MILLING MACHINE

ASSIGNMENT 1
ALIAA NABILA BINTI ABDUL MUTAALI (HA15025)

BHM1811
LECTURER: MOHD NURSYAZWAN BIN MD TALIP

MILLING MACHINE
a) SAFETY

When setting up the machine, install the cutter last to avoid

being cut.
Never adjust the workpiece or work mounting when the
machine is operating.
Set the aim of the cutting fluid properly to avoid it from
splashing to the floor that could cause slippery condition
which may result in accident.
Maintain cutting fluids properly and discard them when they
become rancid or contaminated.
Store milling cutters, arbors, collets, adapters carefully after
being used to avoid damage to it.
Do not start a cut unless you are sure there is adequate
clearance of all moving parts

b) Types of milling machines and its components function

i.

Knee type milling machine

ii.

Universal horizontal milling machine

iii.

RAM-type milling machine

iv.

Universal RAM-Type milling machine

v.

Swivel cutter head RAM-type milling machine

Base
The base of the machine is Grey iron casting accurately
machined on its top and bottom surface and serves as a
foundation member for all the other parts which rest upon it. It
carries the column at its one end.

Column
The main supporting frame mounted vertically on the bage.
Heavily ribbed inside and houses all the driving mechanisms
for the spindle and table feed. The front vertical face of the
column is accurately machined and is provided with dovetail
guide ways of supporting knee. The top of the column is
finished to hold an over-arm that extends outward at the front
of the machine.

Knee
The knee is the rigid gray iron casting that slides up and down
on the vertical way of the column face. Adjust height by
elevating screw on the base that also supports the knee. The
knee houses the feed mechanism of the table, and in different
controls to operate it. The top face of the knee forms slid way
for the saddle to provide cross travel of the table.

Saddle
The saddle is placed on the top of the knee, which slides on
guide ways set exactly at 90 to column face. A cross feed
screw near the top of the knee engages a nut of the bottom of
the saddle to move it horizontally, by hand or power, to apply
cross feed.

Table
The table rest on ways on the saddle and travels
longitudinally. The top of the table is accurately finished and Tslots are provided for clamping workpieces. A lead screw
under the table engages a nut on the saddle to move the table
horizontally by hand or power.

Over hanging arm

Over hanging arm is mounted on the top of column extends
beyond the column face and serve as a bearing support may
be provided nearest to the cutter. More than one bearing
support may be provided for the arbor.

Front Brace
An extra support that is fitted between the knee and over arm
to ensure further rigidity to the arbor and the knee. It is
slotted to allow for adjustment of the height of the knee
relative to over arm.

Spindle
Located on the upper part of the column and receive power
from the motor through belts, gears and clutches and transmit
it to the arbor the front end of the spindle just projects from

the column face and it is provided with a tapered hole into to

which various cutting tools and arbors may be inserted. The
accuracy in metal machining by the cutter depends on
primarily accuracy, strength and rigidity of the spindle.

Arbor
An extension of the machine spindle on which cutters are
securely mounted and rotated. Made with taper shanks for
proper alignments with machine spindles having taper hole on
their nose. It may be supported at the farthest end from the
over hanging arm or may be of cantilever type which is called
stub arbor.

c) Processes perform/operations by the milling machines

i.

ii.

iii.

iv.

v.

End milling
Makes either peripheral or slot cuts, it is determined by
the step-over distance, across the workpiece in order to
machine a specified feature whether as a profile, slot,
pocket or even a complex surface contour. The depth of
feature may be machined in a single pass or may be
reached by machining at a smaller axial depth of cut
and making multiple passes.
Chamfer milling
a peripheral cut along an edge of the workpiece or a
feature to create an angled surface, known as a
chamfer. This chamfer, typically with a 45 degree angle,
can be machined on either the exterior or interior of a
part and can follow either a straight or curved path.
Face milling
machines a flat surface of the workpiece in order to
provide a smooth finish. The depth of the face, typically
very small, may be machined in a single pass or may be
reached by machining at a smaller axial depth of cut
and making multiple passes.
Drilling
enters the workpiece axially and cuts a hole with a
diameter equal to that of the tool. A drilling operation
can produce a blind hole, which extends to some depth
inside the workpiece, or a through hole, which extends
completely through the workpiece.
Boring
enters the workpiece axially and cuts along an internal
surface to form different features. The boring tool is a
single-point cutting tool, which can be set to cut the
desired diameter by using an adjustable boring head.
Boring is commonly performed after drilling a hole in

vi.

vii.

viii.

ix.

order to enlarge the diameter or obtain more precise

dimensions.
Counterboring
enters the workpiece axially and enlarges the top
portion of an existing hole to the diameter of the tool.
Often performed after drilling to provide space for the
head of a fastener, such as a bolt, to sit below the
surface of a part. This tool has a pilot on the end to
guide it straight into the existing hole.
Countersinking
enters the workpiece axially and enlarges the top
portion of an existing hole to a cone-shaped opening.
Often performed after drilling, providing space for the
head of a fastener, such as a screw, to sit flush with the
workpiece surface. Common included angles for a
countersink include 60, 82, 90, 100, 118, and 120
degrees.
Reaming
enters the workpiece axially and enlarges an existing
hole to the diameter of the tool. Removes a minimal
amount of material and is often performed after drilling
to obtain both a more accurate diameter and a
smoother internal finish.
Tapping
enters the workpiece axially and cuts internal threads
into an existing hole. The existing hole is typically drilled
by the required tap drill size that will accommodate the
desired tap. Threads may be cut to a specified depth
inside the hole (bottom tap) or the complete depth of a
through hole (through tap).

d) Cutting tools for milling operation

End-milling cutters
Shell-End mill cutter
Single lip cutter
Two-lipped cutter
Angular cutter
Side milling cutter
Face mill cutter
Circular saw
Ball-nose cutter
Formed cutter
Periphery milling cutters
Light-duty plain mill
Heavy-duty plain mill

Half-side milling cutter

Stagger-tooth side mill
Form mill

e) Clamping techniques
i. Work piece clamping

1. Clean all surfaces of workpiece and clamping kit before

clamping.
2. Firmly secure the workpiece in between the vices but
careful not to damage the workpiece.
3. Ensure that the workpiece in perpendicular to the vice to
avoid cutting that are not 90.
4. Always check that the workpiece is locked before
starting milling process.

ii.

Tool clamping
1. Check that the cutter runs through
2. The direction of the spindle must be the same direction
as the cutting direction.
3. Clean the internal taper of milling spindle
4. Always keep the arbor & collars clean
5. Mount the cutter as quickly as possible

f) Type and method of cutting fluid use in milling processes

i. Cutting fluid is a type of coolant and lubricant designed

ii.

iii.

specifically for metalworking processes, such as machining

and stamping. Cutting fluids helps to remove heat in cutting,
lubricate the chip-tool interface and to wash away the chips.
Type of cutting fluids used are liquids and air or other gases.
Method of use for cutting fluid is to apply the chip and/or
cutting tool to improve cutting performance. A very few
cutting operations are performed dry, without the application
of cutting fluids.

g) Relation of the cutting parameters e.g. cutting speed, feed

rate and depth of cut

Cutting feed - The distance that the cutting tool or workpiece

advances during one revolution of the spindle and tool,
measured in inches per revolution (IPR). In some operations
the tool feeds into the workpiece and in others the workpiece
feeds into the tool. For a multi-point tool, the cutting feed is
also equal to the feed per tooth, measured in inches per tooth
(IPT), multiplied by the number of teeth on the cutting tool.

Cutting speed - The speed of the workpiece surface relative to

the edge of the cutting tool during a cut, measured in surface
feet per minute (SFM).

Spindle speed - The rotational speed of the spindle and tool in

revolutions per minute (RPM). The spindle speed is equal to
the cutting speed divided by the circumference of the tool.

Feed rate - The speed of the cutting tool's movement relative

to the workpiece as the tool makes a cut. The feed rate is
measured in inches per minute (IPM) and is the product of the
cutting feed (IPR) and the spindle speed (RPM).

Axial depth of cut - The depth of the tool along its axis in the
workpiece as it makes a cut. A large axial depth of cut will
require a low feed rate, or else it will result in a high load on
the tool and reduce the tool life. Therefore, a feature is
typically machined in several passes as the tool moves to the
specified axial depth of cut for each pass.