Lesson – Principles

Milling Machine
Operations

Prepared by:
Ricardo S. Balog, RME, MEng’g

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 Principles of Milling Machine Operations
6.1 Milling Machine and its Working Principle
● A milling machine is device that rotates a circular tool that has a
number of cutting edges symmetrically arranged about its axis; the
workpiece is commonly held in a vise or similar device clamped to
a table that can move in three perpendicular directions.
● Disk- or barrel-shaped cutters are clamped through holes in their
centres to arbors (shafts) attached to the machine spindle; they
have teeth on their peripheries only or on both peripheries and
faces. An end mill is a cutter shaped like a pencil with a tapered
shank that fits into the machine spindle; it has cutting teeth on its
face and spiral blades on the lateral surface.
● In the milling operation the workpiece is carried on a table that is
driven either manually or by power against the rotating cutter.
Milling machines usually produce flat surfaces, but any shape that
can be ground on the cutter will be reproduced on the work.

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 Principles of Milling Machine Operations
6.1 Milling Machine Working Principle
● Milling machines, either vertical or horizontal, are usually
used to machine flat and irregularly shaped surfaces and can
be used to drill, bore, and cut gears, threads, and slots.
● The vertical mill, or “column and knee” mill, is the most
common milling machine found in machine shops today.
The general construction of this mill includes the quill,
which moves vertically in the head and contains the spindle
and cutting tools.
● The knee moves up and down by sliding parallel to the
column. The column holds the turret, which allows the
milling head to be positioned anywhere above the table.
Hand wheels move the work table to the left and right (X
axis), in and out (Y axis), in addition to moving the knee,
saddle, and worktable up and down (Z axis).

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 Principles of Milling Machine Operations
6.1 Milling Machine and its Working
Principle
● The kinematic system comprising of several mechanisms
enables the transmission of motion and power from the
motor to the cutting tool for its rotation at varying speeds
and to the work table for slow feed motions along X, Y and
Z directions.
● The milling cutter mounted on the milling arbor, receives its
rotary motion at different speeds from the main motor though
quick-change speed gearbox.
● The feed motion of the workpiece is given either manually or
by power means, ie. by rotating the respective handwheels or
engaging the power feed lever.
● The workpiece which is clamped on the table by a work
holding device is then fed against the rotating multipoint cutter
causing the removal of excess material from the workpiece at a
fast rate.

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 Principles of Milling Machine Operations
6.2 Types of milling machines
➢ Column and knee type:
❏ Plain or horizontal milling machine.
❏ Universal milling machine.
❏ Omniversal milling machine.
❏ Vertical (Ram-type) milling machine. Omniversal milling machine Saddle-Swivel
table assembly
➢ Manufacturing or bed type:
❏ Simplex milling machine.
❏ Duplex milling machine.
❏ Triplex milling machine.
➢ Planer type Special type:
❏ Drum milling machine.
❏ Rotary table milling machine.
❏ Profile milling machine.
❏ Pantograph milling machine.
❏ Planetary milling machine. Universal milling machine Saddle-Swivel table
assembly

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 Principles of Milling Machine Operations
6.3 Major parts of a milling machine
● Column & Base - Column including base is the main
casting that supports all other parts of milling machine.
The column contains an oil reservoir and a pump
which lubricates the spindle. The column rests on the
base and base contains coolant reservoir and a pump
which is used during machining operation that requires
coolant.
● Knee - It is a casting that supports the saddle and table.
All gearing mechanism is enclosed within the knee. It
is fastened to the column by dovetail ways. The knee
is supported and adjusted by a vertical positioning
screw (elevating screw). The elevating screw is used to
adjust the knee up and down by raising or lowering the
lever either with the help of hand or power feed.

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 Principles of Milling Machine Operations
6.3 Major parts of a milling machine
● Saddle and Swivel Table -The saddle is present on the knee
and supports the table. It slides on a horizontal dovetail on
the knee and dovetail is parallel to the axis of the spindle ( in
horizontal milling m/c). The swivel table (in universal
machines only) is attached to the saddle that can be swiveled
(revolved) horizontally in either direction.
● Table- It is a rectangular casting which is present on the top
of the saddle. It is used to hold the work or work holding
devices. It contains several T-slots for holding the work and
work holding devices (i.e. jigs and fixtures).The table can be
operated by hand or by power.To move the table by hand,
engage and turn the longitudinal hand crank. To move it
through power, engage the longitudinal direction feed
control lever.

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 Principles of Milling Machine Operations
6.3 Major parts of a milling machine
● Power Feed Mechanism - Contained in the knee, the
power feed mechanism is used to control the longitudinal
(left and right), transverse (in and out) and vertical (up and
down) feeds. To get the desired rate of feed on the machine,
the feed selection lever is positioned as indicated on the
feed selection plates.
➢ On some universal knee and column milling machine,
the feed is obtained by turning the speed selection
handle until the desired rate of feed is indicated on the
feed dial.
➢ Most of the milling machines have a rapid traverse lever
that can be engaged when a temporary increase in the
speed of the longitudinal, transverse or vertical feeds is
required. For example this lever would be engaged
when the operator is positioning or aligning the work.

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 Principles of Milling Machine Operations
6.3 Major parts of a milling machine
● Spindle - It is the shaft that is used to hold and drives the
cutting tools of the milling machine.
➢ The spindle is mounted on the bearings and supported
by the column.
➢ Spindle is driven by the electric motor through gear
trains. The gear trains are present within the column.
➢ The face of the spindle which lies near to the table has
an internal taper machined on it. The internal taper at the
front face of the spindle permits only a tapered cutter
holder or arbor. It has two keys at the front face which
provides a positive drive for the cutter holder or arbor.
➢ The drawbolt and jam nut is used to secure the holder
and arbor in the spindle.

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 Principles of Milling Machine Operations
6.3 Major parts of a milling machine
● Over Arm / Overhanging Arm - It is a horizontal beam
present at the top face of the column. It may be a single casting
which slides on the dovetail ways present on the top face of the
column. The overarm is used to fastened arbor support. It may
consist of one or two cylindrical bars which slide through the
holes in the column.
● Arbor Support - It is a casting with bearing that supports the outer
end of the arbor. It also helps in aligning the outer end of the arbor
with the spindle. It prevents the springing of outer end of the arbor
during cutting operations. There are generally two types of arbor
supports used in the milling machine. The first one has small
diameter bearing hole, 1-inch in maximum diameter. And the other
one has large diameter bearing hole, usually upto 2 3/4 inches. The
arbor support has an oil reservoir that lubricates the bearing
surfaces. It can be clamped anywhere on the overarm. The arbor
support is used only in the horizontal types of milling machine.

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 Principles of Milling Machine Operations
6.3 Major parts of a milling machine
● Ram - The overhanging arm in the vertical
machine is called ram. One end of the ram is
mounted on the top of the column and on the
other end milling head is attached. The ram can
be a moved transversally (in and out) on the
column by a hand lever.

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 Principles of Milling Machine Operations
6.4 Fundamental milling machine
operations
6.4.1 Face Milling
● In the operation, the axis of the milling cutter
remains perpendicular to the surface being
milled. In this case cutting action is done by
cutting edges of both sides (end and outside)
periphery of the milling cutter.

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 Principles of Milling Machine Operations
6.4 Fundamental milling machine operations
6.4.1 Face Milling
● Depending upon the relative geometry of workpiece and
milling cutter, different face milling operations can be
described as:
➢ Conventional Face Milling - In this case diameter
of the milling cutter is greater than the width of the
workpiece. The milling cutter remains
overhanging on both sides of the workpiece.
➢ Partial Face Milling - In this case the milling
cutter overhangs on the workpiece on one side
only.
➢ End Milling - In this case, of end, a thin (smaller
diameter) cutter is used as compared to workpiece
width. It is used to make a slots in the workpiece.

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 Principles of Milling Machine Operations
6.4 Fundamental milling machine operations
6.4.1 Face Milling
● Depending upon the relative geometry of workpiece and milling
cutter, different face milling operations can be described as:
➢ Profile Milling - This is just like end milling in which the
outer side periphery of a flat part is machined (milled).
➢ Pocket Milling - This is a selective portion milling on the
flat surface of the workpiece used to make shallow
pockets.
➢ Surface Contouring - In this operation, a ball nose cutter
is fed back and forth across the workpiece along a
curvilinear path at short intervals. This creates the required
contours on the surface of the workpiece. This operation is
used to make contours of molds and dies and this time the
operation is named as die sinking.

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 Principles of Milling Machine Operations
6.4 Fundamental milling machine operations

6.4.2 Side Milling

● It is the machining process which produces flat
vertical surface at the sides of a workpiece.
This operation is performed by using side
milling cutter.
6.4.3 Plain (Slab) Milling
● It is a Process of milling flat surfaces keeping
the axis of the cutter parallel to the surface
being milled. A plain milling cutter is used for
this operation.

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 Principles of Milling Machine Operations
6.4 Fundamental milling machine operations
6.4.4 Straddle Milling
● It is a process in which two side milling cutter are used
to machined two opposite sides of a workpiece
simultaneously.
6.4. 5 Gang Milling
● It is the machining process in which two or more
milling cutters are used together to perform different
milling operation simultaneously. In gang milling the
cutters are mounted on the arbor.
6.4.6 Angular Milling
● It is a process of milling flat surfaces which are
neither parallel nor perpendicular to the axis of the
milling cutter. It is also called as angle milling. A
single angle milling cutter is used to perform this
operation

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 Principles of Milling Machine Operations
6.4 Fundamental milling machine operations
6.4.7 Form Milling
● It is the process of machining special contour (outline)
composed of curves, straight lines, or entirely of curves, at
a single cut. Formed milling cutters shaped to the contour
to be cut are used to perform this operation. This operation
is accomplish by using convex, concave and corner
rounding milling cutters.
6.4.8 Profile Milling
● This milling operation is used to cut a profile on the
workpiece.
6.4.9 End Milling
● It is the process of producing flat surfaces which may be
horizontal, vertical and at any angle taking the worktable
as a reference. End milling cutters are used to accomplish
this operation.

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 Principles of Milling Machine Operations
6.4 Fundamental milling machine operations
● Milling Keyways, Grooves and Slots - This milling operation is used
to produce key ways, grooves and slots on the workpiece.
● Gear Milling - It is the milling process which is used to cut gears on
the workpiece. This operation is done by using formed milling
cutters called involute gear cutters.
● Helical Milling - This milling operation is done to produce objects
having helical design such as helical gears, twisted drills etc. it is
done on the periphery of the cylindrical workpiece.
● Cam Milling - It is a machining process which is used to make cams.
The cams are used to open and close of the valves in the internal
combustion engines.
● Saw Milling - It is machining process which is used to produce
narrow grooves or slots on the workpiece. It is also used for the
parting off the workpiece into two equal or unequal parts. This
milling operation is performed by using saw milling cutter.

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 Principles of Milling Machine Operations
6.5 Methods of cutting in machining operations
● Up milling is a method of milling operation in which the cutter and
the workpiece both move in the opposite direction. In this case, chip
thickness is minimum in the beginning and maximum at the end of
cut.
● Down Milling is a method of milling operation in which the direction
of the rotation of the cutter coincides with the direction of the work
feed. In this case, the chip thickness will be greater at the beginning
and lesser at the end; the tool life is greater and the surface finish is
better as compared with the up-milling, such that the down-milling
method is used for the finishing operations in the industries.
● Higher accuracy can be attained in the case of up-milling as
compared with the down-milling process since in up-milling the
workpiece is pulled against the table so the fasteners will be under
tension, hence the backlash error does not have any effect, resulting
ultimately ultimately to a better accuracy.

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 Principles of Milling Machine Operations
6.6 Work holding devices used in a milling machine
6.6.1 T-bolts and clamps - are used to clamped directly on the milling machine table bulky workpieces of
irregular shapes for effective machining operations.

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 Principles of Milling Machine Operations
6.6 Work holding devices used in a
milling machine
6.6.2 Angle plate - used for holding L-shaped or
similar workpieces. It is made of cast iron and is
accurately machined on two sides at right
angles. One of the sides is clamped to the table
by T-bolts while the other side holds the work
by clamps. Sometimes a tilting angle plate in
which one face can be adjusted relative to
another face for milling at a required angle is
also used.

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 Principles of Milling Machine Operations
6.6 Work holding devices used in
a milling machine

6.6.3 V-blocks- used for holding shafts

(round stocks) on the milling table in
which keyways, slots and flats are to be
milled. A workpiece may be supported on
two V-blocks, one at each end, and is
clamped to the table by T-bolts and
clamps.

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 Principles of Milling Machine Operations
6.6 Work holding devices used in a
milling machine

6.6.4 Milling vises- are the most commonly used for

golding work on the milling machine table.
● A plain vise (a) is the most simple of all types, and may have
single or double screws screws for actuating the movable
jaw. The double screws add gripping strength while taking
deeper cuts or handling heavier jobs.
● A swivel vise (b) has the base graduated in degrees, and
its body may be swivelled at any desired angle along the
horizontal plane. The swivelling is useful in making
bevel cuts at the end of the workpiece.
● A the body of universal vise (c) can be swivelled and at
the same time, can be tilted along the vertical plane up to
90 degrees from the horizontal plane; being so, allows
the machining of an inclined surface.

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 Principles of Milling Machine Operations
6.6 Work holding devices used in a milling
machine
6.6.5 Indexing or dividing head - a special work holding
device used in milling machines for cutting equally-spaced
slots, grooves, etc. around the circumference of a blank, for
example in cutting teeth of gears, sprockets, ratchet wheels,
etc. which necessitate holding of the blank workpiece and
rotating it to the exact position of the next groove or slot to be
cut.
● The work piece is mounted between centres, one inserted
into the dividing head spindle and the other into the tail
stock. The workpiece may also be mounted on a mandrel
between these centres. A chuck may be mounted on the
spindle nose for holding short work pieces having no
centre holes. The work piece is rotated by turning the
index crank by means of handle.

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 Principles of Milling Machine Operations
6.7 Special milling machine attachments

6.7.1 Universal milling machine attachment - used

in horizontal arbor-type milling machines to facilitate
operations to be done by end milling and smaller size
face milling cutters . The rotation of the horizontal
spindle is transmitted into rotation of the cutter about
the vertical axis and also in any inclined direction,
thus extension the processing capabilities of a
horizontal column and knee type milling machine

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 Principles of Milling Machine Operations
6.7 Special milling machine attachments

6.7.2 Slotting attachment - a low cost attachment

mounted on the spindle of a horizontal milling
machine used for cutting internal keyways and
contoured surface where the operations require linear
travel of the single point cutting. The mechanism
inside the attachment converts the rotation of the
milling machine spindle into reciprocating motion of
the tool in the vertical direction. In addition, the
direction of the tool path can also be tilted by
swivelling the circular base of the attachment body.

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 Principles of Milling Machine Operations
6.7 Special milling machine attachments

6.7.3 Rotary table - This device can also be

considered both accessory or attachment and is
generally used in milling machines for both
offline and online indexing or rotation of the
workpiece that is clamped on it about the vertical
axis

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 Principles of Milling Machine Operations
6.8 Cutter holding devices in a milling machine
● Arbors- used to hold cutters that have bores at the center
● Collets - a form of sleeve or bushing for reducing the size
of the taper hole at the nose of the spindle so that an arbor
or a milling cutter with smaller shank than the spindle
taper can be fitted to it.
● Adapter - a form of collet having standardized spindle end,
used to hold cutters with straight shanks. It can be
connected to the spindle by a draw bolt or may be directly
bolted on the spindle.
● Spring collets - usually used to gold straight shank cutters;
the cutter shank is introduced in the cylindrical gole
provided at the end of the adapter and then the nut is
tightened. This causes the split jaws of the adapter to
spring inside and grip the cutter shank firmly.

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 Principles of Milling Machine Operations
6.9 Milling Cutters

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 Principles of Milling Machine Operations
6.9 Milling Cutters
6.9.1 Cutter tool materials
● Carbon steel - The cheapest of the bunch; and this is exactly why it still finds use. As carbon steel is
not very durable, it is only suitable for low-speed operations. Carbon steel loses its hardness at 200° C.
This is the reason for lower speeds – to keep the heating effect low.
● High-speed steel - High-speed steel, a grade of tool steels, has a few alloying elements added to it to
provide better response to heat and wear than regular carbon steel. While the life cycle of such a tool
goes up, so does the cost. It loses its hardness at 600° C. Therefore, higher milling speeds are suitable
for these tool steels.
● Cemented carbides - This material is harder than high-speed steel but the toughness qualities are not
that impressive. The higher hardness provides better protection against wear but lower toughness levels
make it a little more susceptible to cracking and chipping. The upper temperature of use is at 900° C.
● Cutting ceramic - Cutting ceramics are even harder than cemented carbides but lose in the toughness
aspect. Both aluminium oxide and silicon nitride are used to produce these tools with varying
properties. Cutting ceramic tools are prone to cracking when used on hard materials and with high
temperatures. Therefore, they are not really suitable for machining steels, for example. Otherwise, a
short tool life is to be expected.

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 Principles of Milling Machine Operations
6.9 Milling Cutters
6.9.2 Milling Cutter Types
6.9.2.1 Slab (Plain) milling cutters: Straight or helical flute
● Are made from high speed steel. These are mostly used in a gang
milling processes and for machining surfaces which are broad in shape
as well as large; used in milling flat surfaces with the milling cutter
axis parallel to the surface being milled. Machining is usually done by
the teeth on the cylindrical surface of the cutter.
6.9.2.2 Face mill cutter
● With this type of mill cutter, machining is done by the teeth on the flat
surface of the cutter. The finished surface is usually perpendicular to
the axis of the cutter. The cutting teeth are present on its sides. Another
interesting feature of this cutter is that it has got carbide inserts which
are gold in color and these tips can be exchanged. You can also replace
it with a newer one, whenever one of the tips get damaged. The
cemented carbide in it also refers as indexable carbide insert.

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 Principles of Milling Machine Operations
6.9 Milling Cutters
6.9.2 Milling Cutter Types
6.9.2.3 End mill cutter
● Used for machining the faces and sides of metal
pieces and objects, this cutter has a rotating
cutting tool with a cylindrical shank with teeth
at the end. It is used more in the vertical milling
processes. To create end mills, high speed steel
(HSS) or the cemented carbide is used. When
the temperature increases, the high speed steel
doesn't loose its hardness. The high speed steel,
hence, is used to make end mills due to better
hardness. The end mills are mostly used in
tracer milling, plunging and face milling.

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 Principles of Milling Machine Operations
6.9 Milling Cutters
6.9.2 Milling Cutter Types
6.9.2.4 Side milling cutters
● Designed аs mасhine tооl аrbоr-mоunted сutters, side milling
cutters аre reсоmmended fоr use on unusuаl mаteriаls, аnd аre
рerfeсt fоr deeр slоtting. Аdditiоnаl teeth аre inсluded fоr fine
finishing. Сhiр remоvаl is greаt, thаnks tо the аlternаte tооth
соnfigurаtiоn. Side milling cutters аre used tо mill slоts,
grооves, аnd оther machining operations thаt require the use оf
the рeriрherаl аnd/оr side сutting edges. When deeр сutting is
nоt required, the tооl is suited fоr side сutting аnd strаddle
milling орerаtiоns. Multi-tооth сutters hаve their сutting teeth
оn bоth sides аnd the рeriрhery. Side Milling Сutters аre
designed аnd рrороrtiоned tо рrоvide а wide сutting rаnge of аs
well аs а high level stiffness.

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 Principles of Milling Machine Operations
6.9 Milling Cutters
6.9.2 Milling Cutter Types

6.9.2.5 Form milling cutters - have irregular

profiles on the cutting edges to generate
irregular outline on the works’ machined
surfaces. Some of the most common form
cutters are:
➢ T-slot milling cutter
➢ Gear (teeth) milling cutters
➢ Spline shaft cutters

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 Principles of Milling Machine Operations
6.9 Milling Cutters
6.9.2 Milling Cutter Types

6.9.2.5 Form milling cutters - have

irregular profiles on the cutting edges to
generate irregular outline on the works’
machined surfaces. Some of the most
common form cutters are:
➢ Convex and concave milling cutters,
Corner rounding milling cutter
➢ Angle milling cutters

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 Principles of Milling Machine Operations
6.9 Milling Cutters
6.9.2 Milling Cutter Types

6.9.2.6 Woodruff keyway cutter

● Are small standard cutters similar in
construction to a thin small diameter plain
milling cutter provided with a shank and have
either straight or staggered teeth; used for
milling Woodruff key slots.

6.9.2.7 Fly cutter

● Are simplest form of cutters and are used
mainly in tool room works; consist of SPTT
attached to the end of the arbor. The form of the
tool’s tip is the replica of the tool to be
machined.

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 Principles of Milling Machine Operations
6.10 Calculations in Milling Operations
6.10.1 Definitions: Milling process /cutter parameters
● Cutting speed,vc​- Indicates the surface speed at which the cutting edge machines the
workpiece
● Effective or true cutting speed, ve - Indicates the surface speed at the effective diameter
(DCap). This value is necessary for determining the true cutting data at the actual depth of
cut (ap). This is a particularly important value when using round insert cutters, ball nose
end mills and all cutters with larger corner radii, as well as cutters with an entering angle
smaller than 90 degrees.​
● Spindle speed, n - The number of revolutions the milling tool makes per minute on the
spindle. This is a machine oriented value, which is calculated from the recommended
cutting speed value for an operation.
● Feed per tooth, fz - A value for calculating the table feed. The feed per tooth value is
calculated from the recommended maximum chip thickness value.
● Feed per revolution, fn - Auxiliary value indicating how far the tool moves during one
complete rotation. It is used specifically for feed calculations and often to determine the
finishing capability of a cutter.

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 Principles of Milling Machine Operations
6.10 Calculations in Milling Operations
6.10.1 Definitions: Milling process / cutter parameters
● Feed per minute, vf - Also known as the table feed, machine feed or feed speed. It is the
feed of the tool in relation to the workpiece in distance per time-unit related to feed per
tooth and number of teeth in the cutter. The number of available cutter teeth in the tool
(zn) varies considerably and is used to determine the table feed while the effective
number of teeth (zc) is the number of effective teeth in cut. Feed per revolution (fn) in
mm/rev (inch/rev) is a value used specifically for feed calculations and often to
determine the finishing capability of a cutter.
● Maximum chip thickness, hex - This value is a result of the cutter engagement as it is
related to (fz), (ae) and (kr). The chip thickness is an important consideration when
deciding the feed per tooth, to ensure that the most productive table feed is employed.
● Average chip thickness, hm - A useful value in determining the specific cutting force,
used for net power calculations.

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6.10 Calculations in Milling Operations

6.10.1 Definitions: Milling process / cutter parameters

● Metal removal rate, Q (cm3/min) - The volume of metal removed in cubic mm per minute
(inch3/minute). It is established using the values for cutting depth, width and feed.
● Specific cutting force, kc - A material constant which is a factor used for power calculations,
expressed in N/mm2
● Machining time, Tc (min) - Machining length (lm) divided by the table feed (vf).​
● Net power, Pc and efficiency, ηmt - Machine tool-oriented values, which assist in calculating the net
power to ensure that the machine can handle the cutter and operation.​
● Entering angle, (kr) (degrees) - The major cutting edge angle (kr) of the cutter is the dominant
factor as it affects the cutting force direction and the chip thickness.​
● Cutter diameter – Dc (mm) - The cutter diameter (Dc) is measured over the point (PK), where the
main cutting edge meets the parallel land. The most important diameter to consider is (Dcap) – the
effective cutting diameter at the actual depth of cut (ap) – used for calculation of the true cutting
speed. D3 is the largest diameter of the insert, for some cutters it is equal to Dc.​

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6.10 Calculations in Milling Operations
6.10.1 Definitions: Milling process / cutter parameters
● Cutting depth – ap (mm) - The cutting depth (ap) is the difference between
the uncut and the cut surface in axial direction. Maximum ap is primarily
limited by the insert size and machine power. Another critical factor in
roughing operations is torque, and in finishing operations, it is vibration.​
● Cutting width, ae (mm) - The radial width of the cutter (ae) engaged in cut.
Especially critical in plunging step over, and for vibration in corner milling,
where maximum ae is especially critical.
● Radial immersion, ae/Dc - Radial immersion (ae / Dc) is the width of the cut
in relation to the diameter of the cutter.
● Number of effective cutting edges on the tool, zc - For determining the table
feed (vf) and the productivity. This often has a critical influence on chip
evacuation and operational stability.
● The total number of cutting edges on the tool, z n

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6.10 Calculations in Milling Operations

6.10.2 Milling formulas and definitions

Definition Symbol Metric Imperial
Table feed 𝑣 𝑓 𝑣 𝑓 = 𝑓 𝑧 𝑥 𝑛 𝑥 𝑍 𝑒𝑓𝑓 ; 𝑚𝑚/𝑚𝑖𝑛
𝜋 𝑥 𝐷𝑐𝑎𝑝 𝑥 𝑛
Cutting speed
𝑣𝑐 𝑣 𝑐= ; 𝑚/ 𝑚𝑖𝑛
1000
Spindle speed
𝑣 𝑐 𝑥 1000 𝑣 𝑐 𝑥 12
𝑛 𝑛= ; 𝑟𝑝𝑚 𝑛= ; 𝑟𝑝𝑚
𝜋 𝑥 𝐷𝑐𝑎𝑝 𝜋 𝑥 𝐷𝑐𝑎𝑝

Feed per tooth 𝑣𝑓 𝑣𝑓

𝑓 𝑓 𝑧= ; 𝑚𝑚 / 𝑡𝑜𝑜𝑡h 𝑓 𝑧= ; 𝑖𝑛𝑐h / 𝑡𝑜𝑜𝑡h
𝑧 𝑛 𝑥 𝑍 𝑒𝑓𝑓 𝑛 𝑥 𝑍 𝑒𝑓𝑓

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 Principles of Milling Machine Operations
6.10 Calculations in Milling Operations

6.10.2 Milling formulas and definitions

Definition Metric Imperial
Feed per revolution 𝑣𝑓 𝑣𝑓
𝑓 𝑛= ;𝑚𝑚 / 𝑟𝑒𝑣 𝑓 ; 𝑖𝑛𝑐h / 𝑟𝑒𝑣
𝑛 𝑛=
𝑛
Metal removal rate
𝑎𝑝 𝑥 𝑎𝑒 𝑥 𝑣 𝑓
𝑄=
3
; 𝑐𝑚 / 𝑚𝑖𝑛 𝑄=𝑎 𝑝 𝑥 𝑎 𝑒 𝑥 𝑣 𝑓 ; 𝑖𝑛𝑐h / 𝑚𝑖𝑛3
1000
Net power requirement 𝑎 𝑝 𝑥 𝑎 𝑒 𝑥 𝑣 𝑓 𝑥 𝑘𝑐 𝑎 𝑝 𝑥 𝑎 𝑒 𝑥 𝑣 𝑓 𝑥 𝑘𝑐
𝑃 𝑐= ; 𝑘𝑊 𝑃 𝑐= 3
; 𝐻𝑝
60 𝑥 10
6
396 𝑥 10
Torque
m 𝑃 𝑐 𝑥 16501
𝑀 𝑐= ; 𝑓𝑡 − 𝑙𝑏
𝜋 𝑥𝑛

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 Principles of Milling Machine Operations
6.10 Calculations in Milling Operations
6.10.3 Specific milling cutter formulas
• Formulas for milling cutters having a straight cutting edge:
a) Max. cutting diameter at a specific depth (mm)

b) Face milling (centered workpiece) straight edge and side milling

(

c) Side milling () straight edge

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 Principles of Milling Machine Operations
6.10 Calculations in Milling Operations
6.10.3 Specific milling cutter formulas
• Formulas for milling cutters with round inserts:
a) Max. cutting diameter at a specific depth (mm)

b) Face milling straight edge and side milling (

c) Side milling () straight edge

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 Principles of Milling Machine Operations
6.10 Calculations in Milling Operations
6.10.3 Specific milling cutter formulas
• Ball nose end mills:
a) Max. cutting diameter at a specific depth (mm)

b) Feed per tooth (mm/tooth), cutter centered

c) Feed per tooth (mm/tooth), side milling

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 Principles of Milling Machine Operations
6.10 Calculations in Milling Operations
6.10.3 Specific milling cutter formulas
• Internal circular ramping (3-axes) or circular milling (2-axes):
a) Peripheral feed (mm/min)

b) Tool center feed (mm/min),

c) Radial depth of cut

d) In a solid workpiece where

e) Feed per tooth (mm) when widening a hole

)

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 Principles of Milling Machine Operations
6.10 Calculations in Milling Operations
6.10.3 Specific milling cutter formulas
• External circular ramping (3-axes) or circular milling (2-axes):
a) Peripheral feed (mm/min)

b) Tool center feed (mm/min),

c) Feed/tooth (mm)

d) and

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 Principles of Milling Machine Operations
6.11 Indexing Calculations
6.11.1 Direct indexing

Direct indexing plate: Most dividing heads have an indexing plate

permanently attached to the spindle. This plate is located at the end of
the spindle, very close to where the work would be mounted. It is
fixed to the spindle and rotates with it. This plate is usually equipped
with a series of holes that enables rapid indexing to common angles,
such as 30, 45, or 90 degrees. A pin in the base of the dividing head
can be extended into the direct indexing plate to lock the head quickly
into one of these angles. The advantage of the direct indexing plate is
that it is fast and simple and no calculations are required to use it. The
disadvantage is that it can only be used for a limited number of
angles.

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 Principles of Milling Machine Operations
6.11 Indexing Calculations
6.11.1 Direct indexing

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 Principles of Milling Machine Operations
6.11 Indexing Calculations
6.11.2 Plain (Simple) indexing
• Index plate - helps to accomplish indexing (dividing) the work into equal divisions. It is a
circular plate approximately 6 mm thick, with holes (equally spaced) arranged in
concentric circles. The space between two subsequent holes is the same for each circle;
however, it is different for different circles. A plate can have through holes or blind holes
on its faces. For a plain dividing head, the index plate is fixed to the body of the dividing
head while in the case of a universal dividing head it is mounted on the sleeve of the
worm shaft.
• Various manufacturers in the U.S.A. and other countries have produced index plates with
different numbers of hole circles. For example, The index plates available with the Brown
and Sharpe milling machines are:
Plate No. 1 - 15, 16, 17, 18, 19, 20
Plate No. 2 - 21, 23, 27, 29, 31, 33
Plate No. 3 - 37, 39, 41, 43, 47, 49
• The index plate used on the Cincinnati and Parkinson milling machine are:
Obverse (A) - 24, 25, 28, 30, 34, 37, 38, 39, 41, 42, 43
Reverse (B) - 46, 47, 49, 51, 53, 54, 57, 58, 59, 62, and 66

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 Principles of Milling Machine Operations
6.11 Indexing Calculations
6.11.2 Plain (Simple) indexing
• Index plates made in Germany are:
Plate No. 1 - 23, 25, 28, 31, 39, 43, 51, 59
Plate No. 2 - 16, 27, 30, 33, 41, 47, 53, 61
Plate No. 3 - 22, 24, 29, 36, 37, 49, 57, 63
• A high number of index plates are used to increase the indexing capacity. These index
plates are similar to those discussed earlier except that these contain a very large
number of holes. Cincinnati Milling Machine Co. U.S.A. produces a set of three plates
with holes on both sides of the plate as given below:
Plate No. 1 Obverse (A) - 30, 48, 69, 91, 99, 117, 129, 147, 171, 177, 189
Reverse (B) - 36, 67, 81, 97, 111, 127, 141, 157, 169, 183, and 194

Plate No 2 Obverse (A) - 34, 46, 79, 93, 109, 123, 139, 153, 167, 181, 197
Reverse (B) - 32, 44, 77, 89, 107, 121, 137, 151, 163, 179, and 193

Plate No. 3 Obverse (A) - 26, 42, 73, 87, 103, 119, 133, 149, 161, 175, 191
Reverse (B) - 28, 38, 71, 83, 101, 113, 131, 143, 159, 173, and 187

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 Principles of Milling Machine Operations
6.11 Indexing Calculations
6.11.2 Plain (Simple) indexing
• Plain indexing on the spiral head is very similar to indexing with ordinary index centers. It
depends entirely upon how many times the index crank must be turned to cause the work to
make one revolution. When this ratio is known, it is easy matter to calculate the number of
turns or fractions of a turn of the index crank to produce a given number of spaces on the
periphery of the work.
• To find how many turns of the crank are necessary for a certain division of the work,
40 is divided by the number of the divisions which are desired. The quotient will be the
number of turns, or the part of a turn of the crank, which will give each desired
division.
• When the quotient contains a fraction or is a fraction, it will be necessary to give the
crank a part revolution in indexing. The numerator of the fraction represents the
number of holes that should be indexed for each division. If the fraction is so small
that none of the plates contains the number of holes represented by the denominator,
both numerator and denominator should be multiplied by a common multiplier that will
give a fraction, the denominator of which represents a number of holes that is
available. On the other hand, if the fraction is of large terms, it should be reduced so
that its denominator will represent the number of holes that is available.

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 Principles of Milling Machine Operations
6.11 Indexing Calculations
6.11.2 Plain (Simple) indexing
For example, seven divisions are desired:
Turns of the index crank to each division ;
There is no plate containing so few holes as 7, so this should be raised.
Multiplying the fractional part by the common multiplier say 3, we have ;
Hence, we use index plate #2 and the index crank pin is to be set in the 21-hole circle, and
the sector arm is set to cover 15 holes. The crank is given 5 complete turns plus 15
additional holes per division.
Likewise, we can use plate #3, set crank pin in the 49-hole circle, set sector arm to cover
35 holes.

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 Principles of Milling Machine Operations
6.11 Indexing Calculations
6.11.3 Indexing Angles (Degrees, Parts of a Degree)
To index for any angle, proceed as follows:
Since 40 turns on the index crank will give one revolution (3600) of the crank, one
complete turn on the index crank will give ; hence, to determine the number of turns on
the index crank, to index any angle will be given by:

For example, if a machinist wanted to index (rotate) his workpiece by 22.5 degrees then
he would turn the hand crank two full revolutions plus one-half of a turn. Since each full
revolution is 9 degrees and a half-revolution is 4.5 degrees, the total is 22.5 (9 + 9 + 4.5 =
22.5). The one-half turn can easily be done precisely using any indexing plate with an
even number of holes and rotating to the halfway point. In this case, index plate #1 or A
will be used. The crank pin is to be set to fit the 16-hole index circle, and the sector arm
will be set to cover 8 holes on the 16-hole index circle. (Hole #8 on the 16-hole ring).
To illustrate how this applies to parts of degree (the same example)

Engineering and Architecture

 Principles of Milling Machine Operations
6.11 Indexing Calculations
6.11.3 Indexing Angles (Degrees, Parts of a Degree)

Example 3.2: Calculate the indexing for 41 0 .

Indexing required = .
Using the Brown and Sharpe plate No. 1:
- Select and set crank pin to18-hole index circle.
- Set sector arm to cover 10 holes in 18-hole circle.

Example 3.3: Calculate the indexing for 19 0 40’.

190 40’ = (19 x 60) + 40 = 1140 + 40 = 1180’

Indexing required =
Using the Brown and Sharpe plate No.2:
- Select and set crank pin to 27-hole circle
- Set sector arm to cover 5 holes in 27-hole circle.

Engineering and Architecture

 Principles of Milling Machine Operations
6.11 Indexing Calculations
6.11.4 Differential Indexing
• Differential indexing enables a wide range of divisions to be indexed, which
cannot be obtained by plain indexing. With the change gears and three index plates
furnished with the spiral head, it is possible to index all numbers, not obtainable
by plain indexing, from 1 to 382; in addition, many other divisions beyond 382
can be indexed.
• By this method, the index crank is moved in the same circle of holes, and the
operation is like that of plain indexing. The Index head spindle and index plate are
connected by a train of gearing, as shown above, and the stop pin at the back of
the plate is thrown out. As the index crank is turned, the spindle is rotated through
the worm and wheel, and the plate moves either in the same or opposite direction
to that of the crank. The total movement of the crank at every indexing is,
therefore, equal to its movement relative to the plate, plus the movement of the
plate, when the plate revolves in the same direction as the crank, or minus the
movement of the plate, when the plate revolves in the opposite direction to the
crank. The index head cannot be used for cutting spirals (helical) when it is geared
for differential indexing, for when cutting spirals the head is geared to the table
feed screw.

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 Principles of Milling Machine Operations
6.11 Indexing Calculations
6.11.4 Differential Indexing
• In order to select the proper change gears, it is first necessary to
find the ratio of the required gearing between the spindle and
plate. After this has been done, the correct gears can be found.
The following formula shows the manner in which this gearing
is calculated.

For Brown & Sharpe index head the set of change gears furnished have
the following numbers of teeth: 24 (2 gears), 28, 32, 40, 44, 48, 56, 64,
72, 86, 100.

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 Principles of Milling Machine Operations
6.11 Indexing Calculations
6.11.4 Differential Indexing
• In selecting the index circle to be used, it is best to select one with a
number having factors that are contained in the change gears on hand:
When A is greater than N and gearing is simple, use 1 idler.
When A is greater than N and gearing is compound, use no idlers.
When A is less than N and gearing is simple, use 2 idlers.
When A is less than N and gearing is compound, use 1 idler.
• Select "A" so that the ratio of gearing will not exceed 6:1 on account of
the excessive stress upon the gears.

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 Principles of Milling Machine Operations
6.11 Indexing Calculations
6.11.4 Differential Indexing
Example 4.1: Obtain the indexing for 97 divisions.
• The required indexing is 40/97 which cannot be obtained with any of the index
plates available. Choose the nearest possible division. For example, the
indexing decided is 40/100 = 2/5 = 8/20.
• The actual indexing decided is 8 holes in a 20 hole circle. This indexing will be
less than required. Ideally the workpiece should complete one revolution
when the crank is moved through 97 turns at the above-identified indexing.
The actual motion generated when the crank is moved 97 times is:

• Hence, the change gear set used is:

• An idler gear is to be used since the index plate has to move in the same
direction.

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 Principles of Milling Machine Operations
6.12 Milling Spiral (Helical) Cuts
• Spiral (helical) milling (Ex. Milling of teeth of helical gears,
flutes of twist drillbits and endmills, worm threads, etc) can be
facilitated on conventional horizontal or vertical milling
machines equipped with a universal dividing (index) head.
Principles:
• To cut a helix on the periphery of a workpiece, the workpiece
needs to be rotated relatively as it is fed against a rotating
cutter. This relative rotation of the workpiece to the table travel
is obtained by connecting the index head spindle to the
milling machine table leadscrew through a gear train
(simple or compound). The milling machine table is set to the
required degree of helix (helix angle).

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 Principles of Milling Machine Operations
6.12 Milling Spiral (Helical) Cuts
Terminology
Lead of helix – the linear distance the work should travel to give one revolution of the
helix.

Helix Angle, 𝛳

PD

Lead of helix

From the above illustration, lead of helix can be computed as:

𝜋𝑥 𝑃𝐷
𝐿𝑒𝑎𝑑 𝑜𝑓 ℎ𝑒𝑙𝑖𝑥 = ; where 𝛳 is the helix angle and PD is the Pitch Diameter
𝑇𝑎𝑛 𝛳
along which the helix revolve.
Lead of Machine – the distance the milling machine would travel to give one revolution
of the index head spindle. Lead of machine can be computed as:

𝐿𝑒𝑎𝑑 𝑜𝑓 𝑀𝑎𝑐ℎ𝑖𝑛𝑒 = 𝐼𝑛𝑑𝑒𝑥 𝐻𝑒𝑎𝑑 𝑟𝑎𝑡𝑖𝑜 𝑥 𝐿𝑒𝑎𝑑 𝑜𝑓 𝑡𝑎𝑏𝑙𝑒 𝑙𝑒𝑎𝑑𝑠𝑐𝑟𝑒𝑤

Note: Lead of leadscrew is equal to the pitch, since table leadsrew is of single start ACME thread

For a universal milling machine with 4PTI table leadscrew and using a dividing head
𝟏
with index ratio of 40:1, lead of machine will be equal to 𝟒𝟎 𝒙 𝒊𝒏𝒄𝒉 = 𝟏𝟎𝒊𝒏𝒄𝒉𝒆𝒔.
𝟒

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 Principles of Milling Machine Operations
6.12 Milling Spiral (Helical) Cuts
Change Gear Calculation for selecting gears to compose the gear train:
Determining Gear Ratio
𝑷𝒓𝒐𝒅𝒖𝒄𝒕 𝒐𝒇 𝑻𝒆𝒆𝒕𝒉 𝒐𝒇 𝑫𝒓𝒊𝒗𝒆𝒏 𝑮𝒆𝒂𝒓𝒔 𝒍𝒆𝒂𝒅 𝒐𝒇 𝒉𝒆𝒍𝒊𝒙
𝑮𝒆𝒂𝒓 𝑹𝒂𝒕𝒊𝒐 = =
𝑷𝒓𝒐𝒅𝒖𝒄𝒕 𝒐𝒇 𝑻𝒆𝒆𝒕𝒉 𝒐𝒇 𝑫𝒓𝒊𝒗𝒆𝒓 𝑮𝒆𝒂𝒓𝒔 𝒍𝒆𝒂𝒅 𝒐𝒇 𝒎𝒂𝒄𝒉𝒊𝒏𝒆

Gear D ( 2nd driven gear)

Index head spindle

Gear C (2nd driver) Gear B (1st driven gear)

Gear A (1st driving gear)

Milling table leadscrew

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 Principles of Milling Machine Operations
6.12 Milling Spiral (Helical) Cuts
From the above illustration (applying compound gear train);
𝑙𝑒𝑎𝑑 𝑜𝑓 ℎ𝑒𝑙𝑖𝑥 𝐷𝑟𝑖𝑣𝑒𝑛 𝑔𝑒𝑎𝑟𝑠 𝑇𝐵 𝑇𝐷
𝐺𝑒𝑎𝑟 𝑅𝑎𝑡𝑖𝑜 = = = 𝑥 ; where T is the number
𝑙𝑒𝑎𝑑 𝑜𝑓 𝑚𝑎𝑐 ℎ𝑖𝑛𝑒 𝐷𝑟𝑖𝑣𝑖𝑛𝑔 𝑔𝑒𝑎𝑟𝑠 𝑇𝐴 𝑇𝐶
of teeth of each gear that compose the train.

Error in lead of helix – the difference between computed lead of helix and resulting
lead brought about by the actual gear ratio of the selected gears to compose the gear
train.

𝑇𝐵 𝑇𝐷
𝑅𝑒𝑠𝑢𝑙𝑡𝑖𝑛𝑔 𝐿𝑒𝑎𝑑 𝑜𝑓 𝐻𝑒𝑙𝑖𝑥 = 𝑙𝑒𝑎𝑑 𝑜𝑓 𝑚𝑎𝑐ℎ𝑖𝑛𝑒 𝑥 𝑥
𝑇𝐴 𝑇𝐶

Note: Error in lead of helix should not exceed any given tolerance.

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 Principles of Milling Machine Operations
6.12 Milling Spiral (Helical) Cuts
Illustrative example:
Given Helical Gear:
No. of teeth: 48
Diametral Pitch (Dp): 16
Helix Angle: 30 deg. (right hand)
Face width: 1.75inch
Error in lead (max) ±0.05inch
1) Determine indexing
2) Determine the gearing to connect table leadscrew to index head spindle.

The set of change gears furnished have the following numbers of teeth: 24 (2
gears), 28, 32, 40, 42, 44, 48, 56, 60, 64, 72, 86, 100.
Solution:

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 Principles of Milling Machine Operations
6.12 Milling Spiral (Helical) Cuts
Solution:

Check for error in lead (should be < max. error in lead)

Error in lead =
Where :
Thus, Error in lead =
Therefore:
Index head spindle
, and
Gear C (2nd driver) Gear B (1st driven gear)

Gear A (1st driving gear)

Milling table leadscrew

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