Milling is the machining process of using rotary cutters to remove material from a workpiece by advancing (or feeding) in a direction at an angle with the axis of the tool. It covers a wide variety of different operations and machines, on scales from small individual parts to large, heavy-duty gang milling operations.
The milled configuration
Milling has been evolved into a method that machines a very broad range of operations.
In addition to all the conventional applications, milling is a strong alternative for producing holes, threads, cavities and surfaces that used to be turned, drilled or tapped.
The configurations to be milled have to to be carefully considered. These can be located deep, requiring extended tooling, or contain interruptions and inclusions.
The component
Workpiece surfaces can be demanding, with cast skin or forging scale.
In cases of bad rigidity, caused by thin sections or weak clamping, dedicated tooling and strategies have to be used.
The workpiece material and its machinability must also be analyzed to establish optimal cutting data.
The machine
The machine is of great importance for the choice of milling method. Face/shoulder or slot milling can be performed in 3-axes machines, while milling 3D profiles require alternatively 4- or 5-axes machines.
Turning centers today often have milling capability due to driven tools, and machining centres often have turning capability. CAM developments mean that 5-axis machines are increasingly common. They offer increased flexibility, but stability can be a limitation.
The milled configuration
Milling has been evolved into a method that machines a very broad range of operations.
In addition to all the conventional applications, milling is a strong alternative for producing holes, threads, cavities and surfaces that used to be turned, drilled or tapped.
The configurations to be milled have to to be carefully considered. These can be located deep, requiring extended tooling, or contain interruptions and inclusions.
The component
Workpiece surfaces can be demanding, with cast skin or forging scale.
In cases of bad rigidity, caused by thin sections or weak clamping, dedicated tooling and strategies have to be used.
The workpiece material and its machinability must also be analyzed to establish optimal cutting data.
The machine
The machine is of great importance for the choice of milling method. Face/shoulder or slot milling can be performed in 3-axes machines, while milling 3D profiles require alternatively 4- or 5-axes machines.
Turning centers today often have milling capability due to driven tools, and machining centres often have turning capability. CAM developments mean that 5-axis machines are increasingly common. They offer increased flexibility, but stability can be a limitation.
