In Milling operation the work piece is fed against a rotating cylindrical

tool.

The rotating Milling tool consists of multiple cutting edges (multipoint

cutting tool).

The cutting tool used in milling operation is called milling cutter, which
consists of multiple edges called teeth.

Interrupted cutting action subjects the teeth to a cycle of impact force

and thermal shock on every rotation. Thus the tool material and cutter
geometry must be designed to bear the above stated conditions.

Various designing strategies are considered to design the effective

plain milling cutter like diameter, thickness, face width etc. The
design and analysis is carried out using softwares like CREO,
NASTRAN, PATRAN.
Axis of rotation of the cutting tool is perpendicular to the direction of feed,
either parallel or perpendicular to the machined surface.

Milling is an interrupted cutting operation: the teeth of the milling cutter enter
and exit the work during each revolution. This interrupted cutting action
subjects the teeth to a cycle of impact force and thermal shock on every
rotation. The tool material and cutter geometry must be designed to withstand
these conditions.

In every case, the teeth of milling cutters have cutting edges and angles
related to edges. In effect each tool acts like single point tool mounted on a
cylindrical hub. The teeth on the milling cutters are mostly evenly spaced.

A cylindrical milling cutter with teeth on the periphery only, used for milling
plain or flat surfaces, is known as Plain Milling Cutter, Also known as slab
cutter.
Down Milling

Up Milling
 Cutting Velocity, V = DN

Cutting Speed = V = (DN)/1000

Feed rate, F = f. u. N
This figure shows a Milling
Dynamometer.
From the given conditions the force acting on the cutter (W) may be calculated as:

The stress at each speed is determined by:

The maximum allowable stress at the tip of the cutter is determined as:
The main objective of this study has been to perform a
detailed computer-aided design and analysis of a plain milling
cutter by integrating solid modeling and finite element
analysis. Any cutter, single point or multiple point, can be
designed based on the approach presented here. Specifically
for the cutter design, it produced the cutting variables that
yield the minimum cost of manufacturing. The different
design activities, such as design solid modeling, and finite
element analysis, have been integrated. As is evident,
approach presented in this paper is flexible and easy to use.
Finally the design and analysis is carried out using the software
CREO, NASTRAN & PATRAN. The values obtained are compared
with the model and theoretical stress values of the plain milling
cutter.
[1]. Machining and Machine tools by A.B. Chattopadhyay 2011 edition Wiley
India Publications
[2]. Mohan, L. V. Profile Corrections for relieving tool for form relieved milling
cutters. Proceedings of the 12th All India Machine Tool Design and Research
Conference 1986, Dec. l&12, pp. 2255228.
[3]. N and K. Jha and Kathryn Hornik, Integrated computer-aided optimal design
and FEA of a plain milling cutter, Mechanical Engineering Department, Manhattan
College, Riverdale, NY, USA
[4]. A text book of Machine design R.S Khurmi, and J.K Gupta. 2008 edition S.
Chand Publications.