BLOG » What is Milling: All you need to know about it

What is Milling: All you need to know about it

Milling is a type of machining process used to create various mechanical components made of materials such as plastic and metal. This method results in highly precise finished products thanks to the precise tools used to manufacture.

In this article, we will introduce the types of machines used in milling, the various tools employed, and the shapes that can be produced through milling.

What is Milling

Milling is a machining process that involves cutting tools, known as milling cutters, that rotate at high speeds while cutting into a workpiece fixed to a worktable.

By utilizing various types of cutting tools, it is possible to answer a multitude of needs. To list a few: flat surfaces, curved surfaces, hole drilling, and groove cutting.

Complex shapes can be manufactured through this process thanks to its three-dimensional movement. In fact, during manufacturing the milling cutters are moving vertically, while the worktable holding the workpiece slides horizontally. Nonetheless, it’s important to note that the capability to machine certain shapes depends on the specific milling machine, so careful consideration is necessary.

Milling machines are classified into two main types: “vertical-type” milling machine has a spindle perpendicular to the worktable, and it is the most common type of milling machine. On the other hand, a “horizontal-type” milling machine has a spindle parallel to the worktable’s surface.

Key Machines Used in Milling

In milling processes, various machines are employed, each with its unique manufacturing characteristics. Let’s delve into the features of some of the key milling machines below.

Universal Milling Machine

The universal milling machine is a milling table where operators manually attach cutting tools and control the process by hand. The quality of the output can vary depending on the operator’s experience and skill. When operated by a skilled professional, it can achieve precise and high-quality results. Consequently, it is considered suitable for tasks involving complex shapes, prototypes, or orders requiring high precision.

NC Milling Machine

The NC (Numerical Control) milling machine is controlled by a computer, allowing operators to specify processing conditions numerically. By enabling numerical control, this machined has significantly reduced variations in output quality. While manual adjustments were necessary for each step in the universal milling machine, the NC milling machine improved the entire process’ quality and speed.

Machining Center

The machining center is a type of milling machine that not only allows numerical control but also enables automatic tool changes. Unlike other machines, the machining center can simultaneously hold multiple tools. This innovation allows for automatic tool changes, eliminating the need for manual tool swapping and improving work efficiency.

In order to provide the best quality to our customers, this is the main machine we as meviy are using to manufacture our milled parts.

NC Gear Cutting Machine

An NC gear cutting machine is one type of milling machine used for gear processing. It employs a dedicated cutting tool called “hob” which rotates to perform the machining. Gears have intricate shapes and are highly precise components. NC gear cutting machines allow for easy adjustment of the number of teeth and can perform hobbing automatically. This makes them ideal for producing gears efficiently and with precision.

Types of Milling Tools

Besides the milling machines themselves, the other core element that makes milling an unique and precise process is the tool used. Depending on the final components needed, different tools can be used, each of them with specific functionality.

Face Milling Cutter

The face milling cutter features multiple blades along the outer edge of a circle. It achieves flat surface by rotating while moving parallel to the workpiece. This tool offers efficient material removal over a wide area, making it suitable for high-efficiency cutting. It also enables high-precision flat surface machining. It is primarily used with vertical milling machines and is the most commonly used tool.

End Mill

The end mill features a slender, drill-like shape and is a versatile tool capable of various machining tasks, including flat, stepped, and groove machining. While face milling cutters are used for machining large flat surfaces, end mills are employed for smaller and intricate shapes. They can handle various shapes, reducing the need for frequent tool changes.

Add Your Heading Text Here

The groove milling cutter operates by rotating circular blades while moving parallel to the workpiece to create grooves. The width and depth of the grooves are determined by the blade’s width and outer diameter to some extent.

Groove milling cutters offer faster cutting speeds and high precision compared to using end mills. They are especially useful for machining numerous long and deep grooves.

Plain Milling Cutter

A plain milling cutter has blades along the outer surface of its cylindrical shape. It is attached to horizontal milling machines and used for flat surface machining.

Plain milling cutters provide efficient material removal, although they may have slightly lower precision compared to face milling cutters.

As we have seen, milling processes can achieve a wide range of shapes through the use of different tools. Let’s explain some representative types of milling processes.

Summary

Milling is a fundamental process in the realm of custom mechanical component manufacturing. It offers versatility, precision, and efficiency in crafting intricate shapes and structures. From the classic hand-operated universal mills to the advanced automated CNC mills and machining centers, the choice of milling machine depends on the complexity of the task at hand. Similarly, selecting the right milling tool is crucial for achieving desired results. Milling allows engineers and manufacturers to bring their innovative designs to life, ensuring that custom mechanical components meet the highest standards of quality and functionality. As technology continues to advance, milling remains at the forefront of producing precision components that drive various industries forward.