LAB 2

FAKULTI TEKNOLOGI KEJURUTERAAN

MEKANIKAL DAN PEMBUATAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BMMP 1303 MANUFACTURING PRACTICES (AMALAN PEMBUATAN)

LAB SHEET 2

MILLING OPERATIONS

Learning Outcome LO3 Perform the process according to the proper procedure.
(LO):
Program Outcome: PO5 Ability to select and apply appropriate techniques, resources and modern
engineering tools, with an understanding of their limitations.
Synopsis: This lab activity will enrich students’ knowledge on milling operations. Students are
exposed to common equipment for performing manufacturing works such as lathe and
milling machine, arc welding

Related Lecture’s 1. Introduction to Milling Operations (Topic 7)

Topic:
2. Milling Operations-continued (Topic 8)
Prepared by: Ts Dr Norfariza binti Ab Wahab Date: 18 Mac 2021

Approved by Dr Ridhwan Jumaidin Date

LM/SLM/HOD

QMS : REVISION RECORDS

Revision Date Approved by

Description Prepared by :
No (DD/MM/YY) LM/SLM/HOD:

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1.0 OBJECTIVES:

At the end of the practical activity, students will be able to:

1. Apply safety procedures while working in the workshop.

2. Familiarize the milling machine features , handling and operating milling machine.
3. Produce a part by using milling machine based on technical drawing.

2.0 INTRODUCTION

The goal of this lab session is to familiarize the students with safety procedures in the
workshop, proper handling and operation of milling machine. This laboratory activity is
designed to give practical experience for students to produce precision part conforming to
the specifications on technical drawing using a manual mailling machine.

3.0 LIST OF INSTRUMENTS/TOOLS

1. Technical Drawing
2. Vertical Milling Machine
3. Face mill Diameter 32-46 mm
4. End mill Diameters 6, 10, 12 mm 2-4 flutes
5. Center Drill size (Small) Diameter 2-3
6. Drill size Diameter 5
7. Vernier caliper
8. Flat file
9. Parallel bar
10. Height gauge
11. Copper mallet
12. Raw Materials: Refer Technical Drawing

4.0 SYNOPSIS & THEORY

Milling is the process of cutting away material by feeding a work piece past a rotating multiple
tooth cutter. The cutting action of the many teeth around the milling cutter provides a fast
method of machining. The machined surface may be flat, angular, or curved. The surface may
also be milled to any combination of shapes. The machine for holding the work piece, rotating
the cutter, and feeding it is known as the milling machine.

In milling, the work piece is fed in a rotating milling cutter, which is a multi-point tool, unlike
a lathe, which uses a single point cutting. The tool used in milling is called the milling cutter.

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In addition to straight milling of flat and irregularly shaped surfaces, it can perform gear and
thread cutting, drilling, boring and slotting operations, which are normally handled on
machine tools designed specifically for these specific operations. Figure 1.0 shows typical
vertical milling machine and features.

Figure 1.0: Basic Features Vertical Milling Machine & Axis-system

5.0 GENERAL SAFETY PROCEDURE

Refer : Manual “ Taklimat Keselamatan Di dalam Makmal”

5.1 MILLING MACHINE OPERATION SAFETY GUIDELINES

1) Variable Speed Heads: Only CHANGE SPEED WITH THE SPINDLE RUNNING on
machines equipped with variable speed heads.
2) Removing Chips: Never remove chips with your hands. Use a brush to sweep chips
from the part.
*CAUTION: The chips produced by milling cutters are very hot and can be thrown
some distance.
3) Measuring: Never measure parts with the spindle turning.
4) Climb (Up) vs. Conventional (Down) Milling: Use climb milling whenever possible. It
causes less tool wear, requires less cutting force, and leaves a better surface finish.
Conventional milling is best used when milling thin sections, using large cutters, or
when the milling machine has excessive backlash in the feed screw.

5) To remove tooling from the spindle:

a. Ensure that the spindle is fully retracted.
b. Hold the tool with a towel or rag to protect your hand.
c. Press and hold the off button until the tool loosens into your hand.
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6) To install a collet/tool in the spindle:
a. Ensure that the spindle is fully retracted.
b. Clean the inside of the spindle and the collet/tool.
c. Hold the tool with a towel or rag to protect your hand.
d. Insert the collet/tool into the spindle and rotate it until the keyway on the
collet/tool lines up with the key on the spindle.
e. Press and hold the on button until the collet/tool fully engages into the
spindle head.

6.0 PROCEDURES:

Following are some basic procedures in preparing the square block of the part.
Students are required to produce/explain the whole procedure of the project in your own
understanding & words in the lab report.

6.1 SQUARING UP A BLOCK

1) Cut raw material according to size using bandsaw machine. Remove all burrs using
a file or deburring tool.

2) Place the parallel blocks in the vise and place the workpiece on top of the parallels.
Lightly clamp the workpiece and hit it with the cooper/rubber mallet to ensure it
is well seated on the parallels, then tighten up the vise. A second hit with the
mallet may be necessary to ensure good seating of the part.

3) Insert facemill into machine spindle and WITH THE SPINDLE IS RUNNING ON, SET
SPINDLE SPEED to approx. 900-1000 rpm. Milled the raw material according to the
drawing given and do roughing and finishing cuts to controlled surface finished
and the workpiece sizes by using face mills cutter on the milling machine.

4) To set zero position between cutter and workpiece turn Z lever to the clockwise
direction to increase table height until it touches the facemill (if the surface
already mills ensure strips of paper are used to protect surface from cutting marks)

5) Perform a six sided cutting (Figure 2.0) to get a squareness and size on the
workpiece. Mills the first face to remove the rough skin on raw material surface
and after filling the burrs on edges turn the workpiece and clamped the workpiece
to second side which opposite the first side and rise up the workpiece by using a
parallel bar. Knock the workpiece by using copper mallet and check that the
parallel bar not moving and then start cutting. On this second side cutting process
the dimension should be controlled to the tolerance require.

6) Repeat the cutting processes same to first and second side to the third and fourth.
The fifth side, use L-square and clamps the workpiece three to five millimetre out
from vice jaw and start cutting surface to obtain surface square to 90 deg. For the
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 sixth side just clamped the workpiece and mill on the surface and control the
dimension and tolerance according to the drawing.

Figure 2.0: Six Side Cutting Approach

6.2 THE PROJECT

1) Refer Attached Technical Drawing in Appendix

2) Do a layout marking on workpiece surface and cuts using suitable milling cutters
by the x or y axis movement.
3) To perform drill operation, change the arbor from face mill/end mill to drillchuck
arbor and perform drill operation using center drill and drill tool.

7.0 RESULT

Item Details Dimension (mm) ±0.5

Drawing Actual
1
2
3
4
5
Product Completed

8.0 DISCUSSION

1) Why squaring is an important process?

2) List 5 general workshop safety in your workplace.
3) Discuss any finding or difficulty based on the laboratory activities.

9.0 CONCLUSION

Please state your conclusion and recommendation based on laboratory activities.

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APPENDIX

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 LAB 2
FAKULTI TEKNOLOGI KEJURUTERAAN
MEKANIKAL DAN PEMBUATAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BMMP 1303 MANUFACTURING PRACTICES (AMALAN PEMBUATAN)

LAB REPORT 2

MILLING OPERATIONS

INSTRUCTOR’S NAME TS. DR NORFARIZA BINTI AB WAHAB

STUDENT’S NAME MATRIX NO:

S1.
S2.

ASSESSEMENT RUBRICS

Approved By: ………………………………………………..….. Date: …………………………………………….........

(Instructor’s Signature & Stamp)