Introduction – What is a Milling Machine?
Common machine shop tools typically focus on different ways of removing material from a workpiece in order to produce a particular part. A milling machine is no exception. Like its cousin the lathe, a milling machine uses different cutting heads to shape a part. Unlike a lathe, in which the workpiece rotates, in a milling machine both the workpiece and the cutting heads move. Their direction and range of movement vary depending on whether or not the machine is a horizontal or vertical mill.
This article will look at some of the differences between horizontal and vertical milling machines, their uses, and the advantages and disadvantages of each. While each type of milling machine uses essentially the same process, each type is better suited for specific tasks and works in different ways. In the industrial world, milling machines are often used to shape hard metal or work with particularly heavy pieces; while some mills can be quite small for detailed work or small shops, other mills can be room-sized and handle workpieces which weigh tonnes.
Vertical Milling Machines – Types and Uses
On a vertical milling machine, the cutting head is mounted vertically. This is referred to as a spindle. Here’s a good look at one:
Vertical milling machines come in at least two main varieties. On turret mills, the spindle is fixed in place; the bed of the mill, however, can move and rotate. For smaller pieces, this gives a wide range of flexibility, particularly when boring cavities into a workpiece – such as when creating molds. There is a major drawback with turret mills. Fitting larger pieces onto a rotating bed becomes impractical after a certain point. Turret mills tend to perform best on smaller pieces when work is being done on the face and sides of a piece.
For larger pieces, most shops turn to bed mills. In this design, the workpiece is placed on a bed which can be fed along an axis. In some mills, the spindle can be raised or lowered or move back and forth (x and y axis) while the workpiece moves along the bed. In other designs, the spindle is fixed while the bed moves on one or more axis. Here’s a good example:
These mills allow drilling operations, grinding, groove-cutting, etc. The vertical orientation of the spindle provides a great deal of flexibility, but can be limiting when it comes to truly large pieces. In addition, most vertical mills can only mount one cutting head (spindle) at a time. Fortunately, there’s another type of mill which addresses some of those difficulties.
Uses of a Horizontal Milling Machine
At first glance, horizontal and vertical milling machines look very similar, or at least they can look quite similar. The only real difference comes in the cutting heads. Instead of a fixed spindle rotating vertically, horizontal mills (like our Summit® #3 Series Universal Horizontal Milling Machine) have a single horizontal arbor. This arbor (a sort of rod or shaft) is equipped with grinding wheels which frequently resemble thick saw blades. On larger machines, multiple cutting heads can be mounted on a single arbor.
Like vertical mills, there’s a certain amount of flexibility in the beds themselves. Some mill beds will move along one axis only, others can move on more than one. The more movement, the more flexibility – but increased movement does somewhat limit the size of the piece to be milled. Horizontal mills excel at jobs requiring multiple cuts (parallel grooves, as an example) or dealing with unusually hard materials.
Further Considerations
It’s worth noting that most mills can be modified to do either type of milling. With the right adaptors, a horizontal mill can be converted into a vertical mill, and vice versa. This is especially true for smaller models more commonly used in small machine shops or by hobbyists. Larger, industrial-scale milling machines may prove a bit more difficult to convert.
Modern mills, whether horizontal or vertical, can also be equipped with Computer Numeric Control (CNC). This allows for precise cuts and repeat operation, producing parts that are exact copies.
All but the smallest mills are substantial pieces of equipment; large-scale models can be room-sized.
Horizontal and vertical mills have more similarities than differences, but in general vertical mills, particularly turret mills, offer a slightly wider range of operations. However, for larger pieces and tougher metals, horizontal mills provide faster cutting speeds and more power. Both kinds of milling machine are integral parts of every machine shop, from a hobbyist’s garage to a heavy-equipment production floor.