Up Milling and Down Milling:
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- The milling is a process of metal-removing by feeding the work past a rotating multipoint cutter. The diagram is shown below:
- This machine can hold one or more number of cutters at a time and rotates at high speed to remove the metal at a faster rate.
- The metal removal rate is faster as compared to a lathe machine.
- This machine is used to make gears like Spur gears, and also drill the workpiece bore, and produce slots.
- The up milling is also called as conventional milling or Climb up milling.
- In which the cutter and feed moves in opposite direction i.e the rotary cutter moves against the feed.
- With reference to the adjacent figure, the cutter rotates in the anti-clockwise direction, while the direction of feed is from right to left.
- So, due to this opposite motion, the width of the cutting chips gradually increases from minimum to maximum.
- There is massive friction between the cutter and workpiece which results in generating a large amount of heat.
Advantages of Up Milling:
- This is a safe operation because It has no tendency to drag the workpiece into the cutter.
- The up milling is generally used for milling of casting and forging.
- The down milling is also called as Climb down milling.
- In case of down milling, the cutter rotates in the same direction as that of the feed.
- In down milling, there is less friction involved between the cutter and the workpiece as both.
- Therefore, the cutter and feed are moving in the same direction. This small amount of friction results in the generation of minimum heat.
- Here, the thickness of the chip varies from a maximum to minimum during the process.
Advantages of Down Milling:
- This machine poses a longer tool life.
- This machine produces a good surface finish.
- This type of machine generally used for finishing the operation like sawing, grooving, keyway cutting etc.
Difference between Up Milling and Down Milling Machine:
|Sl.No||Up Milling||Down Milling|
|1.||This machine is also called as conventional milling or climb up milling.||Down milling is also called a climb down milling.|
|2.||The cutting forces act upward.||The cutting forces act downward.|
|3.||Up milling is mostly used for rough cutting operations.||Down milling is used for finishing operations.|
|4.||Due to more tool wear rate, their durability of the tool is less.||Due to less tool wear rate, their durability of the tool is more.|
|5.||Tool wear rate is more, as the direction of the rotary cutter is against the feed.||Tool wear rate is less, as the direction of a cutter is the same direction as the feed.|
|6.||This process is mostly used in the conventional way of cutting the surface.||Nowadays, down milling is a better operation choice then up milling machine.|
|7.||Effective cooling is not required during cutting action.||Effective cooling is possible during cutting action.|
|8.||Cutter rotates against the direction of travel of the workpiece during metal cutting.||Cutter rotates in the same direction of travel of the workpiece during metal cutting.|
|9.||Poor surface finish.||Good surface finish.|
|10.||It requires a large amount of force compared to down milling.||For down milling, there is a requirement of less force.|
|11.||This machine is mostly used cutting of brass, bronze, and ferrous materials.||And whereas this is applicable to aluminum and aluminum alloys.|
|12.||Chip thickness starts at zero and increases towards the end of the cut.||Chip thickness is maximum initially and reduces to zero at the end of the cut.|
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