LAB 1

FAKULTI TEKNOLOGI DAN KEJURUTERAAN

MEKANIKAL
UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BMKF 1054 AUTOMOTIVE COMPONENT FABRICATION

LAB SHEET

MILLING OPERATIONS

PREPARED BY

AHMAD RUZAINI NAJMI BIN AZHAN B132410132

‘AMMAR SUFIYY BIN SHAFAWI B132410128
QHAIRUL DANIAL ISKANDAR BIN KHAIRUL AISYAM B132410649
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. 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.
EQUIPMENTS/ EXPERIMENT APPARATUS/ CONSUMABLE MATERIALS

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

PROCEDURES/ METHODOLOGY

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
machinesequipped with variable speed heads.

2) Removing Chips: Never remove chips with your hands. Use a brush to sweep chips from
thepart.
* 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.
 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
thecollet/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.

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.

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 sixth side just clamped the
workpiece and mill on the surface and control the dimension and tolerance according to the
drawing.

4
1 6

5 3

2
Figure 2.0: Six Side Cutting Approach

TASKS:
1) Refer Attached Technical Drawing in Appendix
2) Do a layout marking on workpiece surface and cuts using suitable milling
cutters by thex or y axis movement.
3) To perform drill operation, change the arbor from face mill/end mill to drill
chuck arbor and perform drill operation using center drill and drill tool.
Measure and record the dimension of your product as in Table 1 in 4.0 RESULTS
section.
 RESULTS

Picture of product

Product Detail

Table 1 : Measurement of product

Dimension (mm) ±0.5

Item Details Drawing Actual

1
50mm
2
35mm

3
5.9mm

4
3mm
5
7mm

Product Completed
DISCUSSION

For discussion, you should answer all questions as follows:

1) Why squaring is an important process?

→Squaring process is very important because it ensures that the workpiece has sides that are exactly 90
degrees to each other. In the other things basically, it makes sure everything is properly aligned. This will
include its Accuracy, fit and assembly, efficiency and tool life and machine health.

2) Discuss any findings or difficulties based on the laboratory activities.

→In conducting a laboratory session, there is a difficulty, which is making the cutting process on the upper part
near the hole of a project, which requires precision in order to make the cut neatly while avoiding any defects.

3) List FOUR(4) factors that may cause the quality of milling to change.

1. Tool Wear or Damage – A dull or damaged cutter can cause rough surfaces, inaccurate dimensions, and poor
finishes.

2. Machine Vibration – Any instability or chatter in the machine can leave wavy patterns and reduce precision.

3. Incorrect Feed Rate or Speed – If the feed or spindle speed isn’t right for the material, it can cause burning,
tearing, or poor surface finish.

4. Material Properties – Different materials (hardness, toughness) react differently to milling; tougher materials need
different tools and settings.
 4) List FOUR (4) components in cars that are manufactured using the milling process

Engine blocks – Milling shapes the cylinders and surfaces for precise fits.

Transmission housings – Complex shapes and tight tolerances are achieved with
milling.

Brake calipers – High-precision milling creates the slots and holes for brake pads and
pistons.

Suspension components (like control arms) – Milling ensures strong and accurate
parts for safety and performance.

CONCLUSION

Milling operations are essential in manufacturing because they allow for precise
shaping, cutting, and finishing of a wide range of materials. By using rotating cutters and
carefully controlled movements, milling produces parts with high accuracy and excellent
surface quality. Proper control of machine settings, tool condition, and material handling
is crucial to achieve the best results. Overall, milling is a versatile and fundamental
process in industries like automotive, aerospace, and general engineering.
REFERENCES

1. https://www.rapiddirect.com/blog/types-of-milling-operations/
2. https://testbook.com/mechanical-engineering/milling-operations
3. https://en.wikipedia.org/wiki/Milling_(machining)