Machining Production

Milling Operations(11):Def,5 Types of Milling Cutters,Up&Down Milling

Milling Operations: Def,5 Types of Milling Cutters, Up&Down Milling:

It is a multipoint cutting tool machining operation used for removing a layer of material from the complete surface of the workpiece and it is also used for producing holes in the components.

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1.Types of Milling Cutters

2.Types of Milling Operations

3.Methods of Milling operations

In order to remove the material in the Milling Operations, the milling cutters will be used and are as follows.

Milling Operation
Milling Operations

1.Types of Milling Cutters:

There are two types of milling cutters.

1.End Milling Cutter 

2.Peripheral Milling Cutter

3.Side Milling Cutter

4.Straddle Milling Cutter

5.Gang Milling Cutter

Types of milling cutters in milling operations
Types of milling cutters in milling operations

1.End Milling Cutter: If the cutting teeth are provided at the end face of the circular disc, it is called an End milling cutter. End mill cutter is used either with a vertical milling machine or by using drilling machine also.

2.Peripheral Mill Cutter: if the cutting teeth are provided around the periphery of a circular disc called as a peripheral milling cutter.

  • It is used only with a horizontal milling machine.
  • The peripheral milling cutter is mounted on the expandable shaft called Arbor.

3.Side Milling Cutter: In addition to the face, if the cutting teeth are provided on periphery also called as a Side Milling Cutter.

  • If the peripheral milling cutter is superimposed on the end mill cutter called as side end mill cutter.

4. Straddle Milling Cutter: In addition to the periphery, if the cutting teeth are provided on faces also called aa s straddle milling cutter. i.e. End milling cutter is superimposed on to the peripheral milling cutter.

5.Gang Milling Cutter: If a gang of peripheral milling cutters of different sizes is kept together for removing the material simultaneously from one workpiece called a Gang Milling Cutter.


2.Types of Milling Operations:

They are two types of milling operations.

1.Face Milling Operation

2.Slot or Slab Milling Operation

3.End Milling Operation

4.Angular Milling Operation

5.Side and Face Milling Operation

6.Form Milling Operation

7.Slitting Operation

8.Keyway Milling Operation

9.Gear Cutting Operation

10.Profile Milling Operation

11.Helical Milling Operation

The detailed explanation for the different types of milling operations is as follows.

1.Face Milling Operations:

If the Milling Operation is used for removing a layer of material from a complete surface of the workpiece is called a face Milling Operations.

2.Slot/Slab Milling Operations:

If the Milling Operation is used for producing slots in the component is called a slab or slot Milling Operations.

In general, both the types of milling operations will be performed by using both the type of milling cutters but it is preferable to perform face Milling Operation with end mill cutter and slab Milling Operations with a peripheral milling cutter.

When peripheral milling cutter is used for performing the Milling Operation there are two methods of milling will be used.

3.End Milling Operation:

  • By end mill cutter, we can perform End Milling Operation.
  • For machining slots, pockets, keyway, etc

4.Angular Milling Operation:

  • Angle milling cutter or fitting spindle head in vertical.

5.Side and Face Milling Operation:

  • By side and face milling cutter we can perform this operation.

6.Form Milling Operation:

  • By form milling cutter, we can perform this operation.

7.Slitting Operation:

  • By the metal slit saw.

8.Keyway Milling Operation:

By plain milling cutter or end milling cutter, we can perform this operation.

9.Gear Cutting Operation:

  • by using Formed tooth cutter with dividing head.

10.Profile Milling Operation:

By a ball nose cutter on CNC Milling machine (Both 3D and 2D profiles)

11.Helical Milling Operation:

Produces grooves and prosperity of cylindrical work.


3.Methods of Milling Operations:

There are of two methods.

1.Up Milling or Conventional Milling

2.Down Milling or Climb Milling.

Up Milling and Down Milling Operations
Up Milling and Down Milling Operations

Features:

In UP milling, the direction of movement of workpiece and direction of rotation of the tool is opposite whereas in down milling the directions are same.

In UP milling, because of the opposite direction, the forces, power consumption, and tool wear are high whereas tool life is low.

In case of down milling, because of the same direction, forces, power consumption, and tool wear are low and tool life is longer.

In UP milling, the thickness is varying from minimum at the beginning to the maximum towards the end whereas in Down Milling Operations the uncut chip thickness is varying from maximum at the beginning to the minimum towards the end.

Because of large uncut chip thickness at the end, the surface finish produced is poor in Up Milling whereas in Down Milling because of the small uncut chip thickness at the end, the surface finish is better.

In Up milling because of opposite direction, the tool is lifting the workpiece upwards, therefore strong work holding devices are required whereas in Down milling because of the same direction, forces are less and strong holding devices are not required.

Therefore based on the above, it is preferable to use the Down milling.

This is the detailed information about Types of Milling Cutters, Methods of Milling Operations, etc. If you have any doubt, then you can contact us from the comments section.

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