Grinding vs. Milling – What is the Difference
Whether to choose grinding or milling will depend on the task you wish to perform.
But more importantly, knowing the differences between these two processes will help you choose the right technique for your project.
Let’s dive right in:
What is Grinding?
This is a type of machining process that uses wheel shaped disc to cut out pieces from desired material. In most cases the cutting tools are a mixture of materials such as aluminium, steel, or even copper.
What is Milling?
Milling is also another type of machining process. However, in this case, the process tends to imitate the drilling.
Usually, milling uses a pointed tool that rotates at a very high speed. By rotating at high speeds, it executes the cutting functions.
In most cases, milling tends to create holes and slots on surfaces.
Differences Between Grinding and Milling
Both grinding and milling aim to achieve one goal – fabricate various parts. However, how you achieve this may vary. Besides, the results of the process also vary broadly.
Let’s look at some critical aspects in these machining processes:
1. Types of Tooling System to Use
A tooling system is what you use to machine parts either during milling or grinding.
Tools in Milling Process:
They are available in various types as well. These includes, square shaped end mills,which is the most common type of tool used in milling operations. Roughing end mills which are fitted with a series of serrations. These tools are helpful in removing materials from intended surfaces.
- Face mills
They are tools with a larger surface area and are used to cut materials of large sizes.
Tools for Grinding Operations:
Tooling systems in in grinding operations are quite different. Ideally, they are circular. Common tooling systems you may consider include:
- Die grinders
- Angle grinders
- Grinding wheels
Remember, these wheels are made from abrasive materials that help cut material surfaces.
2. How the Process Works
Grinding and milling processes work differently.
For grinding, since the grinding wheel is made up of coarse material, it simply subjected to a high speed and placed on intended surface. The grinding wheel will then remove any materials on the surface.
To achieve the cutting action, you will subject the tooling system to a high rotating speed. As the machine rotates, it cuts through the material.
At times, we can use grinding as a finishing operation. That is, you first mill part, then use grinding for finishing.
3. Different Techniques in Milling and Grinding Operations
Milling offers a range of techniques you can apply for milling operations. The two most common techniques widely known include face milling and peripheral milling.
Face milling is majorly applied on flat surfaces, thus the tools for cutting can be executed either horizontally or vertically. For peripheral milling, the surface materials can be fed either against or in the same direction of the cutting tool of the milling machine.
Examples of grinding techniques include:
- Form grinding
- Surface grinding
- Center less grinding
- Cylindrical grinding
- Creep-free grinding.
4. Material Removal Rate
Milling has a relatively higher material removal rate.
For this reason, opting milling is a better choice when you want to remove a lot of material. Moreover, if you have metallic material, milling guarantees a satisfactory result
Nonetheless, grinding is a good option for you final bits of works. This entails achieving smooth and polished surfaces.
5. Nature of Cuts on Material
Machining processes are likely to experience interrupted cuts if the cutting tool and working surface is not continuously in contact.
Grinding process is more susceptible to interrupted cuts. The milling process has low incidences of interrupted cuts.
Nonetheless, both machining processes are not free from experiencing interrupted cuts. You should minimize interrupted cuts since they may damage the tools.
6. Heat Generation during Process
Grinding process generates a lot of heat. This is basically due to friction during the grinding process.
Moreover, using a coolant is beneficial to ensuring grinding machines last long. Coolants help get rid of chips and any swarf build up that may cause damage to the grinding machines.
As a result, always use a good coolant to help reduce heat. On the other hand, milling machine produce less heat which is manageable. In fact, most tools for milling process work best under dry conditions.
7. Accuracy and Dimensional Accuracy
Grinding accurately cuts and removes materials from surfaces. In fact, grinding offers more dimensional accuracy. Besides, it can handle even small surfaces to precision.
Dimensional accuracy in milling process may be limited. Besides, the process may not handle very tight sections.
Conclusion
As you can see, both milling and grinding use different tooling mechanism. Besides, the cutting machines are also different.
At TSINFA, we offer wide range of grinding machine and milling machine for a wide range of machining operations. For any inquiries, contact us now.
