter head horizontally across the table. The movement of the cutter
is

follows the
regulated by a hardened guide pin. The pin is held against and
on the table at the side of the job.
outline or profile ofa template mounted
movement of the table and crosswise movement of
the
The longitudinal
cutter head follow the movements of the guide pin on the template.
Tracer controlled milling machine: The tracer controlled milling

irregular or complex shapes of dies,

moulds. by etc.
machine reproduces
cutter and tracing element. The feeding
synchronized movements of the means of a stylus that
motion of the machine is controlled automatically by
or a contoured model
which is to be reproduced.
scans a profiled template in turn
energizes an oil relay system which
The movement of the stylus
for the table. This arrangement is
operates the main hydraulic system
termed as servomechanism.

113 PRINCIPAL PARTS

machine illustrated
column and knee type milling
The principal parts of a
in Fig.11.1 are
 TECHNOLOGY
WORKSHOP
ELEMENTS OF
404
accurately machined
machine is a grey iron casting
Base: The base of the as a
foundation member for all the
bottom surface and serves
on its top and carries the column
at its one end. In some
rest upon it. It
other parts which as a reservoir
serves
for cutting fluid.
hollow and
machines, the base is
mounted vertically on
column is the main supporting frame
Column: The ribbed inside and houses all
The column is box shaped, heavily
the base. feed. The front vertical
for the spindle and table
the driving mechanisms with dovetail
machined and is provided
face of the column is accurately
column is finished to
for supporting the knee. The top of the
guideways machine.
outward at the front of the
hold an overam that extends

slides up and down on the

Knee: The knee is a rigid grey iron casting that
of height is effected by
vertical ways of the column face. The adjustment
on the base that also supports the
knee. The
an elevating screw mounted
different controls to
knee houses the feed mechanism of the table, and
saddle to
operate it. The top face of the knee forms a slideway for the
table.
provide cross travel of the

Table: The table rests on ways on the saddle and travels longitudinally.
The top of the table is accurately finished and T-slots are provided for
clamping the work and other fixtures on it. A leadscrew under the table

engages a nut the saddle to move the table horizontally by hand or

on
power. The longitudinal travel of the table may be limited by fixing trip
dogs on the side of the table. In universal machines, the table may also be
swivelled horizontally. For this purpose the table is mounted on a circular
base, which in its turn is mounted on the saddle. The circular base is
graduated in degrees.

Overhanging arm : The overhanging arm that is mounted on the top of

the column extends beyond the column face and serves as a
bearing
support for the other end of the arbor. The arm is adjustable so that the
bearing support may be provided nearest to the cutter. More than one
bearing support may be provided for the arbor.

Front brace: The front brace is an extra support that is fitted between the
knee and the overarm to ensure
furtier rigidity to the arbor and the knee.
The front brace is slotted to allow
for the adjustment of the
knee relative to the overarm. height of the
 MILLING MACHINES 405

Spindle: The spindle of the machine is located

in the upper part of the
column and receives power from the motor through belts, gears, clutches
and transmit it to the arbor. The front end of the spindle just projects from
the column tace and is provided with a tapered hole into which various
cutting tools and arbors may be inserted. The accuracy in metal machining
by the cutter depends primarily on the accuracy, strength, and rigidity of
the spindle.

Arbor: An arbor may be considered as an extension of the machine

spindle on which milling cutters are securely mounted and rotated, The
arbors are made with taper shanks for proper alignment with the machine
spindles having taper holes at their nose. The taper shank of the arbor
conforms to the Morse taperor self release taper whose value is 7:24. The
arbor may be supported at the farthest end from the overhanging arm or
arbor. According to the
may be of cantilever type which is called stub
shanks are available
Indian standard specification, arbors with Morse taper
from 16 to
from 13 to 60 mm in diameter and arbors with self release type
available from 13 to 16 mm in
100 mm in diameter. The stub arbors are the spindle taper
diameter. The arbor shanks are properly gripped against of the hollow spindle
by a draw bolt 7 which extends throughout the length
hole of the
The threaded end of the draw bolt I is fastened to the tapped
3. the spindle. This
arbor shank 5 and then the locknut 2 is tightened against
the
the arbor shank to be pulled inside gripping it firmly against
causes 4 for imparting
of the spindle. The spindle has also two keys
taper hole friction developed in the taper
to the arbor in addition to the
positive drive arbor is effected by unscrewing
the locknut 2
surfaces. The ejection of the
45
3

Arbor assembly
Figure 115 block, 5. Arbor,
6. Setscrew,
4. Key
Locknut, 3. Spindle, 9. Bearing bush,
1. Draw bolt, 2. 8. Cutter
7. Spacing collars,
406 ELEMENTS OF WORKSHOP TECHNOLOGY

and then rapping the draw bolt 7 lightly. The cutter 8 is set at the required
position of the arbor by spacing collars 7 or spacers of various lengths but
of equal diameter. The entire assembly of the milling cutter and the spacers
are fastened to the arbor by a long key. The end spacer 9 on the arbor is
slightly larger in diameter and acts as a bearing bush for bearing support
which extends from the overarm. The whole set up is locked from the end
by the arbor nut. Fig.11.5 illustrates an arbor assembly the draw bolt
arrangement for locking the arbor with the spindle.
 ATTACHMENTS
11.8 MILLING MACHINE

devices intended to be
The attachments are standard or special auxiliary
more components of the milling machine
fastened to orjoined with one or
for the purpose of augmenting the range, versatility, productivity or

Some classes of milling machine attachments are

accuracy of operation.
the cutter by altering the cutter axis and
used for positioning and driving
classes are used for positioning, holding
and feeding
speed, whereas other
 412 ELEMENTS OF WORKSHOP TECHNOLOGY

the work along a specified geometric path. The following are the different
attachments used on standard column and knee type milling machine.

Vertical milling attachment: A vertical milling attachment can convert a

horizontal milling machine into a vertical machine by orienting the cuting
spindle axis from horizontal to vertical for performing specific operations.
The attachment consists of a right angle gear box which is attached to the
nose of the horizontal milling machinespindle by bolting it on the column
face. The speed of the vertical spindle is same as that of the machine
spindle. The attachment with the spindle can also be swivelled at any angle
other than at right angles to the table for machining angular
surfaces
Universal milling attachment: The attachment is similar to the vertical
milling attachment but it has an added arrangement for swivelling the
spindle about two mutually perpendicular axes)This feature of the
attachment the cutting spindle axis to swivel at practically
pemits any
angle and machine any compound angular surface of the work The
attachment is supported by the angular surface of the workThe
attachment is supported by the overarm and operates at either the
speed or at higher speed than the machine spindle.

High speed milling attachment: The attachment consists of a gearing

arrangement enclosed within its casting to increase the regular spindle
speeds by four to six times. This is for operating smaller diameter of
milling cutters efficiently and at the proper cutting speed. The attachment
is bolted to the face of the column and enables the cutters to be operated at
speeds beyond the scope of the machine.

Slotting attachment A slotting attachment converts the rotary motion of

the spindle into the reciprocating motion of theram by means of an
eccentric or crank housed within the attachment Thus a milling machine
can be converted into a slotter by accepting a single point slotter tool at the
bottom end of the ram and is
conveniently used for cutting intemalor
extemal keyways, splines, etc. The attachment is bolted on the face of the
column and can also be swivelled at an angle of machining
angular
surfaces. The length of stroke of the ram can also be
adjusted.
Universal spiral milling attachment : The universal
attachment may be used in a plain milling machine or inspiral
milling
a universal
milling machine for cutting a spiral groove on a cylindrical workpiece. The
attachment is bolted on the face of the column and its
spindle
head maybe
 MILLING MACHINES 413
wivelled in a vertical or horizontalplane. While using on a plain milling
chine,
machine, the cutter mounted on the attachment
may be swivelled to the
required helix angle tor cuttingg a
spiral similar to the swivelling of the
tohle of a universal milling machine. The attachment
is used in a universal
milling machine for cutting spiral grooves having a helix angle of more
than 45 , which is the maximum limit of swivelling the table.

Rack milling attachment: A rack milling attachment is bolted to the face

of the column and is used for cutting rack teeth on a job mounted on the
table. The attachment consisting of a gear train enables the spindle axis to
be oriented at right angles to the machine spindle in a horizontal plane.
The successive rack teeth are cut by using a rack indexing attachment. The
shanted rack teeth or a skew rack may be machined where the table may be
swivelled to the required helix angle.

Circular milling attachment A circular milling attachment or a rotary

table is a special work holding device which is bolted on the top of the
machine table)1t provides rotary motion to the workpiece in addition to the
cross and vertical movements of the tableThe attachment
longitudinal,
base.
consists of a circular table having T-slots mounted on á graduated
The circular table may be rotated by hand, and in special cases bymachine
power

by linking the rotary table driving mechanism with theattachment

leadscrew. The driving mechanism of a circular milling
fitted with the
consists of a vertical shaft which keyed to a worm gear
worm gear and imparts
circular table. A horizontal worm meshés with the
worm is rotated? The surface
of any
rotary movement to the table when thé three or four
of workpiece can be generated by combining
profile a
the attachment? In some of
movements of the table and rotary movement of
index plate is provided on the
the circular milling attachments an
spaced slots or grooves on the
horizontal worm shaft for milling equally
periphery of a workpiece.

attachment also a special

head is

Dividing head attachment:/a dividjng machine The work may

deyice which is bolted on the table
work holding head spindle or may be
be mounted on a chúck fitted on the dividing is mounted
dead centre
dead [Link]
Supported between live and a
a
table
in a lathe tailstock that is bolted on the machine
on a footstock as
axis with the dividing head spindle, The
after correctly aligning its spindle in
used for dividing the periphery of a workpiece
attachment is principally
number of divisions for machining equally
spaced slots or grooves.
cqual mechanism of the attachment
can be

Dhe worm and worm gear driving

414 ELEMENTS OF WORKSHOP TECHNOLOGY

linked with the table leadscrew for cutting equally spaced helical grooves
on the periphery of a cylindrical [Link] actual construction and
operation of a dividing Art.12.6.
head has been described in
 MILLING MACHINES 417
11.10 STANDARD MILLING CUTTER

There are many different types of standard

milling cutters. They are
classified below:

1 Plain milling cutter.

(a) Light duty plain milling cutter.
(b) Heavy duty plain milling cutter.
(c) Helical plain milling cutter.
2 Side milling cutter.
(a) Plain side milling cutter.
(b) Staggered teeth side milling cutter.
(c) Half side milling cutter.
(d) Interlocking side milling cutter.
3. Metal slitting saw.
(a) Plain metal slitting saw.
(b) Staggered teeth metal slitting saw.
4. Angle milling cutter.
(a) Single angle milling cutter.
(b) Double angle milling cutter.
5. End mill.
(a) Taper shank end mill.
(b) Straight shank end mill.
(c) Shell end mill.
6. T-slot milling cutter
7 Woodruff key slot milling cutter
8. Fly cutter.
9. Formed cutter.
(a) Convex milling cutter.
(b) Concave milling cutter.
(c) Corner rounding milling cutter.
(d) Gear cutter
() Thread milling cutter.
10. Tap and reamer cutter.

ainmilling cutter: The plain milling cutters are cylindrical in shape

and have teeth on the circumferential surface only. The cutters are
ntended for the production of flat surfaces parallel to the axis of rotation
or the spindle. The cutter teeth may be straight or helical according to the
Ze of the cutter. Fig.11.17 illustrates a straight teeth plain milling cutter.
ery wide plain milling cutters are temed as slabbing cutter. These
 TECHNOLOGY
ELEMENTS OF WORKSHOP
418

have nicked teeth.

The nicks
cutters
distributed on the
are uniformly
The
entire periphery of the cutter.

to break the
object of the nicks is
and enable the cutter to take a
chips
coarse feed. The plain milling cutters
areavailable in diameters from 16 to
160 mm and the width of the cutters
range from 20 to 160 mm. Fig.11.18
illustrates a helical plain milling
Figure 11.17 Straight teeth plain
milling cutter
cutter. The different varieties of
plain milling cutters are described below:
Light duty plain milling cutter: The light duty plain milling cutters
have face width less than 20 mm and are made with straight teeth parallel
to the axis. The wider cutters are made with helical teeth, with helix angle
of less than 25 These are relatively fine tooth cutters.
Heavy duty plain
milling cutter The heavy
duty plain milling cutters are
wider cutters and are used for
heavy duty work. The helix
angle of the teeth ranges fromn
25 to 45°. The cutters have
fewer teeth on the periphery
and that increases chip space
permitting them to take
Figure 11.18 Helical plain milling cutter
deeper cuts. They are als0
sometimes called coarse tooth
milling cutters.
Helical plain milling cutter: The helical plain milling eutters have
further coarse pitch and the
helix angle of the teeth
ranges
from 45° to 60°, The cutter is
useful in profile milling work
due to its smooth
cuiting
action and is adapted for
taking light cuts on soft steel
or brasS and
where wide
surfaces are to be maintained.
 MILLING MACHINES
419
ling cutter: The side milling cutters
Side millin
or both of its
have teeth on its
sides. side milling cutters periphery
one
also on The
and
and
metals from the side of a work. are intended
for removing
e cutter.
illing cutter. The side milling cutters are Fig.11.19 illustrates a side
mil width of the cutter ranges available
mill

and the from 50 to 200 mm in

diameter
from 5 to 32 mm. The
typesof side milling cutters are described below: different

Plain side milling cutter The plain side

straight circumterential teeth and have side teeth milling cutters have
both of its sides. Two
on
r more such cutters may be mounted on the arbor and different faces of
the workpiece may be machined simultaneously.
Staggered teeth side milling cutter: The staggered teeth side
milling cutters have alternate
teeth with opposite helix angle.
This design of the cutter teeth
increases the chip space to a
great extent. The cutter is suitable
for milling deep, narrow slots or
key ways on workpieces.
Fig.11.20 illustrates a staggered
teeth side milling cutter.
Half side milling cutter Figure 11.20 Staggered teeth side
The half side milling cutters have milling cutter
straight or helical teeth on its
The peripheral teeth
Circumferential surface and on one of sides only.
its
the actual cutting, whereas the side teeth size and finish the work. While
do mounted on the
milling, when two half side milling cutters are
straddle two end faces of the work
arbor at a fixed distance apart to mill the
having right hand helical
chosen with one
Simultaneously, the cutter are counter-balance the end thrust
hand helix to
eeth and the other having left
on the arbor.
cutter: The interlocking side milling
Interlocking side milling cutters or two staggered
Cutters are formed out of two half side milling fom one unit. The
which are made to interlock to
ctn side milling cutters of alternate helix.
The paths of the

two cutters may be plain

or
the wider slots of
accurate
O used for milling
cutters are
n overlap when the cutter may be varied by inserting spacers o
wIdth, The width of the This feature
the cutter.
halves of
the two after repeated
Dutable thickness between accurate width e v e n
an with a
the cutter to maintain 10 to 32 mm
es ranges
from
width of the cutter available in
e n i n g . The mm. The cutters are
of 4
to the maximum
olOle adjustment
 ELEMENTS O F WORKSHUF

420
illustrates an interlockod
cked
Fig.l1.21
50 to 200 mm.

diameters ranging from

side milling cutter.

Metal slitting saw

The metal slitting

saws resemble a
plain milling cutter

or a side milling
cutter in appearance
but they are of very TYPE B

small width. The -

cutters are used for

parting-off operation
Figure 11.21 Interlocked side milling cutter
or for slotting. D. Nominal diameter, di. Boss diameter,
Fig.11.22 illustrates d. Bore diameter, b. Cutter width
a metal slitting saw.
The different types of metal slitting saws are described below.
Plain metal slitting saw: The plain metal slitting saws are thinner
in construction and the width of the
cutter is limited to 5 mm. The sides
of the cutter is relieved in order that
the side faces may not rub against
the work.
Staggered teeth metal
slitting saw: The staggered teeth
metal slitting saws resembe a
staggered teeth side milling eutter,
but the width of the cutter is l1mited
to 6.5 to 7 mm. The cuter is used for
heavy sawing in steel.
Figure f1.22 Métal sliting saw
Angle milling cuter: The angle miling cnuers are made as single or
double angle cutters and are used to machine angles other than 90°-The
cutting edges are fornmed at theconical surface around the periphery of the
cutter. The different types of angle
míllig cutters are deseribed below.
Single angle milling cutter :The singBé
illusrated in Fig]1,23 haye teeth on the conical orangle milling cutters
cutter and also on the large flat side. The angular face of the
by the included angle between the conicalangle of the cutter is designated
the face and the
having different included angles large
cutter. The cutters flat face of
of 309, 45, 60
 MILLING MACHINES 421

65, 70, 75,

80° and 85 are
ailable with diameter of 50 mm

and width of
and w 12 mm. There are

another set of cutters having the

same range of included angle, but
the diameter of the cutters is 63
mm. There is a
mm and width 28
third set of cutters having included
angle of 78, 75 and 80° degrees,
all having 63 mm in diameter and
Figure 11.23 Single angle milling
28 mm in width. cutter
Double angle milling cutter
: The double angle milling cutters illustrated in Fig.1.24 have V-shaped
teeth with both conical
surfaces at an angle to their
end faces. The angle of CHAMFERED-
teeth may not be
symmetrical with respect to
a plain a right angles to the
cutter axis. The
unsymmetrical double
available
angle cutters are
in diameters of 50, 63, 80,
and 100 mm and their
width varies from 12 to 36
cutters are
mm. The
different Figure 11.24 Double angle milling cutter
availablein Diameter of bore,
60, D. Diameter of cutter, d.
included angles of 55, b. Width, C. Dimension, a, B. angles
65, 70, 75 , 80, 85, 90,
and 100 degrees. The trom 56 to 100 mm having
cutters are
availabie diaeters
in be
cqual angle 28 m m . The included angle of the cutter may

from 10 to used for

width ranging double angle milling cutters are mainly
90. The
45, 60° o r on a picce
of blank.
grooves
cutting spiral
on the end as well as on the
tecth
The end mills have cuting helical and
End mill: The peripheral teeth may be straight
or

of the cutter. used for light

periphery hand or left hand. The end mills are

helix may
be right accurate holes, producing
the
operations like cutting slots, machining Various types of
milling
surfaces and for profile milling operations.
ow flat
 TECHNOLOGY

ELEMENTS OF WORKSHOP
422

shown in
end mills are
end teeth on
of end
Fig.11.25. The different types Two-flute
described below
mills are end mill: The
Taper shank
end mills have a tapered
taper shank
shank or extension on one end for

mounting and driving the cutters. The

Four-flute
fluted or
cutters may be double Gashed-end
multiple fluted. The taper shank end
mills are available from 10 to 63 mm in
diameter and may have tanged end or
tapped end for mounting on the arbor.
The taper shanks conform to the Morse
taper No.5. Fig.11.26 illustrates a taper Centre-cutting
shank end mill.

Straight shank end mill: The

straight shank mills have round shanks
for mounting and driving the cutters
The cutter teeth may be straight or Figure 1125 Types of end teeth
helical. The diameter of the cutter ranges from 2 to 63 mm. Fig.11.27
illustrates a straight shank end mill.

Figure 11.26 Taper shank end mill

Figure 11.27 Straight shank end mill

Shell end mill: The shell end mills are larger and
provided with a central hole for mounting the heavier end mills
design of the cutter gives cutter on a short arbor. This
different diameters may be economy in tool material as the cutters having
edges are provided at the endinterchanged
and around
on a single shank. The cutting
the
periphery of the cutter. tnc
 MILLING MACHINES 423
teeth may be straight
or helical and may
be left or right
handed. Face
milling operations
are usually
performed with
these cutters. The
diameter of cuters -o-5

ranges from 40 to
160 mm and width
from 32 to 50 mm. Figure 11.28 Shell end mill
Fig.11.28 illustrates D. Diameter of cutter, d. Diameter of bore,b. Width,
shell end mill. d, da, d3. Diameters, b,, b2. Widths.

The T-slot
T-slot milling cutter:
cutters are special form of
milling
end mills for producing T-slots.
illustrates a T-slot and
Fig.11.29
dovetails slot milling cutter. The
teeth are provided on the periphery
as well as on both sides of
the
cutter.

Woodruf key slot milling cutter Figure 11.29 Slot milling cutters
A. T-slot milling cutter, B. Dovetail
The woodruff key slot milling
small standard cutters slot milling cutter.
cutters are

similar in construction to a thin -2 -3

small diameter plain milling
intended for the
cutter,
production of woodruff key
slots. The cutter is provided
shank and may have
with a
teeth.
straight or staggered
cutters are
Flycutter: The fly
simplest form of cutters and are
mainly used in experimental
works. Fly cutter
shops or in tool room Figure 11.30
Arbor
The cutter consists of a single screw, 2. Tool, 3.
1. Clamping
to
point cutting tool attached
 424
arbor. The
the end of an

be formed
cutting edge may
to reproduce contoured

The cutter may be

surface.
emergency
considered as an
the standard
tool when
not available. A
cutters are
cutter is illustrated in
ny
Fig.11.30. Figure 1131 Convex milling cutter

formed
Formed cutter: The
cutters have irregular profiles
on the cutting edges
in order
to generate an irregular out
line of the work. The differ-
ent types of standard formed
cutters are described below.
Convex milling cutter
The convex milling cutters
Figure 1132 Concave milling cutter
have teeth curved outwards
on the circumferential surface
to form the contour of a
semicircle. The cutter pro-
duces a concave semicircular
Surface on a workpiece. The
diameter of the cutter ranges
from 50 to 125 mm and the
radius of the semicircle var-
Figure 1133 Corner rounding milling
cutter
ies from 1.6 to 20 mm.
Fig.11.31 illustrates a convex milling cutter.
Concave milling cutter: The concave milling cutters have teetha
curved inwards on the circumferential surface to fom the contour of
semicircle. The concave milling cutters produce a convex semicircular
surfaceon a workpiece, The diameter of the cutter ranges from 56 to 110
mm and the radius
of the semicircle varies from 1.5 to 20 mm. Fig.11S2
illustrates a concave milling cutter.
Corner rounding milling cutter: The corner rounding millingB
cutters have teeth curved inwards on
the circunmferential surface to fom
the contour of a
quarter circle. The cutter produces a convex e
having contour of a quarter circle. The
a Suia
radius on the corners or cutters are used for cutting
edges of the work. The diameter of the
cutte
 MILLING MACHINES 425

ranges from 1.5 to 20 mm. Fig.11.33 illustrates a coner rounding milling

cutter.
Gear cutter: The gear cutters illustrated in Fig.11.34 have formed
cutting edges which reproduce the shape of the cutter teeth on the gear
blank. The shape of the cutter teeth may be involute or cycloida according
to the gear tooth profile. The cutter tooth profile should be differently
shaped for each pitch of the gear and also for
each change in number of teeth on the gear
which it is going to cut. But in practice a
compromise is effected by using one cutter to
cOver a range of gear sizes. Thus for cutting
gear teeth of involute profile, 8 numbers of
cutter are required to cut from a pinion of 12
teeth to a rack and for cycloidal tooth profile
24 cutters are used for cutting different
numbers of gear teeth. A list of cutters with
the number of teeth they are intended to cut Figure 11.34 Gear cutter

is given in Table 11.1.

TABLE 11.1 CUTTER FOR INVOLUTE AND CYCLOIDAL GEAR
TEETH

Imvolute gear Cycloidal gear

No. of teeth cut Cutter No. No. of teeth cut Cutter No. No. of teeth cut
Cutter No.

135 teeth to a No. A 12 teeth No. M 27 to 29 teeth

No. 1
rake
55 to 134 teeth No. B 13 teeth No. N 30 to 33 teeth
No. 2
35 to 54 teeth No. C 14 teeth No. O 34 to 37 teeth
No. 3 15 teeth No. P 38 to 42 tecth
26 to 34 tecth No. D
No. 4 16 teeth No. Q 43 to 49 teeth
21 to 25 teeth No. E
No. 5 17 teeth No. R 50 to 59 teeth
17 to 20 teeth No. F
No. 6 18 teeth No. S 60 to 74 tecth
14 to 16 teeth No. G
No.7 19 teeth No. T 75 to 99 tecth
No. H
No. 8 12 to 13 teeth No. U 100 to 149 teeth
No. I 20 teeth
No. J 21 to 22 No. V 150 to 249 teeth
No. K 23 to 24 No. W 250 or more
No. L 25 to 26 No. X Cuts a rack

The thread milling cutters are designed to

Thread milling cuter: n a workpiece. Generally, worms
form and size
mill threads of specific cutters. The cutters may

and acme threads

are produced by thread milling
shank thread milling cutters
shanks. The parallel
have parallel or taper
 426 ELEMENTS OF WORKSHOP TECHNOLO0GY

wwww

Figure 11.35 Parallel shank thread milling cutter

www
Figure 11.36 Taper shank thread milling cutter
illustrated in Fig.11.35 are available
in
diameters ranging from 8 to 20 mm and
the B
length of the threaded portion varies from 8 to
33 mm. The pitch of the thread
the diameter of the cutter. corresponds to
Thetaper
thread milling cutters illustrated in
shank
are available in diameters Fig.11.36
25 mm and the
ranging from 16 to
length of threaded portion Figure 1137 Tap and
varies from 16 to 40 mm.
reamer cutter
A. Tap cutter, and B.
Tap and reamer cutter: The tap and reamer Reamer cutter.
cutters are special type double angle cutters
intended for producing grooves or flutes in
of the taps or reamers. The point en
tooth is rounded and the tooth
profile corresponds
groove that it is going to make. A tap and reamer
to the type
cutter is illustrated om
Fig.11.37.