EMM3812

MECHANICAL ENGINEERING
LABORATORY (IV)
Semester 1, 2019/2020

Title : Milling
Group : 2A

No. Matric No. Name

1 191160 PARUVINTHA RAJ A/L SHANMUGAM
2 WAN MUHAMMAD FARID BIN WAN
192106
DAUD
3 192396 LUQMAN HAKIM BIN DZULKARNAIN
4 193498 NUR AFIQAH BINTI ADNAN
5 193769 MUHAMMAD NUR AFIQ BIN TUNAN
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TABLE OF CONTENTS

CONTENT PAGE

1.0 INTRODUCTION ………………………………………………………...…… 3

2.0 THEORETICAL BACKGROUND ………………………………………… 4

3.0 EXPERIMENTAL APPARATUS …………………………………………… 6

4.0 PROCEDURE ………………………………………………………………… 7

5.0 RESULT AND DISCUSSION ………………………………………………… 9

6.0 CONCLUSION ………………………………………………………………… 10

7.0 REFERENCES ………………………………………………………………… 11

8.0 APPENDIX …………………………………………………………………….. 12

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1.0 INTRODUCTION
Milling is a machining process that involves the use of cutting tools which rotated at a set speed and
then brought into contact with a work piece. The work piece is often held in place by some variety of
clamping device. The cutting tools begin to get rid of material once they touch the work piece. Milling
machine are often classed in two basic forms, horizontal and vertical, which refers to the orientation of
the main spindle. Both varieties range in size from small, bench-mounted devices to room-sized
machines. Unlike a drill press, that holds the workpiece stationary while cutting as the drill moves
axially to penetrate the material, milling machines additionally move the workpiece radially against the
rotating milling cutter, which cuts on its sides as well as its tip. Milling machines could also be operated
by hand, mechanically automated, or digitally automated via computer numerical control. Milling
machines can perform a vast number of operations, from simple (e.g.; slot and keyway cutting, planning,
drilling) to complex (e.g.; contouring, die sinking. Cutting fluid is commonly pumped to the cutting site
to cool down and lubricate the cut and to clean away the resulting swarf.

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2.0 THEORETICAL BACKGROUND

Milling is a cutting process that uses a milling cutter to remove material from the surface of a
workpiece. The milling cutter is a rotary cutting tool, often with multiple cutting points. As opposed
to drilling, where the tool is advanced along its rotation axis, the cutter in milling is usually moved
perpendicular to its axis so that cutting occurs on the circumference of the cutter. As the milling cutter
enters the workpiece, the cutting edges (flutes or teeth) of the tool repeatedly cut into and exit from the
material, shaving off chips (swarf) from the workpiece with each pass. The cutting action is shear
deformation; material is pushed off the workpiece in tiny clumps that hang together to a greater or lesser
extent (depending on the material) to form chips. This makes metal cutting somewhat different (in
its mechanics) from slicing softer materials with a blade.

The milling process removes material by performing many separate, small cuts. This is accomplished
by using a cutter with many teeth, spinning the cutter at high speed, or advancing the material through
the cutter slowly; most often it is some combination of these three approaches. [2] The speeds and
feeds used are varied to suit a combination of variables. The speed at which the piece advances through
the cutter is called feed rate, or just feed; it is most often measured in length of material per full
revolution of the cutter.

There are two major classes of milling process which are face milling and peripheral milling. In face
milling, the cutting action occurs primarily at the end corners of the milling cutter. Face milling is used
to cut flat surfaces (faces) into the workpiece, or to cut flat-bottomed cavities. In peripheral milling, the
cutting action occurs primarily along the circumference of the cutter, so that the cross section of the
milled surface ends up receiving the shape of the cutter. In this case the blades of the cutter can be seen
as scooping out material from the work piece. Peripheral milling is well suited to the cutting of deep
slots, threads, and gear teeth.

Figure 2.1: Generating shape in machining: (a) plain milling and (b) profile milling.

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Milling machines must provide a rotating spindle for the cutter and a table for fastening, positioning,
and feeding the work part. To begin with, milling machines can be classified as horizontal or vertical.
A horizontal milling machine has a horizontal spindle, and this design is well suited for performing
peripheral milling (e.g., slab milling, slotting, side and straddle milling) on work parts that are roughly
cube shaped. A vertical milling machine has a vertical spindle, and this orientation is appropriate for
face milling, end milling, surface contouring, and die sinking on relatively flat work parts. Other than
spindle orientation, milling machines can be classified into the following types: (1) knee-and-column,
(2) bed type, (3) planer type, (4) tracer mills, and (5) CNC milling machines.

The knee-and-column milling machine is the basic machine tool for milling. It derives its name from
the fact that its two main components are a column that supports the spindle, and a knee (roughly
resembling a human knee) that supports the worktable as illustrated in Figure 2. In the horizontal
version, an arbor usually supports the cutter. The arbor is basically a shaft that holds the milling cutter
and is driven by the spindle. An overarm is provided on horizontal machines to support the arbor. On
vertical knee-and-column machines, milling cutters can be mounted directly in the spindle without an
arbor. One of the features of the knee-and-column milling machine that makes it so versatile is its
capability for worktable feed movement in any of the x–y–z axes. The worktable can be moved in the
x-direction, the saddle can be moved in the y-direction, and the knee can be moved vertically to achieve
the z-movement.

Figure 2.2: Two basic types of knee-and-column milling machine: (a) horizontal and (b) vertical.

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3.0 APPARATUS AND EXPERIMENTAL SETUP

Figure 3.1 shows the vertical milling machine.

1. Knee
-This is a casting that supports the saddle and table.
2. Power Feed Mechanism
-Used to control the longitudinal, transverse and vertical feeds
3. Saddle and Swivel Table
-It is present on the knee and support the table.
4. Column and Base
-Base is the main casting that supports all other parts of milling machine.
5. Table
-Used to hold the work or work holding devices.
6. Spindle
-Used to hold and drives the cutting tools of the milling machine.
7. Ram
-The arm in the vertical machine
8. Arbor Support
-Supports the outer end of the arbor
-Helps in aligning the outer end of the arbor with the spindle.
9. Over Arm
-Used to fastened arbor support.

EQUIPMENT
1. Goggle
- To protect eyes from ashes, dust and chips produced during the experiment.
2. Wire Brush
-To clean the ashes, dust and chips from the milling machine.
3. Spacer
-To support the work piece from the bottom

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4.0 PROCEDURE

1. The work was tapped several times to make sure the tightness and in parallel position with the
plain vise before it being locked.

2. CNC Milling machine was set up by using word address format, as a command for a CNC
Milling machine and being sure that the work-holding clamps do not interfere with the cutting
action.

3. The work piece was adjusted to make it located under the cutter.

Figure 4.1 shows that the workpiece is adjusted under the cutter

4. Then, the machine was turned on. While the machine on, rotation and speed of cutting tool was
adjusted. Water is shot to the tip to prevent overheat and break.

Figure 4.2 shows that the water is shot to the tip to prevent overheating

5. Then, after the machine was turned off, open the door and clean the dust on the top of work
pieces by using wire brush.

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6. This is the work piece that we have got:

Figure 4.3 shows that the final result of the workpiece

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5.0 RESULT AND DISCUSSION

RESULT
Milling is a metal removal process that utilizing a pivoting shaper having one or more cutting teeth as
illustrated in figure 1. Cutting action is carried out by feeding the workpiece against the rotating cutter.
Thus, the spindle speed, the table feed, the depth of cut, and the rotating direction of the cutter become
the fundamental parameters of the procedure. Great outcomes must be accomplished with a well-
adjusted setting of these parameters.

Figure 5.1 shows the cutting process.

Figure 5.2 shows the final effect of milling process

In wear, when you increase speed, feed and depth, wear grow, but speed produce the major influence.
In relation with roughness, reduce feed give better values, increase speed can be reduced also. Depth of
cut do not have significative influence but the depth of cut directly related to the efficiency of the cutting
process that is the deeper the cut the faster will be the production rate.

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DISCUSSION
The product fabrication used on milling process was aluminium alloy which is produce from metal
casting. Advantages of the milling process for product fabrication is that it produces good surface finish.
Before processing, alloys were uneven and dull. However, the surface pattern is not the same because
the feed direction is different when it is done. Furthermore, collecting chips is easier. The chips were
collected using the brush. Next, alloys are less likely to degrade under elevated temperatures on milling
process because typically it has a higher melting-point. The coolant also used to reduce heat and
lubricate the cutter.

There are difficulties that found during milling process. First, the process is done manually to move the
feed on x-axis and saddle on y-axis. So, the process takes time to slowly move the feed and saddle to
prevent the cutter from breaking. The feed rate and saddle rate are also not the same. Next, the alloys
are not well casted. Cavity was appeared on the alloys when milling process is performed so that it does
not look good. In addition, the emulsion cooler used to reduce heat prevents visibility when the process
is engraved on the workpiece. Therefore, the carving process is carefully done to avoid defects as it
needs to be done manually

6.0 CONCLUSION
Milling is a process to remove parts that is not need from the workpiece that are not axially
symmetrical. For example, holes, slots, pockets and even three-dimensional surface contours.
Secondly, it can make the workpieces with precise shape.

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7.0 REFFERENCES

[Book]: Callister, W.D. (2005). Fundamentals of Materials Science and Engineering – An

Integrated Approach. John Wiley & Sons, Inc.

[Book]: Callister, W.D. (2005). Fundamentals of Materials Science and Engineering – An Integrated
Approach. John Wiley & Sons, Inc. − [Journal]: Ismail, M.I.S., Bahari, M.J., Shuib, N. (2018).
Thermal Deformation of Gas Metal Arc Welding on Aluminum Alloy T-Joints, Engineering Solid
Mechanics, Vol.6, pp.21-26.

[Book]: N. Satheesh Kumar, Ajay Shetty, Ashay Shetty, Ananth K, Harsha Shetty (2012). Effect of
Spindle Speed and Feed Rate on Surface Roughness of Carbon Steels in CNC Turning.
International Conference on Modelling, Optimization and Computing (ICMOC 2012).

[Book]: Niebel, B., & Draper, A. (1989). Modern manufacturing process engineering (pp. 148-
153). New York: McGraw-Hill.

[Journal]: Kramer, Thomas R. (1992). "Pocket Milling with Tool Engagement

Detection". Journal of Manufacturing Systems. 11 (2): 112–123. doi:10.1016/0278-

6125(92)90042-E. Retrieved 25 September 2018.

[Journal]: Wu Baohai, Yan Xue, Luo Ming, Gao Ge (2012). Cutting Force Prediction for Circular End
Milling Process. Chinese Journal of Aeronautics. Chinese Society of Aeronautics and Astronautics
& Beihang University.

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8.0 APPENDIX

Figure 8.1 shows the workpiece during the milling Figure 8.2 shows that the workpiece is getting shape
process of rectangle

Figure 8.3 shows that the final result of the workpiece Figure 8.4 shows that the final result of the workpieces

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