DR. J.N. MEHTA GOVT. POLY. AMRELIMECHANICAL DEPARTMENT

PREPARED BY:-DHIREN P PATEL5TH SEM MECH.ENGG.(096110319530)

MILLING CUTTER

MILLING CUTTER

A milling cutter is a special type of cutting tool which has multiple cutting edges. There are many advantages of milling cutters compared to single point cutting tool.

1) High machining2) Completes required machining operation in required time.

NOMENCLATURE OF MILLING CUTTER

MILLING CUTTER MATERIALS

High-Speed Steel:-- Iron with additives

- Carbon: hardening agent- Tungsten and Molybdenum: enable steel to retain hardness up to red heat- Chromium: increases toughness and wear resistance- Vanadium: increases tensile strength

- Used for most solid milling cutters

Cemented-Carbide :-- Higher rates of production (3-10 times faster)- Must select proper type of carbide

- Straight tungsten carbide: cast iron, plastics- Tantalum carbide: low/medium-carbon steel- Tungsten-titanium carbide: high-carbon steel

Cutter Characteristics:-- Harder than metal being machined- Strong enough to withstand cutting pressures- Tough to resist shock resulting from contact- Resist heat and abrasion of cutting- Available in various sizes and shapes

MILLING CUTTER ARE OF DIFFERENT TYPES,THEY ARE CLASSIFIED BASED ON VARIOUS FACTORS1) Based on constructional features of the tooth of milling cutter - Solid teeth milling cutter - Inserted teeth milling cutter - Tipped teeth milling cutter2) According to the relief characteristics  - Profile relieved milling cutter - Form relieved milling cutter3) Based on methods used for mounting - Arbour type - Facing type - Shank type4) According to the direction of rotation of cutter - Right hand rotational milling cutter - Left hand rotational milling cutter5) According to the direction of helix - Parallel or straight teeth milling cutter - Right hand helical milling cutter - Left hand helical milling cutter - Alternate helical milling cutter6) According to purpose or use of cutter - Standard milling cutter - Special milling cutter

THERE ARE MANY TYPES OF STANDARD MILLING CUTTERS SOME OF THEM ARE:-1) Plain milling cutter - Light duty plain milling cutter - Heavy duty plain milling cutter - Helical plain milling cutter2) Side milling cutter - Plain side milling cutter - Staggered teeth side milling cutter - Half side milling cutter - Interlocking side milling cutter3) Metal slitting saw - Plain metal slitting saw - Staggered teeth metal slitting saw4) Angle milling cutter - Single angle milling cutter - Double angle milling cutter5) End mill - Taper shank end mill - Straight shank end mill - Shell end mill6) T-slot milling cutter 9) Formed cutter 7) Woodruff key slot milling cutter - Convex milling cutter 8) Fly cutter - Concave milling cutter

PLAIN MILLING CUTTER

- Once widely used - Cylinder of high-speed steel with teeth cut on periphery- Used to produce flat surface- Several types

- Light-duty- Light-duty helical- Heavy-duty- High-helix

SIDE MILLING CUTTER

- Comparatively narrow cylindrical milling cutters with teeth on each side and on periphery- Used for cutting slots and for face and straddle milling operations- Free cutting action at high speeds and feeds- Suited for milling deep, narrow slots

FACE MILLING CUTTER

• Generally over 6 in. in diameter- Have inserted teeth made of high-speed steel head in place by wedging device

• Most cutting action occurs at beveled corners and periphery of cutter• Makes roughing and finishing cuts in one pass

END MILLING CUTTER

• Face milling cutters under 6 inch• Solid, multiple-tooth cutters with teeth on face and periphery• Held on stub arbor

- May be threaded or use key in shank to drive cutter

ANGULAR CUTTERS

-Teeth neither parallel nor perpendicular to cutting axis - Used for milling angular surfaces

- Grooves, serrations, chamfers and reamer teeth- Divided into two groups

- Single-angle milling cutters- Double-angle milling cutters

- Single-angle- Teeth on angular surface- May or may not have teeth on flat- 45º or 60º

- Double-angle- Two intersecting angular surfaces with cutting teeth on both- Equal angles on both side of line at right angle to axis

FORMED CUTTERS

- Incorporate exact shape of part to be produced- Useful for production of small parts- Each tooth identical in shape- Sharpened by grinding tooth face (may have positive, zero or negative rake)

- Important to maintain original rake- Difficult to sharpen

TYPES OF FORMED CUTTERS

Concave Convex Gear Tooth

SCHEMATIC VIEWS OF CONVENTIONAL UP AND DOWN MILLING

The basic function of milling machines is to produce flat surfaces in anyorientation as well as surfaces of revolution, helical surfaces and contouredsurfaces of various configurations. Such functions are accomplished by slowlyfeeding the work piece into the equispaced multiedge circular cutting toolrotating at moderately high speed as indicated in Fig. Up milling needsstronger holding of the job and down milling needs backlash free screw-nutsystems for feeding.

Cutting motion Cutting motion

1)The inserts rotate as they cut.2) Faster cutting speeds allow faster feed rates.3) Rotating inserts last longer4) Interrupted cuts are no problem5) Heat in the chip increases with efficiency6) "Roll-Shearing" Eliminates breakout in cast iron parts.7) There's less wear and tear on your machinery

ADVANTAGES OF MILLING CUTTER

DISADVANTAGES OF MILLING CUTTER

There are also disadvantages by employing a milling cutter.1) High cost2) High cutting temperatures are generated3) High maintenance cost 

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