DEPARTMENT OF MECHANICAL ENGINEERNG

BMM1821
MECHANICAL LABORATORY 2

MILING REPORT

LECTURER: MAZITA BINTI MOKHTAR

GROUP 6
MEMBERS ID
CHIN SHEN GUI MH 20044
NUR AISYAH BINTI CHE MANSOR TH 20009
 TABLE OF C0NTENTS

1.0 FUNDAMENTAL ON MACHINING 1

1.1 Introduction 1

1.2 Type of Milling Cutter 3

1.3 Tools used in Laboratory 5

2.0 MACHINE HANDLING AND SAFETY PRECAUTION 7

2.1 Introduction 7

2.2 Laboratory Safety 7

2.3 Pre-Operational Safety 7

2.4 Operational Safety 8

2.5 Ending Operational Safety 8

3.0 PART DRAWING AND DIMENSION 9

4.0 MACHINING METHODOLOGY AND TECHNIQUE 10

5.0 FINAL PART IMAGES 12

6.0 SUMMARY 13

8.0 REFERENCES 14

8.0 APPENDIX 15
1.0 FUNDAMENTAL ON MACHINING

1.1 Introduction

Machining is a method that removes the undesired material using cutting tools and
modifies the surfaces of a workpiece by producing chips during the manufacturing
process. Machining commonly used in the prototyping and manufacturing process. In
the machining process, three techniques were used, turning, drilling, and
milling. Whereas boring, drilling, and shaping are possible using a variety of parts such
as drill bits, mill bits, and boring bits.

Milling process is a metal removal process that use the rotary cutters in a feed
motion that perpendicular to the cutting tool's rotational axis called a milling cutter.
There are two types of cutting tools which were a single point cutting tool that has only
one cutting edge and a multi-point cutting tool that has two or more cutting edges. The
workpiece is fed against the rotating cutter to perform the cutting action. As a result,
the spindle speed, table feed, depth of cut, and rotating direction of the cutter become
the primary parameters. Milling was classified into several categories, including face
milling, plain or snub milling, angle milling, end milling, and form milling.

Milling machines can be used for drill, bore, cut gear, and produce slots. Basically,
there are three direction of machine table that can move, which is y, x, z axis. In addition,
horizontal milling machines and vertical milling machines are the two types of milling
machines used in mechanical labs. In figure 1, it shows horizontal milling machines
also known as universal tables with rotary tables that aid in milling at different angles.
The cutter that is used in horizontal milling machines is slab milling cutter, side and
face cutter and slitting saw.

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 Figure 1. A horizontal milling machines.

The spindle axis of the vertical milling machine as shown in figure 2, which is
vertically placed. It rotates by staying on the same axis but for the angle of the milling
head can be adjustable. The spindle can also be extended to perform tasks such as
drilling and cutting. Further, the cutter that is used in vertical milling machines is the
end mill and face milling cutter.

Figure 2. A vertical milling machines.

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1.2 Type of Milling Cutter

Horizontal milling machines and vertical milling machines use different types
of cutters because of the function of the machine, based on the demand of the desired
material form and the design of the cutter. Vertical milling machines are more suitable
for milling more parts with more detail, while horizontal milling machines were suitable
for cutting heavier and deeper grooves into the material.

i. Horizontal Milling Cutter

 Slab milling cutter

It is suitable for flat surfaces and removes more material form once over.

 Side & face cutter

Cutting edges on the teeth's periphery and sides for cutting shoulders and slots.
It is stiffer than a slitting saw.

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  Slitting saw
The cutter was designed to cut thin slot features on parts more accurately and
as well for deep slots.

ii. Vertical Milling Cutter

 End mill
Cutter axis perpendicular to the machine surface. It utilised for milling profiles,
facing, and slotting. Other than that, both sides contain cutting teeth and have
a small diameter cutter.

 Face milling cutter

Face mills always have their cutting edges along the sides. It has a large
diameter cutter and is suitable for heavy cutting.

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1.3 Tools Used in The Laboratory

There are several tools needed to facilitate the milling process.

 Bench Vice
The function as a clamp and hold the workpiece during the milling processes.

 Wire Brush
To remove ashes, dust, chips, or other excess materials from the table and
workpiece.

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 Goggles
To prevent our eyes from ash, dust, or chips while the milling process is in
progress.

 Vernier Calliper
A vernier calliper is a measuring device that used to measure the dimension on
a workpiece. It can measure the length, inner diameter, outer diameter, and
depth of the workpiece. The sensitivity for vernier calliper is 0.1cm.

 Rubber Mallet
To ensure tightness and right position by slightly knock to the workpiece on
the vice.

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2.0 MACHINE HANDLING AND SAFETY PRECAUTION

2.1 Introduction
The milling machine safety procedure are similar to other machine operation in
that it requires the operator's full attention and a throughout understanding of the
hazards associated with its operation. Use the machine with proper guidelines and
procedures. Follow the precautions listed below and take responsibility for
protecting yourself and those around you.

2.2 Laboratory Safety

a) Read and understand all safety precautions in the laboratory manual and
emergency procedures prior to the first laboratory session.
b) Do not use this machine unless operators have been trained and granted permission
by the supervisor or instructor.
c) Wear appropriate clothing and footwear.
d) Rings and jewellery are not permitted.
e) In working areas, safety glasses and close fitting/protective clothing must be
always worn.
f) Long and loose hair must be managed properly.
g) When using this machine, no gloves should be worn.

2.3 Pre-Operational Safety

a) Before the operation, ensure that the instructor and supervisor have provided with
the necessary safety information about the lab and machinery.
b) Make sure there are no slip/trip hazards in the workplace and walkways.
c) Locate and familiarise yourself with the operation of the ON/OFF starter
and E-Stop (if fitted).
d) Do not leave equipment on top of the machine.
e) Check that the cutter is in good condition and is securely mounted.
f) Check the coolant delivery system for sufficient coolant flow.
g) Faulty equipment should never be used, and report suspect machinery immediately.
h) Only a member may operate the machine at any one time.

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2.4 Operational Safety
a) When the machine is running, never leave or move your attention.
b) Follow proper clamping procedures. Ensure to tighten the workpiece and make sure
the workpiece is secure.
c) Set the correct spindle speed to suit the cutter diameter, depth of cut and the material.
d) Make sure that the operator, other person and any unnecessary objects are not too
near the cutting tool and machine rotation compartments.
e) Make sure there is no dust or chip from the material disturbs moving components
or cause excessive clumping.
f) If there is needed to make adjustments or measurements or cleaning to the
workpiece, switch off the machine and make sure it completely stops.

2.5 Ending Operational Safety

a) Switch off the machine.
b) Milling cutters should be removed and stored safely.
c) Clean up all dust or chip using a brush and dispose of it properly.
d) Keep the machine and work area safe, tidy condition and clean.

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3.0 PART DRAWING AND DIMENSION

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4.0 MACHINING METHODOLOGY/ TECHNIQUE

We discovered that this operation is to remove unwanted material from a

workpiece using rotary cutters by feeding in a direction that is at an angle with the tool's
axis, either x, y, or z. Milling is commonly used to produce non-axially symmetric parts
with numerous features such as holes, slots, pockets, and even three-dimensional
surface shapes. We can determine that milling is utilised in operations due to its
adaptability in producing a variety of product shapes.

In this laboratory, it will cover machining techniques that are available or used
on most vertical milling machines. According to the process of the experiment,
machining is related to metal work material and uses the end mill method. The work
pieces are measured using Vernier Callipers. The dimensions and design on the
workpiece according to the drawing scheme presented in Chapter 3.

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The vertical milling machine involves the following processes:
No Milling Process Description
1 Milling Cutters The milling cutters also known as end mills have unique
cutting surfaces on their end surfaces that allow them to be
drilled into the workpiece.
2 Facing Facing is the process of removing material from a
workpiece's end or shoulder with a specific tool to produce
a smooth surface perpendicular to the workpiece's rotating
axis.
3 Centre drill Centre drilling is performed on a mill to provide a starting
point for the cutting edges of a drill. It’s used to create a
dimple on the flat face of a piece of metal so that the drill
does not "walk" when it first encounters it.
4 Drilling Round holes in a workpiece are created or refined with this
tool. A rotary tool with two or four helical cutting edges is
typically used for drilling.
5 Counterbore Counterbores on a milling machine to create a hole that
enlarges another coaxial hole, or the tool used to create that
feature.
6 Tapping Tapping is the process of cutting a thread inside a hole to
insert a cap screw or bolt into it. It's also used to create
thread on nuts.
7 Slotting Depending on the end mill shape, slotting fully engages the
end mill in the workpiece and creates a slot with a
rectangular or rounded profile.
8 Chamfering Machining operations can often produce a sharp edge on a
workpiece, therefore a chamfer mill on a milling machine
is used to create a component. A chamfer mill removes
sharp edges and replaces them with a sloped surface, or
chamfer.

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5.0 FINAL PRODUCT IMAGE

Figure 3：Top View of the Final Product.

Figure 4: Front View of the Final Product.

Figure 5: Back face of the product.

Figure 6: Side View of the Product.

Figure 7: Isometric View of the Final Product.

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6.0 SUMMARY

Throughout the entire laboratory, the group members were able to recognize the
fundamental of machining. During the safety briefing, the group members were able to
understand the machine handling and safety precautions pre-process, during the process
and post process. Besides, the group members were able to interpret the blueprint in the
aspect of dimension, tolerance values, material used, ratio, types of cutting tools
required in each process, etc. In addition, the group members can calculate the
appropriate numerical values of feed rate, rpm and cutting speed by using the equation.
Then, the group members were able to operate the vertical milling machine by applying
the knowledge from the above section. After that, the group members contribute their
initiative to complete the step-by-step procedure such as drilling, slotting, chamfering,
etc. Finally, the product was completed.

However, there is several improvements can be made. The limitation of the

machine causes the rpm values were set at the low speed only. Therefore, the surface
finishing was roughness. A modern and advanced machine can minimize this issue. In
addition, a modern and advanced machine can reduce the time consumption to mill the
workpiece since the machine can be mill at the desire thickness once over, whereas do
not require to mill at only 0.5mm thickness only. Next, the cutting fluid can be applied
to provide lubrication and maintain the hardness of cutting tool.

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7.0 REFERENCES

Calter, S. (2019, Jun 14). Guide to Calculate Speeds and Feeds.

Technical - Speeds & Feeds (cncrouterbits.com.au)
Identifying Machine Parts, Controls, And Their Functions
IDENTIFYING MACHINE PARTS, CONTROLS, AND THEIR FUNCTIONS – Cad
cam Engineering WorldWide
What Is an Edge Finder?
How to choose and use an Edge Finder! (cncphilosophy.com)
ISO System of Limits and Fits.
ISO - ISO 286-1:1988 - ISO system of limits and fits — Part 1: Bases of tolerances,
deviations and fits

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8.0 APPENDIX

15
SUMMARY OF EACH VIDEO

Video 1
i) Objective

a. To introduce each fundamental components in the vertical milling machine.

b. To introduce the fundamental operation method and machine settings (RPM, table
position adjustment, and the replacement of the cutting tool) of vertical milling
machine.

ii) Method: Introduction to the milling machines

iii) Parameters/ Machine Settings

There are many parameters that required to calculate throughout the laboratory. For
instance, feed rate is referred to the distance of cutter moves over workpiece per
minute, which unit is mm/min. The equation for feet rate as shown below:

F = f*u*N

Cutting speed (C.S) also a parameter that concerned in this laboratory. It refers to the
rate of the workpiece moves over the cutting tool. Next, the unit for this parameter is
m/min.

The equation as shown below:

𝐶𝑢𝑡𝑡𝑖𝑛𝑔 𝑆𝑝𝑒𝑒𝑑 × 1000

𝑅𝑃𝑀 =
𝜋 × 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟

The spindle speed of the WARCO vertical milling machine can operate in the range
between 50rpm-3500rpm, while this parameter can be determined by using an
equation, then the rpm can be adjusted with the rotating the variable speed control.

Mostly the spindle will operate in the clockwise direction to perform the milling
process, as well as in this laboratory; yet it also can operate in counterclockwise
direction. In addition, the selection of tools was the crucial process.
 The table can be adjusted in 3-dimension, which are XYZ direction by using the
handwheels manual operation as shown in the figure below.

The built-in compressor is used to hold the cutting tool stable and tightly, so that the
cutting tool would not fly-off from the fixed position especially in high-speed
operation because it might hurt the operator badly.

There is a transparent plastic cover is used for safety precautions. It can retain the
debris fly-off at the particular direction, especially in the direction of the operator.
Even all the operators have been forced to wear the goggles, however this transparent
blockage could provide a double protection to the operator.

Video 2
i) Objective

a. To interpret then understand the blueprint drawing that provided by laboratory

assistance.
b. To have an understanding on the tolerance value and symbol labelled on the
blueprint drawing.
c. To choose the appropriate dimension of cutting tools for each procedure required
based on the ISO.
ii) Method: Technical drawing interpretation

No. Process Symbol Description Cutting Tools

Dimension
1. Tapping M10 * 1.5 -Drill -ø8
-Tapping -ø8.5; Thread1.5
2. Counterbore M8 -Drill (depth 9mm) -ø10.5

3. Slotting ø8H7 Reamer Tolerance: ±μ25mm

4. Chamfering CHAMBER 1 x 45° Countersunk 45°

Note that the cutting tool dimension were refer to the ISO Hole Tolerances (ISO 286).

iii) Parameters/ Machine Settings

a. The ratio aspect printed in the blueprint were 1:1, meanwhile there is the actual
ratio, which do not require any dimension conversion in this entire laboratory.
b. The material of the workpiece was replaced to aluminum instead of mild steel.
c. The tolerance value was noticed at the information column.

No. Tolerances Range Example (mm) Allowed Range (mm)

Symbol
1. X ±0.5 100 99.5≤x≤100.5
2. X.X ±0.2 5.0 4.8≤x≤5.2
3. X.XX ±0.05 1.00 0.95≤ x≤1.05
Video 3
i) Objective

a. To face the aluminum workpiece into the dimension that required in the blueprint
drawing.

ii) Method: Facing

Dimension (mm) Required Value Measured Value Required Cutting Value

Length 100.00 101.5 2.83
Width 48.00 51.00 3.00
Height 24.00 25.00 1.00

iii) Parameters/ Machining Settings

RPM 𝐶𝑠×1000
RPM =
𝜋𝐷
40×1000
RPM =
𝜋∗20
RPM = 636 rev/min
Tools End mill ø20
Cutting Speed Selection 40m/min

Milling Techniques

a. In theoretical, the maximum cutting speed for carbide materials can be 250m/min.
However due to the safety features and limitation of machine, 40m/min of cutting
speed is used in this laboratory.
b. Calculation of rpm can be used the equation as shown below:

𝐶𝑢𝑡𝑡𝑖𝑛𝑔 𝑆𝑝𝑒𝑒𝑑
rpm =
𝜋 ∗𝐷
 c. Therefore, the rpm value used is 2000rpm.
d. To have a great quality of finishing, both sides must be face. Therefore, each side
divided by 2.
e. The height of the workpiece needs to be face in 1.00mm. Hence, 0.5mm would be
face at each side.
f. After the calculation has been done, tight the workpiece on the vice neatly.
g. Adjust the vertical knee so that the end of cutting tools just contact on the
workpiece surface, tare it then moves down the saddle.
h. Rotate the variable speed control, until the meter showed 2000rpm.
i. Rotate the knee until the vertical axes shows zero, then start to face the workpiece
with 0.5mm.
j. Face all the surface, then released the workpiece from the vice.
k. Measured the height of the workpiece using vernier caliper. The height of the
workpiece currently was 24.6mm.
l. Repeat step d-j at the opposite side, notice that this site was needed to face
0.6mm. To have an accurate result, divide the required facing thickness into half.
Meanwhile the facing process need to be double, and the face dimension of height
for each operation was only 0.3mm.
m. Repeat step c-k to face the length, and width of the thickness respectively.

Video 4
i) Objective

a. To use the edge finder determine the center edge.

b. To use the end mill M20 milling the workpiece.

ii) Method: Edge finding and milling

iii) Parameters/ Machine Settings

RPM 400

RPM 2000
 RPM Edge Finder ø5
𝐶𝑠×1000
RPM =
𝜋𝐷
40×1000
RPM =
𝜋 ∗5
RPM = 2546 rev/min

End mill Ø10

𝐶𝑠×1000
RPM =
𝜋𝐷
40×1000
RPM =
𝜋 ∗10
RPM = 1273 rev/min
Tools - Edge finder ø5
- End mill Ø10
- Vernier caliper
- Rubber mallet
Cutting Speed Selection 40m/min

Milling Techniques

a. Tighten the edge finder on the spindle by using compressor. Ensure it is tight
well.
b. Rotate the x and y-axis so that the end of the edge finder is at an edge of the
workpiece. Set it as the reference point (0,0, Z).
c. Since the diameter of edge finder is 5mm, to determine the center of cutting tools
is on the edge. Adjust both x and y-axis in 5mm.
d. Reset it as the new reference point (0,0, Z).
e. Adjust the vertical knee so that the end of cutting tools just contact on the
workpiece surface, tare it then moves down the saddle. Recheck whether its center
edge.
 f. The width of workpiece that need to be milling is 14mm. Currently the setup is
only 10mm width since the diameter of cutting tools is 20mm. Hence the y
direction needs to add 4mm which makes the DRO (digital meter readout) display
14mm in y-axis.
g. Moves away the workpiece in x-axis then rotate the knee so that the z-axis in
0.5mm.
h. Repeat step g until the depth of 7mm is completed.
i. Repeat step a-h in the opposite face.

Video 5
i) Objective

a. To mark the point that need to drill for further tapping, drilling or reamer process.

ii) Method: Center drill and drilling

iii) Parameters/ Machining Settings

RPM 𝐶𝑠×1000
RPM =
𝜋𝐷
40×1000
RPM =
𝜋 ∗3

RPM = 4244 rev/min

Tools -Center drill ø3
-Vernier caliper
-Rubber mallet
Cutting Speed Selection 40m/min

Milling Techniques

a. Tighten the center drill on the spindle by using compressor. Ensure it is tight well.
b. Realign the workpiece into the reference point (0,0,0).
c. Move x-axis in 12.5mm then y-axis in 7m, which is a point that need to drill later.
d. Loosen the key, then press down the quill feed hand lever.
 e. Complete the other marking point by repeating step b-d. Notice that step c, which
is different dimension in each point since the location of the points were different.

Video 6
i) Objective

a. To drill, counterbore, tape on the workpiece according to the dimension printed

on the blueprint.

ii) Method: Drilling, counterbore and tapping

iii) Parameters/ Machining Settings

RPM End mill ø10.4 & Counterbore ø10.4

𝐶𝑠×1000
RPM =
𝜋𝐷
40×1000
RPM =
𝜋∗10.4
RPM = 1224 rev/min

Reamer ø8
𝐶𝑠×1000
RPM =
𝜋𝐷
40×1000
RPM =
𝜋∗8
RPM = 1591 rev/min
Tools -End mill ø10.4
-Counterbore ø10.4
-Reamer ø8
-Tapping tool 1.5mm
-Tap wrench holder
-Vernier caliper
-Rubber mallet
Cutting Speed Selection 40m/min
Milling Techniques

a. Counterbore M8
b. Tighten the end mill ø10.4 on the spindle by using compressor. Ensure it is tight
well.
c. Drill gradually until throughout the whole piece of workpiece.
d. Loosen the end mill, then tighten the counterbore M8 on the spindle by using
compressor. Ensure it is tight well.
e. Since 9mm depth is needed to complete the counterbore, adjust the height of
stopper into 9mm from its initial point. In this case, the initial point was 10 mm,
hence adjust the stopper until 19mm.
f. Press down the quill feed hand lever gradually until the rubber touch the stopper,
which mean 9mm depth of counterbore is completed. Loosen the cutting tool.
g. Repeat step a-e for another counterbore.
h. Reamer ø8H7
i. Tighten the reamer on the spindle by using compressor. Ensure it is tight well.
j. Drill gradually until throughout the whole piece of workpiece. Loosen the cutting
tool.
k. Repeat step g-h for another side.
l. Tapping
m. Tighten the end mill M10 on the spindle by using compressor. Ensure it is tight
well.
n. Drill gradually until throughout the whole piece of workpiece.
o. Use the tapping tool M10*1.5mm and tap wrench holder manually.
p. Repeat step j-l to complete another 3 holes.
Video 7
i) Objective

a. To create a slot on the workpiece.

ii) Method: Slotting

iii) Parameters/ Machining Settings

RPM Edge Finder ø5

𝐶𝑠×1000
RPM =
𝜋𝐷
40×1000
RPM =
𝜋∗5

RPM = 2546 rev/min

End mill ø8
𝐶𝑠×1000
RPM =
𝜋𝐷
40×1000
RPM =
𝜋∗8

RPM = 1591 rev/min

Tools -Edge finder ø5
-End mill ø8
-Vernier caliper
-Rubber mallet
Cutting Speed Selection 40m/min

Milling Techniques

a. Tighten the edge finder on the spindle by using compressor. Ensure it is tight
well.
b. Rotate the x and y-axis so that the end of the edge finder is at an edge of the
workpiece. Set it as the reference point (0,0, Z).
c. Since the diameter of edge finder is 5mm, to determine the center of cutting tools
is on the edge. Adjust both x and y-axis in 5mm.
 d. Reset it as the new reference point (0,0, Z).
e. Loosen the edge finder, then tighten the cutting tool on the spindle by using
compressor. Ensure it is tight well.
f. Rotate the x axis in 21.5 mm and y-axis in 8,5mm from the reference point so that
the end mill is located at the point that want to create the slot.
g. Adjust the vertical knee so that the end of cutting tools just contact on the
workpiece surface.
h. Set the new reference point, x,y and z-axis into (0,0,0).
i. Move the x-axis in 57mm.
j. Z-axis in 0.5mm per operation.
k. Repeat step j-k until the thickness 2mm.

Video 8

i) Objective

a. To chamfer each side of the workpiece in 45°.

ii) Method: Chamfering

iii) Parameter @ Machining Settings

RPM 500rev/min

Tools - Countersunk 45°

-Vernier caliper
-Rubber mallet

Cutting Speed Selection 40m/min

Milling Techniques

a. Tighten the countersunk 45°on the spindle by using compressor. Ensure it is tight
well.
b. Realign the workpiece into the reference point.
c. Add 0.25mm in y-axis.
d. Rotate the crank handle in x-axis to complete the chamfering process.
e. Repeat step c-d until the y-axis was displayed 1.00mm on the DRO.
f. Repeat Step b-e in the other sides.