FACULTY OF OCEAN ENGINEERING TECHNOLOGY AND INFORMATICS

MMT 3082 BENGKEL PERMESINAN DAN KIMPALAN

2023/2024

LECTURER: EN. SHEIKH ALIF ALI

INSTRUCTOR: EN. MOHD HARISAN BIN GAZALI

WORKSHOP REPORT: MILLING

PREPARED BY: HARSHINI A/P KALIMUTHU

MATRIC NO: S65687

GROUP: TM1

TABLE OF CONTENTS

1
 BIL CONTENTS PAGE

1 TABLE OF CONTENTS 2

2 TITLE AND INTRODUCTION 3-4

3 OBJECTIVE 5

4 APPARATUS AND EQUIPMENTS 5-8

5 PROCEDURE 8-11

6 DISCUSSION 12-20

7 SAFETY 20-21

8 RESULTS 22

9 CONCLUSION 23

11 REFERENCES 23-24

12 LAB MOMENTS

TITLE: MILLING

INTRODUCTION:

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1. The purpose of the milling machine: The purpose of the milling machine, like the

lathe, is to shape and cut material by the use of a cutting tool; the cutting tools on a

milling machine are called cutters.

2. How the milling machine works: For milling, the workpiece is fastened to a

movable table. A milling cutter is circular in shape and has teeth on its circumference

(sometimes called the periphery of the cutter). The cutter is rotated at a certain speed.

The workpiece is fed into the teeth of the spinning cutter, as the table is raised.

3. Types of milling machines: Like the lathe, there are several kinds of milling

machines: some are made specially for manufacturing and will produce a large number

of identical parts. A recent, widely-used milling machine is the machining center; it is

controlled by a computer, has several cutters, and can do multiple machining operations

to a workpiece.

There are two common types of milling machines which you will use in the machine

shop while you are training to be a machinist: the horizontal milling machine and

the vertical milling machine:

a. Horizontal milling machine: In this type, the cutter is mounted onto a rotating

shaft called an arbor. The axis of the arbor and the cutter is horizontal (parallel to the

horizontal plane of the table}.

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Cutter for a Horizontal Milling Machine

b. Vertical milling machine: In this type, the cutter has a shank. This shank is mounted

into a spindle. The axis of the spindle, the shank, and the cutter is vertical

(perpendicular to the horizontal plane of the table).

Cutter for Vertical Milling Machine

4. Holding the workpiece: It is important for accuracy and safety that the workpiece

be held very securely on the table. There are a variety of vises, clamps, bolts and

special devices for holding work. We will study them when we look at milling machine

accessories in a later lesson.

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OBJECTIVE

1. To understand how to correctly operate a milling machine

2. To understand functions and application of various milling machines components

3. To produce a specific designed product from milling process.

4. To gradually remove material from a workpiece

APPARATUS

 Knee-Type Vertical Milling Machine

 Face Mill Cutter
 End Mill Cutter
 Vernier Calliper
 Vernier Calliper Height Gauge
 Granite Platform
 Metal Workpiece
 Milling Face Cutter
 Milling End Cutter
 Gauge Block
 Safety Goggles
 Safety Boots

EQUIPMENTS

COMPONENT FUNCTION PICTURE

Digital Readout Digital Readout

(DRO) Systems are
(DRO) used for indicating
the position of the
cutting tool relative to
a workpiece. The
positions are
detected by encoders
mounted on the axis.
They feature a
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 numeric display and
keyboard
Head It holds and rotates
the cutting tool of the
milling machine on
specific or even
custom-built centers
of machining

Saddle and Swivel The saddle is on the

knee and supports
Table the table, while the
Swivel table is
attached to the
saddle, which swivels
(revolves) horizontally
in both directions
coolant Reducing and
removing the heat
build-up in the cutting
zone and workpiece.
Provides lubrication
to reduce friction
between the tool and
removal of the chips.
Knee The knee moves
vertically along ways
machined into the
column. The
knee supports the
table via the saddle.
The knee is
positioned vertically
via the knee elevating
crank

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Knee locks Knee locks provide a
way to hold the knee
rigidly in position.
Knee locks clamp the
knee in position

cross traverse the cross traverse

crank moves the
crank handle table in and out
relative to the
operator. This
direction of motion is
often referred to as
the Y axis. The cross
traverse crank moves
the table in and out in
the Y direction

table traverse X-Axis moves the

table left-right
crank handle

Quill The quill allows the

milling cutter to be
raised and lowered in
a manner similar to a
drill press by moving
the spindle in and out
of the head.

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Table The table is the work
fixturing element of
the milling machine.
On a typical manual
mill, the table can
move in three
directions: left and
right (X axis), in and
out (Y axis) and up
and down (Z axis).

PROCEDURE

A. PRODUCING THE WORKPIECE UTILISING SAW MACHINE

1. A long metal piece approximately 8 feet long is prepared to be produced

2. A vernier calliper is used to measure a dimension of 75 mm to be cut.

3.The stock stop is adjusted for the distance of product between the saw and the

stock stop is approximately 75 mm.

4. The workpiece with dimensions of 74.6 mm width*74.75 mm length*24.5mm

height is produced

B. MACHINE SETUP

1. The cutter is first mounted to the machine. It was imperative that

the machine must be unplugged for safety reasons

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 2. The brakes were maintained to stop the spindle from spinning

3. A wrench is used to fasten the cutter to the spindle.

4. The cutter is placed according to the work to be done and the

work holding device is secured to the spindle.

5. The machine's switch is activated.

6. The user is made sure to have accessibility to the panel and that it is in front of

them. (if the speed of the milling machine happens to be high, change it to low

and test the brake.)

C. SECURING THE WORKPIECE

1. The dimension of the workpiece is measured using a calliper

2. A gauge block is placed under the workpiece if it happens to be too low to

raise the surface to be milled above the level of vice jaws.

3. After the work piece happens to be in place, the vice is tightened securely.

D.FINDING THE ORIGIN

1.the table is moved utilizing the x and y axis handles to position

the workpiece beneath the cutter.

2. The z -axis crank is rotated to raise the table until it is

approximately an inch below the cutter.

3. The switch button is activated for the spindle to spin

4. The table is slowly raised using the z-axis crank until the sound

of the work piece being milled is heard.

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 5.the table is shifted away from the cutter utilizing the y axis handle 6. The spindle is

switched off

7. The z- axis crank scale dial is adjusted to zero.

E. MARKING THE SLOT

1. The dimensions of slot desired to be cut is determined which is 20 mm diameter

and 10 mm depth.

2. The workpiece is being marked on a granite surface Using a vernier calliper

height gauge 3. 25 mm dimension is adjusted on the vernier calliper height

gauge.

3. The width of the workpiece is being marked with the

tip of the scriber.

4. Workpiece is tuned 180° degrees around vertically to be

marked on the other side.

5. 10 mm dimension is adjusted on the vernier calliper height gauge

The surface being marked in step 4 and 5 is faced downwards since 10 mm is

the distance from the measuring jaw to the granite surface.

6. The 10 mm depth measurement is being marked on both sides on height of the

workpiece.

G. MILLING SLOT

1. The x-axis handle is shifted so that the cutting tool is at the edge of the marking of

the part desired to be cut on the workpiece

2. The origin is found, and the micrometre dial on the x-axis handle and z-axis crank

calibrated to zero

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3. The table locks are locked to lock the table therefore the table will not move in x -

axis.

4. The z- axis crank is rotated adding 0.5 mm on the scale dial to raise the table.

5. The coolant switch button is switched on, providing lubrication to reduce friction

between the tool and removal of the chips

6. The y- axis handle is shifted allowing the cutting tool to approach the workpiece until

the workpiece passes the cutting tool.

7. Steps 3 and 4 are repeated adding 0.5 mm during every repetition until the depth of

the slot 10 mm is measured using a vernier calliper.

8. The x- axis handle is shifted 2 mm to the left so that the cutting tool is at the other

edge of the marking on the workpiece. This helps to get the slot in the middle of the

workpiece.

9.The y- axis handle is shift allowing the cutting tool to approach the workpiece until

the workpiece passes the cutting tool.

10. The diameter of the slot cut is measured using a vernier calliper to make sure the

dimension is 20 mm

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DISSCUSSION

Based on the milling project being carried out, it can be concluded that milling is

utilised in operation lbecause of its versatility in producing a variety of product shapes.

The machining process knoun as milling involves feeding a workpiece past a revolving

cylindrical tool with several cutting edges. The geometric shape produced by milling is

also a planar surface. Either the cutter path or the cutter shape can be used to produce

different work geometries. It is discovered that the purpose of this operation is to

remove material from a work piece by feeding in an x, y, and z direction that is at an

angle with the tool's axis. A point worth noting is, the milling centres not only carry out

the cutting automatically, yet also the changing of tools. The versality of milling cutting

tools allows the milling process to be utilised in a wide range of industries and fora

variety of part features and designs, including slots, chamfers, threads, and pockets.

The type of milling operation includes:

Up-Milling Operation

The up-milling is also known as conventional milling. In this, a cutter revolving in the

opposite direction of the workpiece removes the metal in the form of tiny chips as shown

in the figure below. The chip thickness varies from minimum at the beginning and

maximum at the end as the cutter advances.The primary drawbacks of the up-milling

technique are the tendency of the cutting force to lift the work from the fixtures and the

poor surface finish.

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Down Milling Operation

A down-milling operation is also known as ‘climb milling’. In this operation, the cutter

rotates in the same direction as the feed. The chip thickness varies from maximum at

the beginning to minimum at the end. There is always less friction in climb milling which

produces less heat. Thin slots, lengthy cuts, and sharpening of the pieces can be easily

achieved in this operation.

Plain Milling Operation

The most commonly used milling machine operation is plain milling. It is also referred to

as slab milling (Hence, the labelling in the image below). The workpiece is firmly

mounted on the machine before this operation. After choosing the proper speed and

feed, the machine is then turned on. This operation creates a smooth and horizontal

surface that is parallel to the axis of rotation of the cutter as shown in the figure below.

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Face Milling Operation

The most simple operation on a milling machine is face milling. This procedure is

carried out with a face milling cutter that is rotated about an axis perpendicular to the

work surface as shown in the figure below. By turning the cross feed screw of the table,

the depth of the cut can be changed. This operation creates a flat surface with the cutter

positioned on a stub arbour

Gang Milling Operation

The operation of simultaneously milling multiple surfaces of a workpiece by feeding the

table against numerous cutters with the same or various diameters mounted to the

arbour is called gang milling operation.The speed of this group of cutters is determined

by the cutter with the greatest diameter. The approach reduces machining time

significantly and is commonly utilised for repeated tasks.

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Angular Milling Operation

The process of generating an angular surface on a workpiece which is not at right

angles to the spindle axis of the milling machine is known as angular milling. The

angular groove may have a single or double included angle which depends on the type

and geometry of the angular cutter employed. V-block manufacturing is an example of

angular milling.

Side Milling Operation

The process of side milling involves using a side milling cutter to create a flat, vertical

surface on the side of a workpiece. The depth of cut is provided by adjusting the vertical

feed with the help of the screw on the table.

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Gear Cutting Operation

A form-relieved cutter on a milling machine executes the gear-cutting operation. The

cutter type may be either cylindrical or end mill. The cutter profile is made to precisely

match the gear tooth spacing. A universal diving head is used to hold the workpiece

while a process called indexing creates evenly spaced gear teeth on a gear blank.

Keyway Milling Operation

The operation of making keyways, grooves, and slots of various shapes and sizes is

called keyway milling. It can be done with an end mill, a side milling cutter, a plain

milling cutter, or a metal slitting saw. Keyways generally have minute dimensions of

width or depth. Hence, a special tool is necessary for keyway milling like standard

helical or staggered teeth cutters

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Types of Milling Machines

As we concluded our learning about the various operations performed on the machines,

it is natural to be curious about the types. Let us study all the classification of milling

machines.

Horizontal Milling Machine

These machines can hold and rotate the spindle horizontally to remove material from

the surface of a fixed workpiece. Cutting tools for these machines are thicker and

shorter.

Vertical Milling Machine

This is a particular type of milling machine that can hold the spindle in a vertical

configuration while rotating it to remove material from the surface of a stationary

workpiece. Cutting tools for vertical milling machines are longer and thinner.

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Column and Knee Type Milling Machine

This milling machine has a vertical column attached to the bed which has gear drives

that can move the saddle and knee. On top of the knee is a saddle that can move in

transverse directions, allowing the worktable to move along it.

Fixed Bed Milling Machine

These devices are rigidly constructed. The table is fixed to the guideways of the bed.

There are no options for transverse or vertical adjustment and the table can only move

at a right angle to the spindle axis.

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Simplex Milling Machine

The spindle head can only move in one direction with this machine. Surfaces cut using

these machines are flat and have a good surface finish.

Duplex Milling Machine

This machine is a combination of two machines that are arranged across from one

another. They operate independently. Two spindles are used simultaneously to machine

the workpiece on this machine while it functions as one unit.

There are other special types of milling machines apart from these.

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 Additionally, it was discovered that various technological sources of mistakes exist.

The machine's calibration inaccuracy comes first and foremost. When comparing the

project's results with one another, it might not be obvious which set is accurate, raising

the possibility that the machine is of by some unusual factor, in which case the accuracy

of the machine might start to affect the accuracy of the work piece. A milling machine

should be properly calibrated for the purpose of establishing the workpiece coordinate

systems, as well as to detect and fix errors that may arise over time and diverge from

the manufacturer's original requirements

A geometric error in the cutting tool is another issue that could occur. During the

cutting process, every cutting tool will unavoidably begin to wear down, changing the

workpiece's size 'and shape. Depending on the type of tool, the impact of tool geometry

error on machining error varies, and tool manufacturing error will have a direct impact

on the workpiece's machining precision. Since every cutting tool has a predetermined,

limited lifespan, it is advised to change cutting tools frequently due to their direct impact

on machining quality, machining efficiency, and other factors.

As an alternative, we can u a Computer Numerical Control (CNC) milling machine

1o feed the material with greater accuracy. In addition, we discover that using laser

melting is a faster and more efficient approach to feed the cutting process. Although

CNC milling offers higher precision, accuracy, and production rates, however manual

milling is still sometimes advantageous in some particular circumstances

SAFETY

The milling process is a type of machining that makes it possible to model multiple

materials such as, metal, wood, plastic, composites etc. in complex forms and trim

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parts, while removing chips and processing residues. Milling is carried out using

equipment such as milling machines or machining centers\

DO’S & DON’TS IN EXPERIMENTAL

 Do study the owner's manual attentively. Before operating a milling machine, make

sure that you follow directions and are properly trained.

 Do wear appropriate CSA-certified safety glasses. Wear other personal protective

equipment as needed (such as footwear or hearing protection)

 Do make sure that operator is able to reach to stop/start button in case of any

unwanted situation. Ensure all machines have their emergency stop button(e-stop).

 Do keep the work surface free of scraps, clothes and tools as these can get caught

by the milling machine, causing problems and dangerous situations.

 When setting up work, move the table as far as possible from the cutter to avoid

injuring your hands.

 Do not wear gloves, rings, watches or loose clothing. Tie back and confine long hair.

 Do not attempt to mount, measure or adjust work until cutter is completely stop

 Do not reach over or near a revolving cutter. Keep hands at least 30 cm (12 in.) from

a revolving cutter.

 Do not leave machine unattended while it is running

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RESULTS

The transition of the look of the iron block before and after the milling project

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CONCLUSION

As the conclusion, from the milling process demonstration video we have watched, we

have learned in detail about machine mechanism and various types of cutting tools and

how to operate the machine to produce a finish product from the raw material. In

addition, we have clearly understood about the safety rules in carrying out this process.

If we carry out this process in accordance with the proper steps, this process will be

easier but if sufficient precautions are not taken, milling process can also be a

dangerous process

REFERENCES

[1] "Wikipedia," Wikimedia Project, 29 December 2020. [Online]. Available:

https://en.wikipedia.org/wiki/Milling_(machining).

[2] "Milling," Custom Partet, [Online]. Available:

https://www.custompartnet.com/wu/milling.

[3] "Metalworking Machines-Milling machines," Canadian Centre for Occupational

Health & Safety,[Online].

Available: https://www.ccohs.ca/oshanswers/safety_haz/metalworking/

millingmachines.html. [Accessed 31 December 2020].

[4] Newsletters, "Ten Tips To Improve Productivity In Your Machining Operations,"

PROTEM, 14 June2017. [Online]. Available:

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https://www.protemusa.com/latest-news/press-publications/189-ten-tips-to-improve-

productivity-in-your-machining-operations.

[5] "Chapter 8- Milling Operations," [Online]. Available:http://uhv.cheme.cmu.edu/

procedures/machining/ch8.pdf

[6] "Milling Machine Operations," 1988. [Online]. Available: http://www.hnsa.org/wp-

content/uploads/2014/07/milling-machine.pdf.

[7] "Milling Tools," WNT Ceratizit Group, [Online]. Available: https://www.wnt.com/in/

cutting-tools/milling-tools.html

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