A Closer Look at Milling Machines and Processes


Erhan Budak, PhD – Professor, Faculty of Engineering and Natural Sciences, Sabanci University, Orhanli, Tuzla, Istanbul

Series: Manufacturing Technology Research; Mechanical Engineering Theory and Applications
BISAC: TEC020000; TEC046000; TEC009070
DOI: https://doi.org/10.52305/MWUU2566

To produce the complex parts needed in many industries ranging from the aerospace and automotive industries to the medical field and to the energy sector, milling is either a key part of the manufacturing process or enables the tools for these industries to exist. Fundamentally, milling involves a cutting tool with multiple teeth that remove material in the form of chips on a milling machine having multiple axes. The milling processes have advanced significantly in terms of productivity and quality over time and naturally certain new issues have arisen. This book presents the current state of the art regarding these key issues while also proposing effective methodologies to optimize each part of this essential process.

The preliminary chapters focus on the fundamental kinematics, mechanics and dynamics of milling operations followed by design optimization and motion control of milling machines. Spindle dynamics strongly affecting the performance of milling machines is the topic of the following chapter.  The subsequent chapters focus on the milling of thin-walled parts, cutting tools with special geometries suppressing chatter vibrations and the thermal aspects of milling. Tool life has a direct effect on the productivity and cost of milling operations; thus, the next chapters are devoted to wear analysis and coatings for milling tools. Variations on the machine, tool and work conditions over time affect the performance in a milling operation. These changes can only be detected in real-time during operation using process monitoring which is the focus of the next chapter. In the last chapter, turn-milling offering higher productivity for large diameter parts and reduced tool wear in the machining of difficult-to-cut materials is presented as a growing technology of interest.

Table of Contents


Chapter 1. Milling Mechanics and Dynamics
Z. Murat Kilic, PhD
Department of Mechanical, Aerospace and Civil Engineering, The University of Manchester, Oxford Rd, Manchester, United Kingdom

Chapter 2.
Machine Tool Design, Simulation and Dynamics
M. F. Zaeh, PhD, A. Fischer, J. Ellinger, and T. Semm, PhD
Institute for Machine Tools and Industrial Management, TU Munich, Munich, Germany

Chapter 3. Motion Control for Milling Process
Atsushi Matsubara¹, PhD and Soichi Ibaraki², PhD
¹Department of Micro Engineering, Kyoto University, Kyoto, Japan
²Graduate School of Advanced Science and Engineering, Hiroshima University, Higashi Hiroshima, Japan

Chapter 4. Spindle Dynamics
Orkun Ozsahin¹, PhD, Mathieu Ritou², PhD, Matěj Sulitka³, PhD, and Josef Kekula³, PhD
¹Middle East Technical University, Ankara, Turkey
²LS2N (Laboratory of Digital Sciences of Nantes, UMR CNRS 6004), Nantes University, Nantes, France
³RCMT (Research Center for Manufacturing Technology), Czech Technical University in Prague, Prague, Czech Republic

Chapter 5. Mechanics and Dynamics of Thin-Wall Milling Process
Min Wan¹, PhD, Erhan Budak², PhD, and Wei-Hong Zhang¹, PhD
¹School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, Shaanxi, China
²Sabanci University, Manufacturing Research Laboratory, Istanbul, Turkey

Chapter 6. Special Milling Tools for Improving Productivity
Faraz Tehranizadeh¹, PhD, Zahra Barzegar ², PhD, and Erhan Budak ², PhD
¹ Faculty of Engineering and Natural Sciences, Kadir Has University, Istanbul, Turkey
² Manufacturing Research Laboratory, Sabanci University, Istanbul, Turkey

Chapter 7. Thermal Analysis of Milling Operations
Umut Karaguzel, PhD
Mechatronics Engineering Department, Yildiz Technical University, Istanbul, Turkey

Chapter 8. Milling Tool Wear
Tony Schmitz¹, ², PhD and Jaydeep Karandikar², PhD
¹Mechanical, Aerospace, and Biomedical Engineering Department, University of Tennessee, Knoxville, TN, USA
²Manufacturing Science Division, Oak Ridge National Laboratory, Oak Ridge, TN, USA

Chapter 9.
Effective Application of Coated Tools in Milling Considering Coating Fatigue Mechanisms
Konstantinos-Dionysios Bouzakis, PhD
Mechanical Engineering Department, Aristotle University, Thessaloniki, Greece and Mechanical Engineering Department, Turkish-German University, Istanbul, Turkey

Chapter 10. Milling Process Monitoring and Control with Virtual Model Integration
Deniz Aslan, PhD
GE Aerospace Research Center, New York, United States of America

Chapter 11.
Mechanics and Dynamics of Turn-Milling Operation
Alptunç Çomak¹ and Kaveh Rahimzadeh Berenji²
¹MTU Aero Engines AG, Munich, Germany
²Manufacturing Research Laboratory, Sabanci University, Istanbul, Turkey


Editor’s ORCID iD

Erhan Budak: 0000-0002-7002-0563

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