Aimi Izyana binti Ismail 0226962 OBJECTIVES V To identify parts of the vertical milling machine used in the V V V V

workshop and know its functions and operations. To produce a milled article involving face milling, drilling and end milling. To practice and master the skills of handling the milling machine, whether it be manual or automated. To understand the basic milling operations. To learn the safety guide lines in handling the milling machine.

APPARATUS Gage block Wrench Engineering square Vernier caliper Small face mill with carbide inserts Two flute, single-end end mill with diameter 8mm Two flute, single-end end mill with diameter 20mm Four flute, single-end end mill with diameter 16mm Vertical milling machine Soft Hammer (plastic) Parallel Blocks Dial indicator Collet Hook spanner Angle file

PROCEDURES
This workshop activity is divided into two parts, Milling 1 and Milling 2. In Milling 1, only the face milling is dealt with and later on, drilling, slotting and end milling in Milling 2. Milling 1

1. An aluminium block was given to each student with dimensions roughly

around 77mmx52mmx25mm. 2. Two adjacent sides of the block were chosen to be the reference plane, and they are made sure to be flat, and perpendicular to each other. 3. To do this, the surface cutter was attached to the vertical milling machine and the block was clamped securely on the machine and the table

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of the machine is raised until the surface of the block just touches the surface cutter on the spindle. The spindle was then switched on, and the variable speed control was turned on to high speed and the spindle will start rotating. The cross transverse handle was pushed to one side so that the table, and so the block, will move horizontally across the surface cutter. Until all the 6 sides are smooth and are perpendicular to every side adjacent to it, proper milling to the dimensions given for the activity could not be done. When that was completed, the block was milled until the dimension 75mmx45mmx20mm was obtained with the feed being the 0.5mm to 0.2mm. All the rough edges resulting from the cutting was removed using the angle file. To make it easier, the transverse axis of the machine is zeroed so that the amount of metal to be removed can easily be determined. This is done by raising the table until the cutter barely touches the surface of the block. A piece of thin paper was placed between the cutter and the block and the table is raised until the paper cant be taken out. The table is lowered slightly and the paper was taken out. The surface milling was now complete. The block was then brought to the testing room to be marked with the proper dimensions for Milling 2.

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Milling 2 1. For this part of the activity, the drilling was done first, then slotting and finally the end milling. 2. The alignment of the machine plays an important part in this activity. the demonstrator showed how to use a dial indicator to align the table used for Milling 2. 3. A 20 x 13mm deep hole was to be drilled at the center of the block. The 2-flute drill with diameter 20mm was chosen and adjusted until it is directly on top of the marking for the hole. Then a 13mm deep hole is drilled. 4. Then the slotting was done. It requires the 2-flute cutting tool with diameter of 8mm. The block was clamped and adjusted so that the 2flute drill touches the part to be removed accurately. The machine is zeroed as mentioned above in Milling 1. 0.2 to 0.3 mm was removed in one pass until a depth of 15mm was obtained. 5. Last but not least, end milling was done with a 4-flute 16mm drill. The steps for end milling are similar to the slotting process. 6. As before, the sharp edges were removed with an angle file and the work piece was completed. Refer to the next page for the drawing of the piece.

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MEC 1105 Workshop Technology MILLING 1 & 2

Aimi Izyana binti Ismail 0226962 DISCUSSION

Milling is a process of cutting away material by feeding a work piece past a rotating multiple tooth cutter. It is most probably the most versatile machining operations as it can generate most shapes easily and the cutting action of the many teeth around the milling cutter provides a fast method of machining. The milling tool possess a large number of cutting edges, unlike turning. There is a variety of milling machines that are manufactured, but it can be classified as horizontal milling machine and vertical milling machine or universal milling machine. The horizontal milling machine is so called because the milling cutter has an axis held parallel to the work piece i.e. the milling cutter is held in a horizontal position. It is also a column and knee machine as these two parts make up the main structure members of the machine. The milling spindle, feed drive, milling table and cross slide are on the column.

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a) Base and column - The major structural components of this machine tool. b) Knee - Engages the slide on the face of the column and is moved up and down by turning the vertical traverse crank. Supports the saddle and table. c) Saddle - Engages the slide on the top of the knee and can be moved in and out by turning the cross traverse handle. It supports the table. d) Table - Engages the slide on the top of the saddle and is moved right and left by turning the table traverse handle. The work piece or work-holding device is secured to the table. Most milling machines have a power feed mechanism on the table. This permits a variable feed rate in either direction during a milling operation. The machine that is used in the workshop for milling is the vertical milling machine. The difference of this machine with respect to the horizontal milling machine is that, obviously, the milling spindle is held in a vertical position. So, it has no arbour and overarm which are replaced by the spindle and head, respectively.

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Some of the vertical milling machine operations are as below:

For the horizontal milling machine, there are two methods of milling, the up milling and down milling. The up milling, also known as conventional milling, is when the work piece is fed against the direction of the cutter rotation. The depth of cut gradually increases on the successively engaged cutting edges as the chip is first cut off at the thinnest place. Therefore, the machining process involves no impact loading, thus ensuring smoother operation of the machine tool and longer tool life. The quality of the machined surface obtained by up milling is not very high. Nevertheless, up milling is commonly used in industry, especially for rough cuts. Up milling tend to pull the work piece up, therefore, proper clamping is necessary in obtaining a satisfactory result.

When the direction of the cutter rotation is the same as the feed motion, down or climb milling is under way. The maximum depth of cut is achieved directly as the cutter engages with the work piece. The chip formation of down milling opposes that of up milling where the chip thickness gradually decreases. This results in a kind of impact, or sudden loading. Therefore, this method cannot be used unless the milling machine is equipped with a backlash eliminator on the feed screw. The advantages of this method include higher quality of the machined surface and easier clamping of work pieces as the cutting forces act downward.

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The most suitable type of milling cutter for a particular milling operation depends on such factors as : The kind of cut to be made The material to be cut The number of parts to be machined The type of milling machine available Solid cutters of small size will usually cost less, initially, than inserted blade types; for long-run production, inserted-blade cutters will probably have a lower overall cost. Depending on either the material to be cut or the amount of production involved, the use of carbide-tipped cutters in preference to high-speed steel or other cutting tool materials may be justified. Rake angles depend on both the cutter material and the work material. Carbide and cast alloy cutting tool materials generally have smaller rake angles than high-hspeed steel tool materials because of their lower edge strength and greater abrasion resistance. Soft work materials permit higher radial rake angles than hard materials; thin cutters permit zero or practically zero axial rake angles; and wide cutters operate smoother with high axial rake angles.

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There are the features of milling cutter used to identify the major features of the milling cutter. The teeth are said to be radial when each tooth face lies along a line that cuts through the center of the cutter. Teeth are cut either with a radial tooth face or at zero degree., positive rake angle to radial line. There may be two or three clearance on the standard teeth form. A formed tooth-milling cutter has a contour, or tooth outline, of a particular shape. A concave milling cutter with a specific diameter produces a rounded shape. A gear cutter machines a gear tooth that conforms to specific design requirement.

The type of cutter depends on either the material to be cut or the number of part to be machined. The milling cutters have different shapes and types. Arbor types are those, which have a hole for mounting on an arbor or spindle. The arbor may be vertical or horizontal depending on the milling machine type.

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In this activity, there are three types of milling operations that are dealt with, which are the slab milling, face milling and end milling. Slab milling, also called peripheral milling is basically done on a horizontal milling machine, whereby the axis of cutter is parallel to the work piece surface to be machined. The resulting chip have a shape of a wedge. There was no horizontal milling machine in the work shop that I know of. So, for this part, we had to use the vertical milling machine.

Face milling and end milling are both done on the vertical milling machine as the cutter is mounted on an axis perpendicular to the work piece. In face milling, the machine is evenly stressed, resulting in the removal of chips with an even thickness. The cutter in end milling can be tilted on machine tapered surfaces. The cutter has either straight or tapered shanks for smaller and lighter cutter sizes, respectively. End milling can produce flat surface and

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various profiles and are also available with hemispherical ends for producing curved surfaces as in making dies.

Some calculations are involved in milling operations which are for: Cutting Speed The cutting speed in milling is the peripheral speed of the cutter S = D N where d is the cutter diameter and N is the revolution per minute. The cutting speed selection depends on both the work piece and cutter materials.

Feed Rate The linear feed rate in milling is expressed as the rate of feed in mm/min. It is the distance in mm which the milling table travels in one minute. Feed rate is determined from the equation F = f N Z where f is the feed per tooth cutter (mm/tooth), Z is the number of teeth on the cutter periphery (number of teeth/rev) and N is the rotational speed of the cutter (rev/min). Cutting Time Is given by the expression T = L / F where L is the travelling distance of the milling table. It depends on the work piece length (l), the approach and over travel allowances. The approach usually taken as the radius of the cutter in rough milling and as the diameter of the cutter in finish milling. The over travel is usually taken as 2 to 5 mm. Metal Removal Rate The metal removal rate (MMR) in mm3/min is given by MMR = lwd /T where l is work piece length in mm, w is the width of the work piece and d is the depth of the cut.
Inevitably I faced some difficulties in completing this activity but thankfully, there was nothing majorly wrong. There were insufficient machines to cater me and my group, so we had to wait for quite a long time as each person took a lot of time to finish especially for Milling 2. The finishing obtained was

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kind of poor because two kinds of surface were formed on the surface. Attaching the spindle onto the vertical milling machine is quite a problem as it demands for strength and requires tolerable height to reach the top of the machine. Other than that, everything else went quite well. The work piece that was obtained is as the following

CONCLUSION
Alhamdulillah, praise be to Allah SWT for it is with His grace that I was able to finish this activity within the allotted time. All of the objectives have been achieved as I am now able to operate the milling machine, both the manual and automatic as I have had the privilege of using both in doing this activity. Now, I have better understanding of the milling machine; name and function of its components, and how to use them. The practical work using this machine gave an opportunity to me to practice the proper way in applying the basic operations besides develop some skills and technique on those operations. While milling, a lot of care and alertness have to be practiced in order to produce a good work piece. The safety rules must also always be adhered to.

ANSWERS TO QUESTIONS
1. Write down the characteristics and advantages of down milling rotation. The characteristics of down milling rotation are the direction of the cutter rotation is same as the feed motion, where the cutter tooth is almost parallel to the top surface of the workpiece. The chip formation is

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opposite to the formation of chip in up milling as the cutter tooth begins to mill the full chip thickness, whereby the chip thickness gradually decreases. The advantage is that the downward component of the cutting forces holds the work piece in place, particularly for slender parts. Because of the resulting high impact forces when the teeth engage the work piece, this operation must have a rigid setup and backlash must be eliminated in the table feed mechanism. Anyway, climb milling is not suitable for the machining of work pieces having surface scale such as hotworked metals, forging and castings. The scale is hard and abrasive and causes excessive wear and damage to the cutter teeth, shortening tool life. Down milling usually produces a better surface finish on harder steels than does up milling. It is the method that is usually selected for milling operations on slender ad intricate parts. Fixture design is simplified. Less power is required. Increased cutting speeds and feeds are practical. 2. Draw sketch for a face milling operation.

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Draw a sketch showing the end milling operation.

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In face milling operation, the work piece dimensions are 125mm by 250mm. The cutter is 150mm diameter, has 8 teeth and rotates at 300 rpm. The depth of cut is 3.125mm and the feed is 0.125mm / tooth. Calculate the cutting time and metal remove rate, given: N = 300 rpm, D = 150 mm, f = 0.125 mm/tooth, Z = 8

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a)

Case of rough milling. Traveling distance, L = 250 + (150 / 2) = 325 mm Feed rate, F = 0.125 x 300 x 8 = 300 mm/min Cutting time, T = 325 / 300 = 1.083 min Metal removal rate = (250 x 125 x 3.125) / 1.083 = 90172 mm3/min

b) Case of finish milling. Traveling distance, L = 250 + 150 = 400 mm Feed rate, F = 0.125 x 300 x 8 = 300 mm/min Cutting time, T = 400 / 300 = 1.333 min Metal removal rate = (250 x 125 x 3.125) / 1.333 = 73260 mm3/min

REFERENCES
8 8 Course manual Machine Tool Practice (6th Edition) by Prentice Hall Machinerys Handbook (26th Edition) by Industrial Press

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