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Milling

What is milling?

Milling is an essential machining method that uses a multi-edged cutting tool, known as a milling cutter, to remove material from a workpiece by cutting. This process is crucial for achieving complex shapes and precise tolerances for various parts, such as machine components, mold parts, and many others. Milling can be performed with different types of machine tools and methods, enabling efficient and accurate execution of diverse and demanding machining projects.

Machine tools used in milling

The range of machine tools used in the milling process is broad, encompassing various devices that handle workpieces of different sizes and shapes. The most typical machines include:

  • Vertical Machining Centers: Vertical machining centers are extremely versatile and suitable for a wide range of milling tasks. The spindle is mounted vertically, allowing for easy automatic tool changes. Notable manufacturers include Haas, DMG Mori, and Mazak.
  • Horizontal Machining Centers: In horizontal machining centers, the spindle is mounted horizontally, making them ideal for machining large and heavy workpieces. These machines can provide compact and efficient machining paths. Examples of manufacturers include Makino, Okuma, and DN Solutions.
  • Boring Mills: Boring mills are specially designed for creating large and precisely machined holes. They offer high accuracy and rigidity, making them perfect for manufacturing large industrial components. UnionChemnitz and TOS Varnsdorf are well-known manufacturers of these types of machines.
  • Plano Milling Machines: Plano milling machines are designed for milling long, straight surfaces. They are especially suitable for large metal plates and other sizable workpieces. Nicolas Correa is a key manufacturer of industrial plano milling machines.
  • Gantry Milling Machines: In gantry milling machines, the tool moves beneath a gantry structure, which enables milling of extremely large workpieces. Gantry machines offer a large working area and high rigidity. Manufacturers include Hartford and Soraluce.
  • 5-Axis Milling Machines: 5-axis milling machines allow the tool to move in five directions simultaneously, making them highly effective for machining complex and precise parts. DMG Mori and GROB are renowned manufacturers offering advanced 5-axis machines.
  • Multitasking Lathes and CNC Lathes with Live Tools: Modern CNC lathes and multitasking lathes may feature live tooling, enabling both turning and milling operations on the same machine. This reduces the need for part transfers and increases productivity. Examples of manufacturers include Nakamura-Tome, Mazak, and DMG Mori.

Milling methods

There are several different milling methods, selected according to the workpiece's shape, material, and machining goals:

  • Face Milling: Face milling uses a milling cutter to evenly remove material from the surface of the workpiece. This method is especially important for machining large, flat surfaces.
  • Angle Milling: Angle milling uses specialized tools to machine various angles on a workpiece.
  • Dynamic Milling: Dynamic milling utilizes deep axial and shallow radial cuts, allowing for even tool wear and long tool life. This method is specifically developed for roughing difficult-to-machine materials like hard steels and superalloys.
  • Chamfer Milling: Chamfer milling creates chamfers on the edges and corners of a workpiece, improving machinability and finish.
  • Slot Milling: Slot milling is used to cut various grooves, such as keyways, into a workpiece.

Tools used in milling

The milling process requires a wide variety of tools designed for specific applications and material handling:

  • End Mills: These are available as insert-style cutters and solid carbide end mills. Solid carbide end mills are especially popular for their high productivity and long tool life.
  • Indexable Milling Cutters: These are cost-effective, with easily replaceable inserts of different geometries and materials, making them excellent for diverse machining needs.
  • Specialty Milling Tools: This category includes profile mills, segment/profile mills (barrel mills), corner rounding cutters, chamfer cutters, T-slot, and dovetail cutters. They are mainly used for shaping and machining small details.
  • Dynamic End Mills: These tools are designed especially for dynamic milling, utilizing large axial and small radial cutting depths. These tools often feature multiple cutting edges and chip breakers.

Cutting fluids in milling

Cutting fluids are often used in milling, especially to reduce high temperatures and friction. They improve chip evacuation and reduce tool wear, extending tool life and improving surface finish. Cutting fluids are selected and used based on the material being machined and the chosen method.

Milling and CAM software

In modern milling, CAM software (Computer-Aided Manufacturing) is essential. With software like Mastercam, highly complex machining paths can be created precisely and efficiently. They enable methods such as dynamic milling, reducing tooling costs, shortening machining time, and increasing productivity.

Summary

Milling is a versatile and efficient machining method widely using different tools and machine tools. Its versatility also extends to various milling methods, such as face milling, angle milling, dynamic milling, chamfer milling, drilling/milling, and slot milling, which achieve precise and high-quality machining solutions. The use of cutting fluids and modern CAM software is essential for advanced machining methods, significantly improving productivity and machining quality. Successful milling execution requires careful selection of tools and process parameters to ensure a high-quality and cost-effective result.