Milling Operations

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Straddle Milling:

 The straddle milling is the operation of producing a flat vertical surface on both sides of a workpiece by using two side milling cutters mounted on the same arbor. Distance between the two cutters is adjusted by using suitable spacing collars. The straddle milling is commonly used to design a square or hexagonal surface.

Angular Milling:

The angular milling is the operation of producing an angular surface on a workpiece other than at right angles of the axis of the milling machine spindle. The angular groove may be single or double angle and may be of varying included angle according to the type and contour of the angular cutter used. One simple example of angular milling is that the production of V-blocks.

Gang Milling:

 The gang milling is the operation of machining several surfaces of a workpiece simultaneously by feeding the table against a number of cutters having the same or different diameters mounted on the arbor of the machine. The method saves much of machining time and is widely used in repetitive work. Cutting speed of a gang of cutters is calculated from the cutter of the most important diameter.

Form Milling:

The form milling is that the operations of manufacturing the irregular contour by using form cutters. The irregular shape may be convex, concave, or of any other shape. After machining, the formed surface is inspected by a template gauge. Cutting rate for form milling is 20% to 30% but that of the plain milling.

Profile Milling:

The profile milling is the operation of reproduction an outline of a template or complex shape of a master dies on a workpiece. Different cutters are used for profile milling. An end mill is one among the widely used milling cutters in profile milling work.


Saw Milling:

Saw-milling is the operation of producing narrow slots or grooves on a workpiece by using a saw-milling cutter. The saw-milling also performed for complete parting-off operation. The cutter and the workpiece are set in a manner so that the cutter is directly placed over one of the T-slots of the table. 

Keyways and Grooves Milling:

 The operation of producing of keyways, grooves and slots of varying shapes and sizes can be performed in a milling machine. It is done by using a plain milling cutter, a metal slitting saw, an end mill or by a side milling cutter. The open slots are often cut by a clear milling cutter, a metal slitting saw, or by a side milling cutter. The closed slots are produced by using endmills.

T-slot-operation:

A dovetail slot or T-slot is manufactured by using special sorts of cutters designed to offer the specified shape on the workpiece. The second slot is cut at right angles to the first slot by feeding the work past the cutter. A woodruff key is designed by using a woodruff key slot cutter. Standard keyways are cut on the shaft by using side milling cutters or end mills. The cutter is set exactly at the centre line of the workpiece and then the cut is taken.

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