Milling vs Welding: Difference [Know 11 factors]

The main difference between milling and welding is milling is the machining process (material removal process) while welding is the metal joining process used to join two separate metal components.

milling and welding operation


Milling is a conventional machining process in which the material removal is done by the rotating tool which has multiple cutting edges.

The tool has multiple cutting edges which are arranged symmetrically around the rotating axis.

The main two types of milling operations are face milling and peripheral milling.

In a face milling cutter, the cutting edges are arranged in a radial manner. In peripheral milling cutter cutting edges are arranged on the circumference of the cutter.


Welding is a type of metal joining process. In this process, the filler material is melted by generating high heat and applied in between the joining parts.

After cooling, the filler material gets fused with the material of the workpiece. Welding is also the conventional machining process.

Difference between milling and welding:

Sr. No.MillingWelding
1Milling is a machining processWelding is the metal joining process
2It is a material removal process.The material is added to join two workpieces.
3In this, a single piece is machined in the desired shape to form a final product.It joins two or more workpieces by the application of filler material in between joints of two workpieces.
4It is carried at comparatively low temperatures.This process is carried at a much higher temperature.
5There is no risk of fire hazards.There is much risk of fire hazards.
6Material wastage in the form of chip generation.No wastage of material.
7Highly skilled operators are required for milling operationSemi-skilled workers can perform welding operations.
8The setup cost for milling operation is higher.The setup cost for welding operation is less.
9Running cost is less.Running cost is higher.
10It requires the proper holding of a workpiece on the bed of the machine.It doesn’t require the proper holding of the workpiece
11Milling is generally used in industrial processes.Welding is a commonly used process.

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Pratik is a Graduated Mechanical engineer. He enjoys sharing the engineering knowledge learned by him with people.

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