Experiment # 5

Objective:Different parts and operations of milling machine

Apparatus:Horizontal and vertical milling machine

Theory:Milling machines must provide a rotating spindle for the cutter

and a table for fastening, positioning, and feeding the workpart. Various
machine tool designs satisfy these requirements. To begin with, milling
machines can be classified as horizontal or vertical. A horizontal milling
machine has a horizontal spindle, and this design is well suited for
performing peripheral milling (e.g., slab milling, slotting, side and straddle
milling) on workparts that are roughly cube shaped. A vertical milling
machine has a vertical spindle, and this orientation is appropriate for face
milling, end milling, surface contouring, and die-sinking on relatively flat
workparts.
1) Horizontal milling machine:-

Column-The column of the milling machine, along with the base, are the
major structural components. They hold, align, and support the rest of the
machine.

Table-Holds and secures the workpiece for machining.

Saddle-The saddle is attached to the knee. The saddle provides the in
and out, or Y axis table travel.
Knee-The knee supports the saddle and the table. The knee can be
moved up and down for workpiece positioning.
Base- The base of the milling machine, along with the column, are the
major structural components. They hold, align, and support the rest of the
machine.
Spindle-The spindle holds the tool and provides the actual tool rotation.
Spindle Reverse Lever-The position of this lever determines the spindle
direction. The three positions of the handle are; In, Middle, and Out. The
middle position is the neutral position. Never move the spindle reverse
lever when the spindle is turning.
Spindle Speed Selection Lever-The spindle speed selection lever is
used to change the spindle R.P.M. setting. This type of machine has a
geared head so the spindle speed can only be changed when the spindle
is stopped.
Spindle Clutch Lever-The spindle clutch lever engages the spindle
clutch to the motor. By manipulating the spindle clutch lever the operator
can start and stop the spindle.
Feed Rate Selection Lever-The feed rate selection lever is used to
change the feed rate setting. The feed rate settings are expressed in
inches per/mint

Arbor Support-The arbor support supports the end of the arbor that is
opposite the spindle. The arbor support is attached to the over arms bars.
Arbor Support Lock Nut-The arbor support lock nut fastens the arbor
support to the overarm bars.
Overarm Bars-The Overarm bars align and support the arbor support.
Oil Reservoir-The oil reservoir holds and distributes oil to the overarm
support bushing and arbor bearing collar. Proper lubrication and fit
between the arbor bearing collar and the arbor support bushing are
crucial.
Arbor Support Bushing Adaptor-The bushing adaptor comes in various
sizes. The bushing adaptor allows the operator to use different size arbor
support bushings in the same arbor support and also allows for slight
adjustments for fit between the bushing and the collar.
2) Vertical milling machine:-

Classification of Milling Operations

Milling operations may be classified under four general heading as follows:

1) Face Milling, machining flat surfaces which are at right angle to

the axis of the cutter.
2) Plain or Slab Milling, machining flat surfaces which are parallel
to the axis of the cutter.
Mounting the Workpiece :The workpiece is generally clamped directly to the table
or supported in a vise for plain milling. The milling machine table should be checked
for alignment before starting to cut. If the workpiece surface to be milled is at an
angle to the base plane of the piece, the workpiece should be mounted in a universal
vise or on an adjustable angle plate. The holding device should be adjusted so that
the workpiece surface is parallel to the table of the milling machine .
Selecting the Cutter
Flat surfaces may be milled with a plain milling cutter mounted on an arbor.
Deeper cuts may generally be taken when using narrow cutters than with wide
cutters. The choice of milling cutters should be based on the size and shape of the
workpiece. If a wide area is to be milled, fewer traverses will be required using a
wide cutter. If large quantities of metal are to be removed, a coarse tooth cutter
should be used for roughing and a finer tooth cutter should be used for finishing. A
relatively slow cutting speed and fast table feed should be used for roughing, and a
relatively fast cutting speed and slow table feed used for finishing. The surface
should be checked for accuracy after each completed cut.

Figure 4-27. Plain milling.

Setup

A typical setup for plain milling is illustrated in Figure 4-27. Note that the milling
cutter is positioned on the arbor with sleeves so that it is as close as practical to the
milling machine spindle while maintaining sufficient clearance between the vise and
the milling machine column. This practice reduces torque in the arbor and permits
more rigid support for the cutter.

3)
4)

Angular Milling, machining flat surfaces which are at an

inclination to the axis of the cutter.
Form Milling, machining surfaces having an irregular outline.