FACULTY OF

ENGINEERING AND TECHNOLOGY

Workshop and CNC Technologies

LAB REPORT : MILLING

NAME STUDENT ID

Introduction:
Milling is a common machining process used in engineering to shape, cut, or drill a material using a
rotary cutter. The milling machine is a power-driven tool that uses a cutter with multiple teeth to
remove material from the surface of a workpiece. The workpiece is typically held in a vise or
fixture on the milling machine table and moved in various directions under the rotating cutter. In
general, milling can be classified into two main categories: peripheral milling and face milling.
Peripheral milling involves cutting along the circumference of the workpiece, while face milling
involves cutting the flat surface of the workpiece. There are also other types of milling such as end
milling, gang milling, and form milling, each of which has its own unique application and
advantages Milling is widely used in industries such as aerospace, automotive, construction, and
manufacturing to create complex shapes and parts from a wide range of materials, including metal,
plastic, wood, and composites. The process can be used to produce parts with tight tolerances,
intricate shapes, and high surface quality.[2]

Milling machine is a type of machining tool that uses a rotating cutting tool to remove material
from a workpiece. It can perform various operations such as cutting, drilling, and shaping metal or
other materials to create complex parts with high precision and accuracy. [1]

Figure 1.0 : Milling machine

Base The foundation of the milling machine is made of cast iron (high compressive
strength) to support the weight of the machine.
Knee The knee is supported and adjusted by a vertical positioning screw (elevating
screw). The elevating screw is used to adjust the knee up and down by raising or
lowering the lever either with the help of hand or power feed.
Power It is the knee which contains the power feed mechanism. It is used to control the
Feed longitudinal ( left and right), transverse ( in and out) and vertical (up and down)
feeds. To get the desired rate of feed on the machine, the feed selection lever is
positioned as indicated on the feed selection plates.
 Column Serve as housing and support for all the driving members. There are many
driving gears and sometimes even the motor of the spindle fits in the hollow area
of the milling machine.
Spindle The place where the cutting tools are held. It provides the rotary motion and drive
for arbours, cutters, and attachments on the machine.
Ram The overhanging arm in the vertical machine is called ram. One end of the ram is
mounted on the top of the column and on the other end a milling head is attached.
The ram can be moved transversally ( in and out) on the column by a hand lever.

Milling machines typically have a vertical or horizontal orientation and a bed that holds the
workpiece. The cutting tool, called a milling cutter, is mounted on a spindle that can move in
different directions to perform the desired cuts. The spindle can also be adjusted for speed and
depth, allowing for different types of cuts to be made. There are different types of milling machines,
including manual milling machines, computer numerical control (CNC) milling machines, and 3D
milling machines. CNC milling machines are the most common type used in industrial
manufacturing, as they allow for precise and efficient production of complex parts with high
accuracy and consistency.[3]

Objectives:

1. To produce a workpart using a milling operation.

Procedure:

1. A piece of material was selected with the suitable dimension.

2. The material was set on the milling machine.

 3. The milling machine was operated and the milling operation was performed according to the
drawing dimension in Figure 1.1.

4. Guidance and supervision were provided by the laboratory technician.

5. The instructions given were followed properly when performing the milling process.

6. Quality of the part after milling was inspected and measurement on the sample was
performed.

7. The sample by your programme and tutorial and laboratory group number were labelled.

8. A picture of the completed samples was taken and the work sample was submitted.

Figure: 1.1 : MIlling machining

Apparatus:
 Figure 1.2 : File

Figure 1.3 : Milling machine

 Figure 1.4 : Bench vice

Figure 1.5 : Aluminium block

 Figure 1.6 : Paint brush

Figure 1.7 : Vernier calliper

Safety Equipment:

Figure 1.8 : Safety goggle

Workflow:

1. The dimension of the aluminium block was measured using a vernier calliper and recorded.
2. The extra part of the aluminium block was calculated to be cut off on the next process.
3. The aluminium block was clamped properly on the milling machine to undergo the milling
process by adjusting the vertical knee traverse crank before the process.
Figure 1.9 : Milling Process

4. After the milling process, the aluminium block was moved to the bench vice and the milling
machine was cleaned.

Figure 2.0 : Cleaning of Milling Machine

5. A filing process was carried out to remove the extra chips and to achieve a smooth surface
and edge.

Figure 2.1 : Filing Process

6. The vernier calliper was used again to measure the dimension of the aluminium block.
7. The process was repeated until the desired dimension was achieved.
8. Cut of 16mm length on both sides and 2.5mm depth were required and the width of the
protruding rectangle was 19mm on the 51 x 65 mm² surface of the aluminium block.

9. The cutter was adjusted downward to 2.5mm by rotating the vertical knee traverse crank as
shown in Figure 2.2. The handle was then turned to move the table to a suitable position.
 Figure 2.2 : Adjusting the vertical knee traverse crank.

10. The adjustment was stopped when the cutter slightly touched the block, this point was
considered as the starting point of the cutter.

Figure 2.3 : The cutter slightly touched the metal block.

11. Before the milling operation, the setting of x-axis and y axis of the monitor was ensured to
indicate 0.
12. The y-axis was set to -16.000, then – 35.995 to let the cutter move automatically by the
previous setting.

Figure 2.4 : The setting of the y-axis.

13. Then turning the table power feed to operate the milling machine and the desired dimension
was obtained.

Figure 2.5 : The milling process on one side of the metal block and the result.
14. After the filing process, the sample block was turned 180° vertically to begin the second
milling on the other side.
15. Then, two lines which are 15.5 cm were marked away, each edge of the surface having
length of 65 cm.
16. The aluminium block was then clamped properly on the milling machine and the milling
tool was moved to the side and slightly touched.
17. The axis of the machine was set to zero again and the y-axis was adjusted into 31.500.
18. The milling machine was operated to cut the block between the marking lines with a depth
of 2.5 mm.
19. The second cut was carried out by adjusting the y-axis by 4 which will be 35.500.
20. After the second cut, the aluminium block was moved to the bench vice to undergo the filing
process again to smoothen all surfaces and edges.
21. Finally, the dimensions of the aluminium block was measured using vernier calliper.

Results & Discussion:

Our group was given 2 aluminium blocks by the lab technician to perform the same process for
each block. Block A which was performed by Zi Kang, Qing Hwee and Sohalia had the dimension
of (67×51×51)mm³. Block B which was performed by Roshan and had the dimension of
(65×51×51)mm³. The cutter has a diameter of 16mm. The two blocks were filled to obtain a smooth
side. The file was ensured to be parallel to the surface so that a curved surface is not formed.

After the filing process, a milling process was performed for both the blocks simultaneously using
two milling machines. The initial length of both the blocks is 69mm. Block A was cut into 67mm
by setting 2mm of depth in the machine. Block B was cut into 65mm by setting 4mm in the
machine. Before the block is cut, we need to ensure that the cutter touches the part of the surface of
the block that is to be cut by using the power feed to adjust the position of the cutter. Two types of
milling process were T-slot end mill followed by face milling.
Face milling was carried out on the front of the surface whereby the desired dimension is to cut
16mm at each side on the surface which will result in obtaining a protruding rectangle in between
of the sides with the width of 19mm. Both blocks obtained a slightly different value whereby Block
A obtained sides of 15.7mm and 15.8mm instead of 16mm each. Block B obtained a value of
exactly 16mm at each side. The protruding part of Block A and Block B obtained the same width of
19mm.

The next milling process(T-slot end mill) was conducted to form a slot in between of the aluminium
block on the back of the surface. The desired dimension of the slot is 20mm. Considering the
diameter of the cutter(16mm), The blocks were milled 16mm for the first cut, followed by 4mm for
the second cut to satisfy the desired dimension of 20mm. Both blocks obtained a slightly different
value whereby Block A obtained a value of exactly 20mm and Block B obtained 19.5mm with
0.5mm different from the desired dimension. In this case, the position of the cutter was adjusted to
enable the cutting of dimension 4mm to be successful.

One main factor that resulted in the slight difference in the final dimensions is due to the inaccuracy
settings of the y-axis. Since the sensitivity of the machine is high, we faced difficulties in setting the
desired reading accurately.
Calculation for getting the slot:
1.Requirement in obtaining 16mm cut at both sides:
(Figure 2.8 shows the results of block A and block B )
𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑙𝑒𝑛𝑔𝑡ℎ − 2 × 16𝑚𝑚 = 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑙𝑒𝑛𝑔𝑡ℎ
𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑙𝑒𝑛𝑔𝑡ℎ = 𝑥 = 19𝑚𝑚
(x is the value of protruding part)
Cutting tool diameter: 16mm
Figure 3.0 and 3.1 show the starting point for the cutter and since the cutter is 16mm in diameter,
the first cut will proceed from left to right to obtain the first 16mm slots.
In order to obtain the second slot, the cutter should move forward :
16mm + x
16mm + 19mm
= 35mm # to start a second cut.

2. Requirement in having a 20mm slot:

(Figure 2.9 shows the results)
𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑙𝑒𝑛𝑔𝑡ℎ − 20 = 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑙𝑒𝑛𝑔th
𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑙𝑒𝑛𝑔𝑡ℎ ÷ 2 = 15. 5𝑚𝑚
𝑦 = 15. 5𝑚𝑚
(y is the value of the right and left side of the slot)
Cutting tool diameter: 16mm
To reach the starting point as shown in Figure 3.0 and 3.1 the cutter need to move
y + 16mm = 15. 5𝑚𝑚 + 16𝑚𝑚
= 31. 5𝑚𝑚 # to do the first cut.
Since the result is only 16mm and the requirement has not been fulfilled, therefore a 4mm is needed
for the cutting tool to move forward.
20𝑚𝑚 − 16𝑚𝑚 = 4𝑚𝑚#
Figure 2.6 : Initial length(69mm) of Block A and Block B

Figure 2.7: Width(51mm) of Block A and Block B

 (a) (b)
Figure 2.8 : Width of protruding part : (a) Block A is 19mm. (b)Block B is 19mm.

(a) (b)
Figure 2.9 : Width of slot: (a) Block A is 20mm. (b) Block B is 19.5mm.
Figure 3.0: Top view of back and front surface of Block A

Figure 3.1: Top view of back and front surface of Block B

Conclusion:
To conclude, milling comprises various sorts of processes depending on the design needed.
Calculation is essential before carrying out the milling process in order to obtain the exact
dimension needed. Our group performed two types of milling processes which are T-slot end mill
and face mill. Throughout the whole process, we learned many tips in handling the apparatus by the
lab technician which is not stated in the procedure itself. The two aluminium blocks had slight
differences in the dimension which was (67×51×51)mm³ for Block A and (65×51×51)mm³ for
Block B. The width of the slot of Block A and Block B are 20mm and 19.5mm respectively. The
width of the protruding part at the back surface along with the sides of Block A and Block B are
19mm,15.7mm,15.8mm and 19mm,16mm,16mm respectively.

References:

1. Er. Amrit Kumar.[online]Milling Machine: Definition, Parts, Operation, Working Principle,

Application, Advantages. Available at:
<https://themechanicalengineering.com/milling-machine/.>
[Accessed 6 MAR 2023].

2. Vishu Sharma.[online]Machine in Workshop. Available at:

<https://www.slideshare.net/VishuSharma13/common-machines-used-in-workshop.>
[Accessed 6 MAR 2023].

3. Mishra, P.[online]What is a Milling Machine? Available at:

<https://www.mechanicalbooster.com/2016/12/what-is-milling-machine-operation-parts-typ
es.html.>[Accessed 6 MAR 2023].