7 Milling Operations

1. Face Milling

Face milling is a milling operation where the primary cutting action is performed on the face of the workpiece. The cutting tool, typically a face mill, removes material to create a flat surface. This operation is commonly used to machine the top or bottom surfaces of workpieces.

Example: When machining a metal block to create a flat top surface, a face mill is used. The tool rotates and moves across the block, removing material to achieve a smooth, flat surface. This is essential for ensuring that the block can be used as a base or mounting surface.

2. Slab Milling

Slab milling involves using a large milling cutter to remove material from a large area of the workpiece. This operation is often used for roughing operations, where the primary goal is to remove a significant amount of material quickly. The workpiece is typically moved against the rotating cutter.

Example: When machining a large metal plate to reduce its thickness, a slab mill is used. The plate is moved against the rotating cutter, which removes material in large chunks. This operation is efficient for initial material removal before more precise milling operations.

3. End Milling

End milling is a milling operation where the cutting tool, typically an end mill, removes material from the sides and ends of the workpiece. This operation is versatile and can be used to create slots, pockets, and complex shapes. The workpiece is moved against the rotating end mill.

Example: When machining a metal block to create a slot, an end mill is used. The block is moved against the rotating cutter, which removes material to create the slot. This operation is crucial for creating features like keyways and channels in mechanical components.

4. Pocket Milling

Pocket milling is a milling operation used to create recessed areas or pockets in the workpiece. This operation often involves using a series of toolpaths to remove material from the interior of the workpiece. Pocket milling is essential for creating cavities and internal features.

Example: When machining a metal block to create a rectangular pocket, a series of toolpaths are used. The block is moved against the rotating cutter, which removes material to create the pocket. This operation is vital for creating features like gear housings and electronic enclosures.

5. Slot Milling

Slot milling is a milling operation used to create elongated slots in the workpiece. This operation typically involves using a slot cutter or end mill to remove material along a linear path. Slot milling is essential for creating features like keyways and splines.

Example: When machining a metal shaft to create a keyway, a slot cutter is used. The shaft is moved against the rotating cutter, which removes material to create the keyway. This operation is crucial for ensuring that the shaft can be properly keyed to other components.

6. Profile Milling

Profile milling is a milling operation used to create complex, three-dimensional shapes on the workpiece. This operation often involves using a series of toolpaths to remove material along a specific contour. Profile milling is essential for creating intricate parts with complex geometries.

Example: When machining a metal part with a complex, curved surface, a series of toolpaths are used. The part is moved against the rotating cutter, which removes material to create the desired profile. This operation is vital for creating parts like turbine blades and mold cavities.

7. Drilling

Drilling is a milling operation where a rotating drill bit is used to create a hole in the workpiece. This operation is typically performed on a milling machine by moving the drill bit into the workpiece. Drilling is essential for creating holes of various diameters and depths.

Example: When machining a metal plate to create a series of holes, a drill bit is used. The plate is moved against the rotating drill bit, which removes material to create the holes. This operation is crucial for creating features like bolt holes and mounting points.