Milling

Milling refers to a cutting Production method which is used for manufacturing components with a specific geometric contour. Thanks to its high efficiency, productivity and precision, milling is particularly popular in metal-processing production technology.
The milling can be used both for the processing of planar surfaces and for the production of complex, three-dimensional contours. A milling tool with geometrically determined cutting edges is used and, during the milling process, material is removed from a workpiece by a rotating circular movement. Milling can now be carried out both manually and using state-of-the-art CNC machine tools with a high degree of automation.

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Technical basics for milling

According to DIN 8589, milling is one of the cutting methods with geometrically determined cutting edges. This means that the geometric contour of the milling cutter – unlike other manufacturing methods such as grinding, honing or lapping – is clearly defined.

Milling of an injection mould - Aringer Formenbau

The centerpiece of the method is the tool, which is also referred to as a milling cutter. The milling cutter is usually characterized by several cutting edges and can be used for machining both perpendicularly and obliquely to the axis of rotation. The tool can be used either in manual milling machines or in machining centers. When milling, it is necessary to take into account a whole range of cutting parameters in order to achieve the desired contour and to meet the requirements for surface quality. These include:

Speed:
The speed of the milling cutter depends on material and cutting material and has a decisive influence on the cost-effectiveness of the method.
Promotion:
As the feed speed increases, the wear of the tool and the chip thickness increase. Therefore, the feed movement has a significant influence on the surface quality.
Width:
The width of the cut determines how far the cutting edge of the tool engages in the material. The ratio of cutting width to tool width is usually about 2/3.
Intrusion angle:
The angle between the entry and exit of the cutting edge is referred to as the engagement angle. It determines the number of cutting edges which are simultaneously in engagement, wherein the milling course is more calm and uniform with increasing number of cutting edges.

The different variants during milling

In milling, a distinction is made in principle between the direct and counterrunning milling. Continuous milling is characterized by the fact that the milling cutter enters the material with a maximum chip thickness and exits with a minimum thickness – particularly narrow tolerances with respect to the surface quality can be achieved.
In addition, milling processes are further differentiated depending on the feed motion and surface processing. Examples include:

Planting:
Plan milling is used to produce flat surfaces. The method is distinguished by a straight feed and a rotary movement executed perpendicular to the tool.
Rundmilling:
circular cylindrical surfaces are produced by round milling. Depending on the resultant shape, a distinction is made between the inner round milling and the outer round milling.
Form milling:
The shaping milling with a controlled feed movement can be used in many ways for producing flat and spatial surfaces.
Hobbing:
In rolling milling, a profiled milling cutter is used which simultaneously performs a feed and a rolling movement. Thus, flat and spatial contours can be produced.
Profile milling:
The profile milling is characterized in that a specific tool profile is formed on the workpiece during machining.
Screw milling:
In screw milling, helical surfaces can be produced by helical feed movements in order to produce approximately threads.

In addition to the classifications mentioned here, milling is divided into further variants, such as the HSC milling with high-speed cutting and the 5-axis milling for producing particularly complex contours. For higher quantities, the CNC milling is usually used on modern CNC machine tools.

What materials are processed during milling?

Milling is very popular as an efficient cutting process with high surface quality, especially in the metal processing industry. Milling parts are used in a wide variety of industries, from machine and plant engineering to electrical engineering, medical technology and aerospace technology to the automotive industry. In addition, the method is also suitable for plastic and wood processing. Among the most important milling materials include:

Steel and steel casting
Aluminium and aluminium casting
titanium
Gold
Silver
Bronze
Brass
Plastic
Wood

Milling machine C 400 by Hermle in use at MZW Weber GmbH

Good to know: To the story of milling

While most machine tools – such as the lathe or the planing machine – were developed during the industrial revolution in England, milling is primarily an American development. In 1818, the American engineer and inventor Eli Whitney developed the first metal milling machine and revolutionized the market again. Years before, with the invention of the cotton graining machine, he had already made the labor-intensive separation of seeds from cotton extremely easier.

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