Millwright Level 1 Practice Exam

Which type of milling produces a thicker chip?

1. Climb milling

2. Conventional milling

3. Face milling

4. Slot milling

The correct answer is: Conventional milling

Conventional milling, also known as up milling, typically produces a thicker chip compared to climb milling. In this process, the cutter rotates against the direction of the feed motion of the workpiece. As the cutter engages with the material, it starts with a very thin area of contact, increasing to a thicker section as the chip is formed. This gradual increase in chip thickness allows for a thicker chip to be produced overall during the cutting process. Additionally, conventional milling is characterized by a more gradual cutting engagement, which also contributes to the thicker chip formation. This method can lead to a rougher surface finish and is often less efficient than climb milling, which tends to produce thinner chips and smoother finishes. Understanding the mechanics of how chips are produced in milling is critical for selecting the correct milling technique for a specific machining operation.