INSTRUCTIONS HOW TO USE A MILLING MACHINE

Milling is the process of machining flat, curved, or irregular surfaces by feeding the
workpiece against a rotating cutter containing a number of cutting edges. The usual
Mill consists basically of a motor driven spindle, which mounts and revolves the
milling cutter, and a reciprocating adjustable worktable, which mounts and feeds the
workpiece.

Milling machines are basically classified as vertical or horizontal. These machines are
also classified as knee-type, ram-type, manufacturing or bed type, and planer-type.
Most milling machines have self-contained electric drive motors, coolant systems,
variable spindle speeds, and power-operated table feeds

Diagram of typical “Bridgeport style” milling machine head

TYPES OF MILLING MACHINES
KNEE-TYPE
Knee-type mills are characterized by a vertically adjustable worktable resting on a
saddle which is supported by a knee. The knee is a massive casting that rides
vertically on the milling machine column and can be clamped rigidly to the column in
a position where the milling head and milling machine spindle are properly adjusted
vertically for operation.

The plain vertical machines are characterized by a spindle located vertically, parallel
to the column face, and mounted in a sliding head that can be fed up and down by
hand or power. Modern vertical milling machines are designed so the entire head can
also swivel to permit working on angular surfaces.

The turret and swivel head assembly is designed for making precision cuts and can be
swung 360° on its base. Angular cuts to the horizontal plane may be made with
precision by setting the head at any required angle within a 180° arc.

The plain horizontal milling machine’s column contains the drive motor and gearing
and a fixed position horizontal milling machine spindle. An adjustable overhead arm
containing one or more arbor supports projects forward from the top of the column.
The arm and arbor supports are used to stabilize long arbors. Supports can be moved
along the overhead arm to support the arbor where support is desired depending on
the position of the milling cutter or cutters.

The milling machine’s knee rides up or down the column on a rigid track. A heavy,
vertical positioning screw beneath past the milling cutter. The milling machine is
excellent for forming flat surfaces, cutting dovetails and keyways, forming and fluting
milling cutters and reamers, cutting gears, and so forth. Many special operations can
be performed with the attachments available for milling machine use. the knee is used
for raising and lowering. The saddle rests upon the knee and supports the worktable.
The saddle moves in and out on a dovetail to control cross feed of the worktable. The
worktable traverses to the right or left upon the saddle for feeding the workpiece past
the milling cutter. The table may be manually controlled or power fed.
UNIVERSAL HORIZONTAL MILLING MACHINE

The basic difference between a universal horizontal milling machine and a plain
horizontal milling machine is the addition of a table swivel housing between the table
and the saddle of the universal machine. This permits the table to swing up to 45° in
either direction for angular and helical milling operations. The universal machine can
be fitted with various attachments such as the indexing fixture, rotary table, slotting
and rack cutting attachments, and various special fixtures.
RAM-TYPE MILLING MACHINE

The ram-type milling machine is characterized by a spindle mounted to a movable

housing on the column to permit positioning the milling cutter forward or rearward in
a horizontal plane. Two popular ram-type milling machines are the universal milling
machine and the swivel cutter head ram-type milling machine.
UNIVERSAL RAM-TYPE MILLING MACHINE

The universal ram-type milling machine is similar to the universal horizontal milling
machine, the difference being, as its name implies, the spindle is mounted on a ram or
movable housing.
SWIVEL CUTTER HEAD RAM-TYPE MILLING MACHINE

The cutter head containing the milling machine spindle is attached to the ram. The
cutter head can be swiveled from a vertical spindle position to a horizontal spindle
position or can be fixed at any desired angular position between vertical and
horizontal. The saddle and knee are hand driven for vertical and cross feed adjustment
while the worktable can be either hand or power driven at the operator’s choice.

Basic milling machine configurations are shown in Figure 8-1.

SAFETY RULES FOR MILLING MACHINES

Milling machines require special safety precautions while being used. These are in
addition to those safety precautions described in Chapter 1.

* Do not make contact with the revolving cutter.

* Place a wooden pad or suitable cover over the table surface to protect it from
possible damage.

* Use the buddy system when moving heavy attachments.

* Do not attempt to tighten arbor nuts using machine power.

* When installing or removing milling cutters, always hold them with a rag to prevent
cutting your hands.

* While setting up work, install the cutter last to avoid being cut.

* Never adjust the workpiece or work mounting devices when the machine is
operating.

* Chips should be removed from the workpiece with an appropriate rake and a brush.

NOTE Chip rake should be fabricated to the size of the T-slots (Figure 8-2).

* Shut the machine off before making any adjustments or measurements.

* When using cutting oil, prevent splashing by using appropriate splash guards.
Cutting oil on the floor can cause a slippery condition that could result in operator
injury

TOOLS AND EQUIPMENT

MILLING CUTTERS

Classification of Milling Cutters

Milling cutters are usually made of high-speed steel and are available in a great
variety of shapes and sizes for various purposes. You should know the names of the
most common classifications of cutters, their uses, and, in a general way, the sizes
best suited to the work at hand.

Milling Cutter Nomenclature

Figure 8-3 shows two views of a common milling cutter with its parts and angles
identified. These parts and angles in some form are common to all cutter types.
* The pitch refers to the angular distance between like or adjacent teeth.

* The pitch is determined by the number of teeth. The tooth face is the forward facing
surface of the tooth that forms the cutting edge.

* The cutting edge is the angle on each tooth that performs the cutting.

* The land is the narrow surface behind the cutting edge on each tooth.

* The rake angle is the angle formed between the face of the tooth and the centerline
of the cutter. The rake angle defines the cutting edge and provides a path for chips
that are cut from the workpiece.

* The primary clearance angle is the angle of the land of each tooth measured from a
line tangent to the centerline of the cutter at the cutting edge. This angle prevents each
tooth from rubbing against the workpiece after it makes its cut.

* This angle defines the land of each tooth and provides additional clearance for
passage of cutting oil and chips.

* The hole diameter determines the size of the arbor necessary to mount the milling
cutter.

* Plain milling cutters that are more than 3/4 inch in width are usually made with
spiral or helical teeth. A plain spiral-tooth milling cutter produces a better and
smoother finish and requires less power to operate. A plain helical-tooth milling cutter
is especially desirable when milling an uneven surface or one with holes in it.

Types of Teeth

The teeth of milling cutters may be made for right-hand or left-hand rotation, and with
either right-hand or left-hand helix. Determine the hand of the cutter by looking at the
face of the cutter when mounted on the spindle. A right-hand cutter must rotate
counterclockwise; a left-hand cutter must rotate clockwise. The right-hand helix is
shown by the flutes leading to the right; a left-hand helix is shown by the flutes
leading to the left. The direction of the helix does not affect the cutting ability of the
cutter, but take care to see that the direction of rotation is correct for the hand of the
cutter (Figure 8-4).

Saw Teeth

Saw teeth similar to those shown in Figure 8-3 are either straight or helical in the
smaller sizes of plain milling cutters, metal slitting saw milling cutters, and end
milling cutters. The cutting edge is usually given about 5 degrees primary clearance.
Sometimes the teeth are provided with off-set nicks which break up chips and make
coarser feeds possible.

Helical Milling Cutters

The helical milling cutter is similar, to the plain milling cutter, but the teeth have a
helix angle of 45° to 60°. The steep helix produces a shearing action that results in
smooth, vibration-free cuts. They are available for arbor mounting, or with an integral
shank with or without a pilot. This type of helical cutter is particularly useful for
milling elongated slots and for light cuts on soft metal. See Figure 8-5.

Metal Slitting Saw Milling Cutter

The metal slitting saw milling cutter is essentially a very thin plain milling cutter. It is
ground slightly thinner toward the center to provide side clearance. These cutters are
used for cutoff operations and for milling deep, narrow slots, and are made in widths
from 1/32 to 3/16 inch.

Side Milling Cutters

Side milling cutters are essentially plain milling cutters with the addition of teeth on
one or both sides. A plain side milling cutter has teeth on both sides and on the
periphery. When teeth are added to one side only, the cutter is called a half-side
milling cutter and is identified as being either a right-hand or left-hand cutter. Side
milling cutters are generally used for slotting and straddle milling.

Interlocking tooth side milling cutters and staggered tooth side milling cutters are
used for cutting relatively wide slots with accuracy (Figure 8-6). Interlocking tooth
side milling cutters can be repeatedly sharpened without changing the width of the
slot they will machine.