There are many different classifications of milling machines, and each classification contains several types of machines. These different milling machines are:
based on the main axis direction
Spindle orientation refers to the direction of the spindle axis. There are three categories in this regard:
①vertical milling machine
The spindle axis of a vertical milling machine lies in a vertical plane. Cutting tools can penetrate deep into the workpiece to perform additional functions such as drilling and cutting. Vertical mills come in two configurations: bed mills and turret mills. Typically, these machines have long, thin cutting tools.
②Horizontal milling machine
The spindle axis of a horizontal milling machine is located in the horizontal plane. Therefore, the cutting tool approaches the workpiece from the side rather than from the top. These machines often feature a turntable that provides an angled approach to the cutting tool. The cutting tools in horizontal milling machines are shorter and thicker.
③Universal milling machine
The universal milling machine can process both horizontal milling machines and vertical milling machines. This is achieved through a workbench that can be rotated into an almost vertical orientation, allowing access to complementary planes.
Which is better, vertical milling machine or horizontal milling machine?
Vertical milling machines are considered better than horizontal milling machines because of their greater versatility and simpler setup. This is why most milling machines come in a vertical configuration. Vertical milling machines have lower maintenance requirements than horizontal milling machines.
based on the number of axes
The axes of a milling machine represent the degrees of freedom of the cutting tool. Simply put, the tool axis is the number of directions the tool can move. According to these standards, the various milling machines are:
①Three-axis milling machine
Three-axis milling machines are the most basic type of equipment. The cutting tool is capable of movement in three linear X, Y and Z axes. Three-axis milling machines are popular because of their low cost and simplicity of operation. These machines also have lower maintenance requirements compared to multi-axis options.
②Four-axis milling machine
Four-axis milling machines can move in three linear axes as well as an additional rotary axis. The rotation axis can be any one of the A, B, and C axes. The A-axis rotates around the X-axis, the B-axis rotates around the Y-axis, and the C-axis rotates around the Z-axis. Due to the angular movement of the cutting tool, 4-axis milling machines can manufacture highly complex parts.
③Five-axis milling machine
Five-axis mill uses all three linear axes and any two rotary axes. A rotary table is often used to simplify the spindle axis complexity. Five-axis machines can manufacture complex parts at high speeds suitable for mass production.
As a leading provider of CNC milling and machining services and parts, 3ERP has 32 in-house 5-axis milling machines, allowing us to meet tight tolerances and produce complex geometries. For low cost parts we have 3 and 4 axis milling machines.
④Six-axis milling machine
Six-axis milling machines can move in all three linear axes and three rotary axes. This provides the ability to machine the work surface from all sides simultaneously without repositioning. six-axis milling machines provide high precision suitable for any requirement. The machine's production speed is sufficient for high-volume production.
based on machine structure
There are many different types of milling machines depending on their construction. These different types are:
①Fixed bed milling machine
Fixed bed milling machines have a fixed bed that is fixed to the frame. Parts such as the knee and saddle assemblies in fixed bed grinders are not adjustable. Fixed bed milling machines are an excellent choice for performing cutting operations. Fewer moving parts also make maintenance of the equipment easier.
②Knee milling machine
A knee mill is a vertical milling machine configuration in which the table is mounted on a movable casting called a "knee." The knee can move vertically on the Z-axis. This enables the operator to adjust the vertical position of the workbench. Knee mills increase the versatility of milling machines in operations such as drilling.
③Milling machine
A gantry mill is a simple device that cuts a flat surface on the workpiece perpendicular to the axis of the machine tool. These mills are most commonly found in the woodworking industry and are used to produce finished lumber. Gantry milling machines are easy to operate and maintain due to their simple setup.
④C frame milling machine
frame mills have a fixed spindle and knee structure that can only move vertically (Z-axis). The X and Y axes are merged into the workbench. C-frame milling machines are used in mass production due to their high milling speeds.
⑤Mobile column milling machine
Mobile column mills have columns that slide horizontally. Moving column milling machines are used when very long parts need to be machined. The movement of the column is achieved through guide rails on the machine tool bed.
⑥Milling machine
Gantry milling machines have a long bed that supports a gantry frame. Multiple tools can be installed on this gantry. The installed tool is able to move horizontally along the gantry, similar to a mobile column mill. It is used for the processing of large parts.
based on control methods
Different milling machines depending on the type of control mechanism are:
①Manual milling machine
Manual milling machines require the operator to manually move the cutting tool. This is the cheapest option for milling machine control. However, it has the lowest accuracy due to the high human error involved.
②Tracking Control Milling Machine
Track-controlled milling machines use a replica of the final part to guide the milling machine. The probe scans the replica counter and guides the cutting tool to create a similar pattern on the workpiece. It also requires a lot of manual work to scan the copies using probes. Furthermore, it is a time-consuming and low-precision control system.
③Milling machine with DRO (digital readout)
Digital readout milling machines are an improved form of manual control and feature counters that display the exact tool position. This helps the operator position the cutting tool precisely without any human error. While it improves accuracy over a manual mill, it still requires a long processing time. It is difficult to machine complex shapes using this method.
④CNC milling machine (computer numerical control)
Computer CNC milling machines use programmed instructions to control cutting tools. Computer numerical control (CNC) programs are written in CAM software prior to machining operations. CNC is the most precise and fastest way to move tools. Most industries extensively use CNC milling machines instead of any other control system.