Objectives:

i.

Methods of Lathe Machine and Milling Machine usage in manual

ii.

Analysis the components in the machines

iii.

The procedures of the machines usage

LATHE MACHINE
Purpose :

To rotate a part against a tool whose position it controls.

Useful for fabricating parts and/or features that have a circular cross section. The
spindle is the part of the lathe that rotates.

Workholding attachments :

Chucks, collets, and face plate can be held in the spindle.

The spindle is driven by an electric motor through a system of belt drives and/or gear
trains.

Spindle speed is controlled by varying the geometry of the drive train.

Tailstock :

Can be used to support the end of the workpiece with a center, or

to hold tools for drilling, reaming, threading, or cutting tapers.

It can be adjusted in position along the ways to accommodate different length

workpieces.

PARTS OF LATHE MACHINE

Bed : - Supports all major components of the lathe.

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Carriage: - Slides along the ways and consists of an assembly of the cross-slide, tool
post and apron.

Tool post: where cutting tools mounted

Cross-slide: moves radially in and out, controlling the radial position of the cutting
tool

Apron: equipped with mechanisms for both manual & mechanized movement of the
carriage and the cross-slide by means of the lead screw

Headstock: - Fixed to the bed and is equipped with motors, pulleys and V-belts that
supply power to spindle at various rotational speeds.

Tailstock : - Can slide along the ways and be clamped at any position, supports the
other end of workpiece.

Tail center: - To hold the end of long pieces of workpiece.

Feed rod & lead screw: - The feed rod is powered by a set of gears through the
headstock. It rotates during the lathe operation and provide movement to the carriage
and the cross-slide. Closing a half nut lever around the lead screw engages it with the
carriage.

Chuck: - To hold the workpiece.

WORKHOLDING DEVICES

Workholding device is important, particularly in machine tools and machining

operations

Must hold workpiece securely

One end of the workpiece is clamped to the spindle by the workholding device
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Types of workholding devices : Chuck, Collet, Face plate , Steady Rest, Follow Rest

1. Universal Chuck - 3 Jaw Chuck

Use to hold a work piece which are cylinder or hexagon. For facing or center drilling the
end of the work piece.

Shows 3 positions 3 jaw chuck hold a work piece.

Be careful when use position (a) and (c) because the work piece can easily slip when
machining at high feed rate and high depth of cut.

2.Independent chuck (4 jaw chuck)

Can hold work piece more precise rather than 3 jaw chuck.

Shows 3 positions 4 jaw chuck hold a work piece.

3.Collet chuck
Use to hold and machined small components

Generally for workpiece with a maximum diameter of 25mm

Collet chuck

4. Steady rest

Used to support a long workpiece which is 3 times its diameter.

To prevent workpiece from bending

5. Follow rest

Suitable for small and long workpiece during parallel lathe machining

To minimize flex under the pressure of the cutting tools

6. Face Plate

Used for clamping irregularly shaped workpieces.

The plates are round and have several slots and holes through which the workpiece is
clamped.

TOOL BITS
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A piece of high-strength metal, usually steel, ground to make single-point cutting

tools for metal-cutting operations.

In lathe, it refers to a non-rotary cutting tool and also often referred to by the setphrase name of single-point cutting tool. The cutting edge is ground to suit a
particular machining operation and may be sharpened or reshaped as needed. The
ground tool bit is held rigidly by a tool holder while it is cutting.

Cutting tools must be made of a material harder than the material which is to be
cut, and the tool must be able to withstand the heat generated in the metal-cutting
process.

Standard And Various Shapes Of Tool Bit

Facing tools are ground to provide clearance with a center.

Roughing tools have a small side relief angle to leave more material to support the
cutting edge during deep cuts.

Finishing tools have a more rounded nose to provide a finer finish.

Round nose tools are for lighter turning. They have no back or side rake to permit
cutting in either direction.

Left hand cutting tools are designed to cut best when traveling from left to right.

Various
angle in
a cutting tool have important functions in machining operation:
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1. Rake angle: Control direction of chip flow and the strength of the tool tip.
2. Side rake angle: Control direction of chip flow. Angle typically about 5.
3. Cutting-edge angle: Affects chip formation, tool strength, and cutting force to various
degree. Angle typically about 15.
4. Relief angle: Control interference and rubbing at the tool-work piece interface.
If it too large, the tool tip may chip off, if it too small, flank wear may be excessive.
Relief angle typically are 5.
5. Nose radius: Affects surface finish and tool tip strength.
The smaller the nose radius(sharp tool), the rougher the surface finish of the work piece and
the lower the strength of the tool. How ever, long nose radius can lead to tool chatter.

TOOL BIT MATERIALS

1. Carbon steel

Contain 0.9%-1.2% of carbon

The oldest of tool material and widely use.

Advantages: Cheap and easily shape and sharpened.

Disadvantage: Do not have sufficient hot hardness and wear resistance for cutting at high
speed when the temperature rises.

2. High-speed steel (HSS)

Contain: Tungsten, chromium, cobalt, molybdenum.

Use to machine at higher speed, and complex such as drilling.

Advantage: High toughness, resistance to fracture.

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Disadvantage: Low hot hardness.

3. Stellite

Contain 25%-35% chromium, 4%-25% Tungsten, 1%-3% carbon and the rest is cobalt.

Use for roughing cuts at high feed and speed-twice the rates possible with HSS

Advantage: high hardness, good wear resistance

Disadvantage: not as tough as HSS and sensitive to impact forces.

4. Ceramic

Consist of aluminium oxide.

Moderately inexpensive

Advantage: High hardness, high wear resistance, extremely resistant to heat, desirable in
high speed applications.

Do not need coolant during machining.

Disadvantage: High fragility. Ceramics are considered unpredictable under unfavorable

conditions. The most common ceramic materials are based on alumina (aluminium
oxide), silicon nitride and silicon carbide. Used almost exclusively on turning tool bits.
Hardness up to about HRC 93. Sharp cutting edges and positive rake angles are to be
avoided.

5. Carbide

2 major group of carbide (Tungsten Carbide and Titanium Carbide)

Consist of 82% Carbide, 10% titanium and tungsten and 8% cobalt.

Advantage: Very hard and can stand with high temperature

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Disadvantage: Low wear resistance

Triple the rates possible with HSS (in term of cutting speed during machining)

6. Diamond

Use for surface finish

High accuracy machining(0.002-0.005 mm)

Disadvantage: easy fracture low impact resistance.

LATHE MACHINE OPERATION

Turning: To produce straight, conical, curve or groove work piece.

Boring: To enlarge a hole or cylindrical cavity made by previous process or to

produce circular internal grooves.

Facing: To produce flat surface at the end of the part and perpendicular to its axis.
Drilling: To produce a hole which may be followed by boring to improve its
dimensional accuracy and surface finish.

Knurling: To produce a regularly shaped roughness on cylindrical surface(making

knobs)

Tread cutting: To produce external/internal threads.

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Off-centre turning: To produce various axis symmetric shapes for functional or

aesthetic purpose.

SAFE OPERATION PRACTICES

To prevent risk of injury or even death, the following are some basic safety guidelines.
They apply to lathes for both wood and metal, unless otherwise specified.
When working on the lathe, always stand straight; never lean on the lathe or reach over
the chuck when it is in operation.
The area directly in front of and behind the workpiece is called the "red zone," because
it is at greatest risk for projectile pieces. When turning the lathe on, try to avoid
standing in the red zone, while keeping contact with the power switch in case the
machine needs to be turned off.
If the workpiece vibrates, this is an indication that the speed is too fast. Reduce the
speed until the workpiece rotates steadily, without vibration.
Threaded spindle noses should be used with caution, since rotating in the reverse
direction can cause the chuck or driver plate to unscrew and detach.
If working with wood, beginners should avoid material that has splits, knots, or heavy
bark.
Before sanding or polishing, remove the tool rest.
Metal chips can be razor-sharp and should not be removed with hands. Instead, use
pliers for long chips and a brush or vacuum for short chips. Compressed air should not
be used to remove chips from the lathe, since it can blow the chips back into the users
face.
The lathe motor should always be turned off before adjusting the tool rest or any other
parts, or before cleaning, lubricating, or measuring. Likewise, turn off the power and
wait until the lathe comes to a full stop when mounting or removing accessories.
Never leave a running lathe unattended. Power it off and wait until it has come to a full
stop before leaving the work area.
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Users should avoid operating the lathe when tired or under the influence of alcohol or
drugs. Alertness is vital for safe lathe operation.
Special Considerations for Metalworking Lathes: Filing
Filing requires special attention, since the user needs to reach over the rotating
workpiece. It is recommended that the file be gripped in the left hand, which is closest
to the head stock. With the right hand, balance and guide the file.

A SAFE WORK ENVIRONMENT

The working environment is also a factor in safe lathe operation.
The floor should be free from grease, oil, shavings, and clutter, which can cause
someone to slip or trip. There should be proper air ventilation and plenty of light.
Keeping the lathe and its accessories in good shape is an important safety procedure.
Check regularly for any damaged parts, misalignment, and wear on moving parts.
Sharpen tools regularly, and avoid working with dull or makeshift tools.

CONCLUSION
Lathes have been in use for millenia, used in the crafting of metal, wood, and other solid
materials. They brace the working material lengthwise and rotate it at high speeds,
allowing the user to perform various operations on it. Because of the nature of the
machine, the lathe can present several serious risks. Anyone using a lathe is strongly
advised to exercise caution, and first-time users should be particularly fastidious about
safety. Before getting started, it is essential that users have a complete understanding of
the machine and its tools, as well as its safe operation. There are basic steps to take prior
to turning on the machine, such as ensuring all components are securely in position and
that there are no loose parts that may fly off when the gears start moving. Protective gear
is necessary to safeguard against dangerous debris, while certain clothing and items
should not be worn as they may get caught in the machinery. There are a number of
guidelines for operating the lathe safely; they should be reviewed in detail before
beginning. Finally, maintaining a safe work environment helps reduce the risk of
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accidents. By carefully reading a lathes owner manual and following advice from
experienced professionals, first-time lathe users can safely enjoy the fruits of
craftsmanship.

MILLING MACHINES
Milling is the process of machining flat, curved, or irregular surfaces by feeding the
workpiece against a rotating cutter containing a number of cutting edges. The usual Mill
consists basically of a motor driven spindle, which mounts and revolves the milling cutter,
and a reciprocating adjustable worktable, which mounts and feeds the workpiece.
Milling machines are basically classified as vertical or horizontal. These machines are also
classified as knee-type, ram-type, manufacturing or bed type, and planer-type. Most milling
machines have self-contained electric drive motors, coolant systems, variable spindle speeds,
and power-operated table feeds

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Diagram of typical "Bridgeport style" milling machine head

TYPES OF MILLING MACHINES
KNEE-TYPE
Knee-type mills are characterized by a vertically adjustable worktable resting on a saddle
which is supported by a knee. The knee is a massive casting that rides vertically on the
milling machine column and can be clamped rigidly to the column in a position where the
milling head and milling machine spindle are properly adjusted vertically for operation.
The plain vertical machines are characterized by a spindle located vertically, parallel to the
column face, and mounted in a sliding head that can be fed up and down by hand or power.
Modern vertical milling machines are designed so the entire head can also swivel to permit
working on angular surfaces.
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The turret and swivel head assembly is designed for making precision cuts and can be swung
360 on its base. Angular cuts to the horizontal plane may be made with precision by setting
the head at any required angle within a 180 arc.
The plain horizontal milling machine's column contains the drive motor and gearing and a
fixed position horizontal milling machine spindle. An adjustable overhead arm containing one
or more arbor supports projects forward from the top of the column. The arm and arbor
supports are used to stabilize long arbors. Supports can be moved along the overhead arm to
support the arbor where support is desired depending on the position of the milling cutter or
cutters.
The milling machine's knee rides up or down the column on a rigid track. A heavy, vertical
positioning screw beneath past the milling cutter. The milling machine is excellent for
forming flat surfaces, cutting dovetails and keyways, forming and fluting milling cutters and
reamers, cutting gears, and so forth. Many special operations can be performed with the
attachments available for milling machine use. the knee is used for raising and lowering. The
saddle rests upon the knee and supports the worktable. The saddle moves in and out on a
dovetail to control cross feed of the worktable. The worktable traverses to the right or left
upon the saddle for feeding the workpiece past the milling cutter. The table may be manually
controlled or power fed.

UNIVERSAL HORIZONTAL MILLING MACHINE

The basic difference between a universal horizontal milling machine and a plain horizontal
milling machine is the addition of a table swivel housing between the table and the saddle of
the universal machine. This permits the table to swing up to 45 in either direction for angular
and helical milling operations. The universal machine can be fitted with various attachments
such as the indexing fixture, rotary table, slotting and rack cutting attachments, and various
special fixtures.
RAM-TYPE MILLING MACHINE
The ram-type milling machine is characterized by a spindle mounted to a movable housing on
the column to permit positioning the milling cutter forward or rearward in a horizontal plane.
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Two popular ram-type milling machines are the universal milling machine and the swivel
cutter head ram-type milling machine.
UNIVERSAL RAM-TYPE MILLING MACHINE
The universal ram-type milling machine is similar to the universal horizontal milling
machine, the difference being, as its name implies, the spindle is mounted on a ram or
movable housing.
SWIVEL CUTTER HEAD RAM-TYPE MILLING MACHINE
The cutter head containing the milling machine spindle is attached to the ram. The cutter head
can be swiveled from a vertical spindle position to a horizontal spindle position or can be
fixed at any desired angular position between vertical and horizontal. The saddle and knee are
hand driven for vertical and cross feed adjustment while the worktable can be either hand or
power driven at the operator's choice.

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Basic milling machine configurations are shown in figure 1.

There are several types of milling machines. One is called a vertical milling machine as
shown in Figure 1. It has high flexibility and good handling, though it has lower processing
speed than another type of the milling machines.
In the milling macine, a rotating tool cuts a material. As the cutting tool, a drill or an endmill
is used. The table of the milling machine can be adjusted accurately at the x- (side direction),
y- (vertical direction) and z- (height direction) axises with operating handles as shown inthe
above figure.

GENERAL MILLING OPERATION

Setup
The success of any milling operation depends, Before setting up a job, be sure that the to a
great extent, upon judgment in setting up the job, workpiece, the table, the taper in the
spindle, selecting the proper milling cutter, and holding the cutter by the best means under the
circumstances Some fundamental practices have been proved by experience to be necessary
for and the arbor or cutter shank are all clean and good results on all jobs. Some of these
practices are mentioned below...

Before setting up a job, be sure that the workpiece, table, the taper in the spindle, and
the arbor or cutter shank are free from chips, nicks, or burrs.

Do not select a milling cutter of larger diameter than is necessary.

Check the machine to see if it is in good running order and properly lubricated, and
that it moves freely, but not too freely in all directions.

Consider direction of rotation. Many cutters can be reversed on the arbor, so be sure
you know whether the spindle is to rotate clockwise or counterclockwise.

Feed the workpiece in a direction opposite the rotation of the milling cutter
(conventional milling).
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Do not change feeds or speeds while the milling machine is in operation.

When using clamps to secure a workpiece, be sure that they are tight and that the
piece is held so it will not spring or vibrate under cut.

Use a recommended cutting oil liberally.

Use good judgment and common sense in planning every job, and profit from
previous mistakes.

Set up every job as close to the milling machine spindle as circumstances will permit.

MILLING OPERATIONS
Milling operations may be classified under four general headings as follows:

Face milling. Machining flat surfaces which are at right angles to the axis of the
cutter.

Plain or slab milling. Machining flat surfaces which are parallel to the axis of the
cutter.

Angular milling. Machining flat surfaces which are at an inclination to the axis of the
cutter.

Form milling. Machining surfaces having an irregular outline.

SPECIAL OPERATIONS
Explanatory names, such as sawing, slotting, gear cutting, and so forth have been given to
special operations. Routing is a term applied to milling an irregular outline while controlling
the workpiece movement by hand feed. Grooving reamers and taps is called fluting. Gang
milling is the term applied to an operation in which two or more milling cutters are used
together on one arbor. Straddle milling is the term given to an operation in which two milling
cutters are used to straddle the workpiece and mill both sides at the same time.
TOOLS AND EQUIPMENT: MILLING CUTTERS
Classification of Milling Cutters
Milling cutters are usually made of high-speed steel and are available in a great variety of
shapes and sizes for various purposes. You should know the names of the most common
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classifications of cutters, their uses, and, in a general way, the sizes best suited to the work at
hand.
Milling Cutter Nomenclature
The figure shows two views of a common milling cutter with its parts and angles identified.
These parts and angles in some form are common to all cutter types.

The pitch refers to the angular distance between like or adjacent teeth.

The pitch is determined by the number of teeth. The tooth face is the forward facing
surface of the tooth that forms the cutting edge.

The cutting edge is the angle on each tooth that performs the cutting.

The land is the narrow surface behind the cutting edge on each tooth.

The rake angle is the angle formed between the face of the tooth and the centerline of
the cutter. The rake angle defines the cutting edge and provides a path for chips that
are cut from the workpiece.

The primary clearance angle is the angle of the land of each tooth measured from a
line tangent to the centerline of the cutter at the cutting edge. This angle prevents each
tooth from rubbing against the workpiece after it makes its cut.

This angle defines the land of each tooth and provides additional clearance for
passage of cutting oil and chips.

The hole diameter determines the size of the arbor necessary to mount the milling
cutter.

Plain milling cutters that are more than 3/4 inch in width are usually made with spiral
or helical teeth. A plain spiral-tooth milling cutter produces a better and smoother
finish and requires less power to operate. A plain helical-tooth milling cutter is
especially desirable when milling an uneven surface or one with holes in it.

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Types of Teeth
The teeth of milling cutters may be made for right-hand or left-hand rotation, and with either
right-hand or left-hand helix. Determine the hand of the cutter by looking at the face of the
cutter when mounted on the spindle. A right-hand cutter must rotate counterclockwise; a lefthand cutter must rotate clockwise. The right-hand helix is shown by the flutes leading to the
right; a left-hand helix is shown by the flutes leading to the left. The direction of the helix
does not affect the cutting ability of the cutter, but take care to see that the direction of
rotation is correct for the hand of the cutter.

LEFT AND RIGHT CUTTER

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Saw Teeth
Saw teeth similar to those shown in Figure 8-3 (above) are either straight or helical in the
smaller sizes of plain milling cutters, metal slitting saw milling cutters, and end milling
cutters. The cutting edge is usually given about 5 degrees primary clearance. Sometimes the
teeth are provided with off-set nicks which break up chips and make coarser feeds possible.
Helical Milling Cutters
The helical milling cutter is similar, to the plain milling cutter, but the teeth have a helix angle
of 45 to 60. The steep helix produces a shearing action that results in smooth, vibration-free
cuts. They are available for arbor mounting, or with an integral shank with or without a pilot.
This type of helical cutter is particularly useful for milling elongated slots and for light cuts
on soft metal.

PLAIN AND HELICAL MILLING CUTTER

Metal Slitting Saw Milling Cutter
The metal slitting saw milling cutter is essentially a very thin plain milling cutter. It is ground
slightly thinner toward the center to provide side clearance. These cutters are used for cutoff
operations and for milling deep, narrow slots, and are made in widths from 1/32 to 3/16 inch.
Side Milling Cutters
Side milling cutters are essentially plain milling cutters with the addition of teeth on one or
both sides. A plain side milling cutter has teeth on both sides and on the periphery. When
teeth are added to one side only, the cutter is called a half-side milling cutter and is identified
22

as being either a right-hand or left-hand cutter. Side milling cutters are generally used for
slotting and straddle milling.
Interlocking tooth side milling cutters and staggered tooth side milling cutters are used for
cutting relatively wide slots with accuracy. Interlocking tooth side milling cutters can be
repeatedly sharpened without changing the width of the slot they will machine.

VARIOUS MILLING CUTTER

After sharpening, a washer is placed between the two cutters to compensate for the ground
off metal. The staggered tooth cutter is the most washer is placed between the two cutters to
compensate for efficient type for milling slots where the depth exceeds the width.
End Milling Cutters
The end milling cutter, also called an end mill, has teeth on the end as well as the periphery.
The smaller end milling cutters have shanks for chuck mounting or direct spindle mounting.
End milling cutters may have straight or spiral flutes. Spiral flute end milling cutters are
classified as left-hand or right-hand cutters depending on the direction of rotation of the
flutes. If they are small cutters, they may have either a straight or tapered shank.
The most common end milling cutter is the spiral flute cutter containing four flutes. Two-flute
end milling cutters, sometimes referred to as two-lip end mill cutters, are used for milling
slots and keyways where no drilled hole is provided for starting the cut. These cutters drill
their own starting holes. Straight flute end milling cutters are generally used for milling both
soft or tough materials, while spiral flute cutters are used mostly for cutting steel.
Large end milling cutters (normally over 2 inches in diameter) (Figure 8-10) are called shell
end mills and are recessed on the face to receive a screw or nut for mounting on a separate
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shank or mounting on an arbor, like plain milling cutters. The teeth are usually helical and the
cutter is used particularly for face milling operations requiring the facing of two surfaces at
right angles to each other.
SPEEDS FOR MILLING CUTTERS
The speed of milling is the distance in FPM at which the circumference of the cutter passes
over the work. The spindle RPM necessary to give a desired peripheral speed depends on the
size of the milling cutter. The best speed is determined by the kind of material being cut and
the size and type of cutter used, width and depth of cut, finish required, type of cutting fluid
and method of application, and power and speed available are factors relating to cutter speed.
FACTORS GOVERNING SPEED
There are no hard and fast rules governing the speed of milling cutters; experience has shown
that the following factors must be considered in regulating speed:

A metal slitting saw milling cutter can be rotated faster than a plain milling cutter
having a broad face.

Cutters having undercut teeth (positive rake) cut more freely than those having radial
teeth (without rake); hence, they may run at higher speeds.

Angle cutters must be run at slower speeds than plain or side cutters.

Cutters with inserted teeth generally will stand as much speed as a solid cutter.

A sharp cutter may be operated at greater speeds than a dull one.

A plentiful supply of cutting oil will permit the cutter to run at higher speeds than
without cutting oil.

SELECTING PROPER CUTTING SPEEDS

The approximate values given in Table 8-1 in Appendix A may be used as a guide for
selecting the proper cutting speed. If the operator finds that the machine, the milling cutter, or
the workpiece cannot be handled suitably at these speeds, immediate readjustments should be
made.

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Table 8-1 lists speeds for high-speed steel milling cutters. If carbon steel cutters are used, the
speed should be about one-half the recommended speed in the table. If carbide-tipped cutters
are used, the speed can be doubled.
If a plentiful supply of cutting oil is applied to the milling cutter and the workpiece, speeds
can be increased 50 to 100 percent. For roughing cuts, a moderate speed and coarse feed
often give best results; for finishing cuts, the best practice is to reverse these conditions, using
a higher speed and lighter feed.
SPEED COMPUTATION
The formula for calculating spindle speed in revolutions per minute is as follows:

Where RPM = Spindle speed (in revolutions per minute).

CS = cutting speed of milling cutter (in SFPM)
D = diameter of milling cutter (in inches)
For example, the spindle speed for machining a piece of steel at a speed of 35 SFPM with a
cutter 2 inches in diameter is calculated as follows:

Therefore, the milling machine spindle would be set for as near 70 RPM as possible.
Table 8-2 in Appendix A is provided to facilitate spindle speed computations for standard
cutting speeds and standard milling cutters.
FEEDS FOR MILLING
The rate of feed, or the speed at which the workpiece passes the cutter, determines the time
required for cutting a job. In selecting the feed. there are several factors which should be
considered.
Forces are exerted against the workpiece, the cutter, and their holding devices during the
cutting process. The force exerted varies directly with the amount of feed and depth of cut,
25

and in turn are dependent upon the rigidity and power of the machine. Milling machines are
limited by the power they can develop to turn the cutter and the amount of vibration they can
resist when using coarse feeds and deep cuts. The feed and depth of the cut also depend upon
the type of milling cutter being used. For example, deep cuts or coarse feeds should not be
attempted when using a small diameter end milling cutter. Coarse cutters with strong cutting
teeth can be fed at a faster rate because the chips may be washed out more easily by the
cutting oil.
Coarse feeds and deep cuts should not be used on a frail workpiece if the piece is mounted in
such a way that its holding device is not able to prevent springing or bending.
Experience and judgment are extremely valuable in selecting the correct milling feeds. Even
though suggested rate tables are given. remember that these are suggestions only. Feeds are
governed by many variable factors, such as the degree of finish required. Using a coarse feed,
the metal is removed more rapidly but the appearance and accuracy of the surface produced
may not reach the standard desired for the finished product. Because of this fact, finer feeds
and increased speeds are used for finer, more accurate finishes, while for roughing, to use a
comparatively low speed and heavy feed. More mistakes are made on overspeeding and
underfeeding than on underspeeding and overfeeding.
Overspeeding may be detected by the occurrence of a squeaking, scraping sound. If vibration
(referred to as chattering) occurs in the milling machine during the cutting process, the speed
should be reduced and the feed increased. Too much cutter clearance, a poorly supported
workpiece, or a badly worn machine gear are common causes of chattering.
Direction of Feed
It is usually regarded as standard practice to feed the workpicce against the milling cutter.
When the workpiece is fed against the milling cutter, the teeth cut under any scale on the
workpiece surface and any backlash in the feed screw is taken up by the force of the cut.

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Direction of feed
As an exception to this recommendation, it is advisable to feed with the milling cutter when
cutting off stock or when milling comparatively deep or long slots.
The direction of cutter rotation is related to the manner in which the workpiece is held. The
cutter should rotate so that the piece springs away from the cutter; then there will be no
tendency for the force of the cut to loosen the piece. No milling cutter should ever be rotated
backward; this will break the teeth. If it is necessary to stop the machine during a finishing
cut, the power feed should never be thrown out, nor should the workpiece be fed back under
the cutter unless the cutter is stopped or the workpiece lowered. Never change feeds while the
cutter is rotating.

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Fig.2, Handles of a Milling Machine

Fig.1, Milling Machine

ACCESSORIES OF MILLING MACHINE

There are several accessories for the milling process except the cutting tools. Following
accessoriess are very useful.
Vise
A vise is used for fixing of the material, and it
is fixed to the table of the milling machine
firmly. In the case of the cutting of a largesized material, the vise can be remived from
the table. But when the vise is installed again,
it has to be fix accurately in the x-axis. We
should not remove the vise except unavoidable
cases.

Fig.3, Vise

Digital Scale
The table of the milling machine can be
adjusted accurately at the x-, y- and z- axises.
We can adjust the positions with seeing the
scales on the operating handles. Moreover, if a
digital scales as shown in Figure 4 is set, it is
efficient that we operate with seeing the values
of the digital scale. The digital scale indicates Fig.4, Digital Scale
with the minimum unit of 5/1000 mm of x28

and y- axises.
Point Master
In order to get a high accurate processing, the
zero point must be adjusted exactly. A point
master as shown in Figure 5 is the convenient
tool for the adjustment. LEDs of the point
master light when the point touches a metal
material including the vise. We can find the
zero point easily with this tool.

Fig.5, Point Master

MECHANICAL PARTS MADE BY A MILLING MACHINE

The parts of various form can be made from using the milling machine. Mechanical parts
made by the milling machine are introduced in followings.

Fig.6, A Part of a Fish Robot

Fig.7, Backbone of a Fish Robot

This is the part used for the power unit of a

Some parts manufactured using the milling

fish robot, UPF-2001. Its complicated form

machine are put together. Almost all parts

is made using an endmill.

are the simple form near a rectangular

parallelepiped.

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(a) Connecting Rods

(b) A Drive Mechanism of a Stirling Engine

Fig.8, Connecting Rods of a Stirling Engine

These are connecting rods of a 50 W Class Stirling engine, Mini-Ecoboy. Since the thickness
of parts is quite thin, the fixation to the table is difficult, and it is hard to manufacture. And
since it was the parts which need remarkable accuracy, we had to be careful in the processing.

SAFETY RULES FOR MILLING MACHINES

Milling machines require special safety precautions while being used. These are in addition to
those safety precautions as described.

Do not make contact with the revolving cutter.

Place a wooden pad or suitable cover over the table surface to protect it from possible
damage.

Use the buddy system when moving heavy attachments.

Do not attempt to tighten arbor nuts using machine power.

When installing or removing milling cutters, always hold them with a rag to prevent
cutting your hands.

While setting up work, install the cutter last to avoid being cut.

Never adjust the workpiece or work mounting devices when the machine is operating.

Chips should be removed from the workpiece with an appropriate rake and a brush.

NOTE Chip rake should be fabricated to the size of the T-slots.

Shut the machine off before making any adjustments or measurements.

30

When using cutting oil, prevent splashing by using appropriate splash guards. Cutting
oil on the floor can cause a slippery condition that could result in operator injury

Figure: Chip Rake

CONCLUSION
Milling cutters play an important role in performing milling machine operations. We can
know which cutter to select and use for a specific operation or determine the overall
quality of the final product. The knowledge gained in this task during the workshop
practice will assist us in determining the type of cutter(s) to employ for a specific operation,
to include the nomenclature, selection, use and care of milling cutters when tasked to perform
milling machine operations. All extra precautions measures should be taken before and while
conducting the milling machines.

31

REFERENCES
1. http://www.powershow.com/view/13f25bNTMyZ/MILLING_powerpoint_ppt_presentati
on/ accessed on 6 March 2015.
2. https://www.google.com.my/search?
q=milling+machine+parts+and+functions+ppt&espv=2&biw=1440&bih=785&tbm=isch
&tbo=u&source=univ&sa=X&ei=5LkMVdHYFI2jugT00YCwDQ&ved=0CC4QsAQ&d
pr=1 accessed on 6 March 2015.
3. http://www.ebay.com/gds/Important-Safety-Tips-for-First-Time-LatheUsers-/10000000177630397/g.html accessed on 6 March 2015.
4. http://www.slideshare.net/muhammadabidibrahim/report-for-milling-project accessed on
6 March 2015.
5. http://armyordnance.tpub.com/od16448/od164480075.htm accessed on 6 March 2015.

32

APPENDICES
Tool life
As a general rule the relationship between the tool life and cutting speed is
VTn = C
where;
V = cutting speed in m/min
T = tool life in min
C = a constant
For high-speed steel tools the value of C ranges from 0.14 to 0.1 and for carbide tools the
value would be 0.2.
Characteristics of Tool Material
For efficient cutting a tool must have the following properties:
Hot Hardness
This means the ability to retain its hardness at high temperatures. All cutting operations
generate heat, which will affect the tools hardness and eventually its ability to cut.
Strength and Resistance to Shock
At the start of a cut the first bite of the tool into the work results in considerable shock
loading on the tool. It must obviously be strong enough to withstand it.
Low Coefficient of Friction
The tool rubbing against the workpiece and the chip rubbing on the top face of the tool
produce heat which must be kept to a minimum.
Rake Angle
Rake angle is the angle between the top face of the tool and the normal to the work surface at
the cutting edge. In general, the larger the rake angle, the smaller the cutting force on the tool.
A large rake angle will improve cutting action, but would lead to early tool failure, since the
tool wedge angle is relatively weak. A compromise must therefore be made between adequate
strength and good cutting action.
Metal Being Cut

Cast Iron

Hard Steel /
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Medium

Mild Steel

Aluminium

Top Rake Angle

Brass

Carbon
Steel

14

Typical value for top rake angle

34

20

40