Introduction: Milling Machine

A milling machine is a machine tool used to machine solid materials. Milling machines are often classed in two basic forms, horizontal and vertical, which refers to the orientation of the main spindle. Both types range in size from small, bench-mounted devices to room-sized machines. Unlike a drill press, which holds the workpiece stationary as the drill moves axially to penetrate the material, milling machines also move the workpiece radially against the rotating milling cutter, which cuts on its sides as well as its tip. Workpiece and cutter movement are precisely controlled to less than 0.001 in (0.025 mm), usually by means of precision ground slides and leadscrews or analogous technology. Milling machines may be manually operated, mechanically automated, or digitally automated via computer numerical control (CNC). Milling machines can perform a vast number of operations, from simple (e.g., slot and keyway cutting, planing, drilling) to complex (e.g., contouring, diesinking). Cutting fluid is often pumped to the cutting site to cool and lubricate the cut and to wash away the resulting swarf.

Types of milling machine uses: VERTICAL MIL In vertical mil the spindle axis is vertically oriented. Milling cutters are held in the spindle and rotate on its axis. The spindle can generally be extended (or the table can be raised/lowered, giving the same effect), allowing plunge cuts and drilling. There are two subcategories of vertical mills: the bed mill and the turret mill.

A turret mill has a stationary spindle and the table is moved both perpendicular and parallel to the spindle axis to accomplish cutting. The most common example of this type is the Bridgeport, described below. Turret mills often have a quill which allows the milling cutter to be raised and lowered in a manner similar to a drill press. This type of machine provides two methods of cutting in the vertical (Z) direction: by raising or lowering the quill, and by moving the knee. In the bed mill, however, the table moves only perpendicular to the spindle's axis, while the spindle itself moves parallel to its own axis. Turret mills are generally considered by some to be more versatile of the two designs. However, turret mills are only practical as long as the machine remains relatively small. As machine size increases, moving the knee up and down requires considerable effort and it also becomes difficult to reach the quill feed handle (if equipped). Therefore, larger milling machines are usually of the bed type. Also of note is a lighter machine, called a mill-drill. It is quite popular with hobbyists, due to its small size and lower price. A mill-drill is similar to a small drill press but equipped with an X-Y table. These are frequently of lower quality than other types of machines.

Their functions: Column The column houses the spindle, the bearing, the gear box, the clutches the shafts the pumps and shifting mechanism for transmitting power from electric motor to the spindle at a selected speed Knee The knee mounted in front of the column is for supporting the table and provide an up or down motion along the z-axis Saddle Consist of two slide ways, one at the top and one at the bottom located 90 to each other , for providing motions in the X or Y axes by means of lead screws.

Table A mounted on top of the saddle and can be moved along the X axis . on top of the table are some T-slots for the mounting of workpiece or clamping fixtures

Arbor An extension of the spindle for mounting cutters. Usually, the thread end of an arbour is of left hand helix

Milling head Consisting the spindle, the motor, and the feed control unit is mounted on a swivel base such that it can be set at any angle to the table

Ram Which the milling head is attached can be positioned forward and backward along the slide way on the top of the column

The Milling Machine uses a rotating milling cutter to produce machined surfaces by progressively removing material from a work piece. The vertical milling machine also can function like a drill press because the spindle is perpendicular to the table and can be lowered into the work piece.

THE CONTROLS

START/STOP The green button starts the spindle motor and the red button shuts the motor off. Variable Motor Drive used on some Milling Machines

FORWARD/REVERSE This switch changes the rotation direction of the spindle. When the milling machine is in high range this switch is in the forward position for cutting but in low range the switch is in the reverse position. Putting the switch in the opposite position while remaining in the same range reverses the rotation of the spindle.

HAND BRAKE Also known as the spindle brake, it is used to bring the spindle rotation to a stop after the power is turned off and to aid in removing collets and chucks. The spindle can be locked by pressing or pulling the brake and then pushing it up.

SPINDLE SPEED This wheel is used to change the speed of the spindle for both high range and low range. The milling machine must be running when changing the speed.

POWER FEED The power feed uses a motor to control the motion of the longitudinal feed in either direction at various speeds. Not all of the milling machines in the shop have this option.

CROSS-FEED HANDWHEEL This hand-wheel moves the table in and out.

VERTICAL FEED HANDCRANK This is used to raise and lower the table.

LONGITUDINAL HANDWHEEL This hand-wheel moves the table left and right. On some machines the handles are spring activated to keep them from rotating when the power feed is used.

HIG-LOW SPEED CONTROL The high-low speed switch changes the range from high to low and vise-versa. The spindle may need to be turned by hand while engaging the gears.

QUILL FEED HANDLE You can raise and lower the quill (spindle) with this handle. QUILL LOCK Pushing this lever down will lock the quill, pulling it back up releases the lock. The quill must be locked when milling. QUILL STOP The quill stop can be adjusted by hand to set a limit on the quill travel is also used to disengage the quill feed. This is useful when multiple holes have to be drilled to the same depth.

QUILL FEED LEVER AND SELECTOR These are used to activate the power feed for the quill. The selector will adjust the speed of the power feed and the lever activates the drive. The quill can be Feed down into the part or up.

DIGITAL READOUT Digital readouts (DRO) are added to the milling machines to aid in the accuracy of cuts and increase productivity. The lateral movement of the table can be measured to 2/10,000th of an inch with the readouts. Other operations the readout can perform include dividing any dimension by two, running with absolute or relative measurements, and displaying in inches or millimeters.

LONGITUDINAL/CROSS-FEED AXIS The digital readout will display the distance traversed in both the X and Y-axis.

ZERO BUTTONS These two buttons will set their respective displays to zero. This is used after the machinist finds the edge of their part and wants to reference all of the other measurements off that axis. INCHES/METRIC BUTTON The readout can give all measurements in inches or millimeters, by pressing this button it will switch from one system of measurement to the other. KEYPAD Dimensions can be entered into the readout using the keypad. This can be helpful when a reference point is needed other than zero.

OBJECTIVE
The objectives of learning this modules is to help student to be able: i. ii. iii. Apply and practice workshop safety regulations during working in conventional milling workshop. Utilize the tools ,measurement tools and machine operation correct and accurately for conventional milling work according to a given task Describe the usage of conventional milling machine , various types of hand and cutting tools used for measurement , marking and metal removal.

Types of Milling Cutter

1. Solid cutter - A solid cutter has teeth integral with the cutter body.

2. Tipped solid cutter - A tipped solid cutter is similar to solid cutter, except that the cutter teeth are made of cemented carbide

3. Inserted teeth cutter - In large milling cutter the teeth or blades are inserted or secured in a body of less expensive materials. 4. Profile relieved cutter - In this type of milling cutter a relief to the cutting edge is provide by grinding a narrow land at the back of the cutting edges.

5. Form relieved cutter - In this type of cutter a curved relief is provided at the back of the cutting edges. 6. Arbor type cutter - The arbor type cutters are provided with a central hole having a keyway for a mounting them directly on the milling machine arbor.

PROCEDUCE 1.An aluminium block of 63mmX51mmX52mm is given to the students. 2.The block is clamped tightly at the machine vise. The block given has the very accurate angle of 90 o, thus the block can be used directly without cutting it into the 90o shape. 3.The faces of the block is alike uneven and the height and width is not same with the designed block, thus it is faced by using a face mill tool until the length of the block become 60mm. The same methods is used so the width and height of the block become 48mm respectively. 4.Some parts of the block need to be removed to cut it into the designed shape. 5.A vernier high scale is used to mark the parts need to be removed. 6.A end mill tools is used to cut the unwanted parts off. 7.The block is clamped on the machine vise. A steel bar is placed below the block to support it. To ensure the block is clamped tightly, the block is hit by a hammer when clamping the block. 8.The teeth of end mill is adjust above the marking line, then the block is being rose to the position the teeth just touch it . The reference point is being set at this position. 9.The machine is switchd on, the block is pushed backward and forward to cut with the end mill.

SAFETY PRECAUTION :

1. No attempt should be made to operate the mill until you understand the proper procedures for its use and have been checked out on it. 2. Dress appropriately. Remove all watches and jewelery. Safety glasses or goggles are a must. 3. Plan out your work thoroughly before starting. 4. Know were the location of the OFF switch is. 5. Be sure the work and holding device are firmly attached to the table. 6. Get help in moving any heavy attachments associated with the mill. 7. Stop the machine before making any adjustments or measurements. 8. Never reach over or near any rotating cutter. 9. Take care to prevent running the cutter into the vice or table. 10. Never leave a machine running unattended. 11. Stop the machine before removing chips, ( remember that chips can be very sharp). 12. Keep the floor around the machine clear of chips. Wipe up spilled cutting fluids immediately. 13. Use a piece of cloth for protection of the cutter and your hands when handling the milling cutters.

DISCUSSION :

1.

Explain several safety factors that should be consider before operating milling machine.

First, make sure emergency button working because when an accident occur , so the milling machine can stop immediately before the accident getting more worst. Second, check the machine for proper

lubrication levels because it can cause the milling machine working smoothly. Inspect all electrical connections and cords to ensure that no broken wires are visible that can caused short circuit. Secure all vises tightly to the table with only approved methods. Lastly, test run the motor and spindle speed to ensure the rotation and speed is correct.

2.

Explain briefly the types milling machine.

Theres 2 types milling machine :

Horizontal milling machines Vertical milling machines

3.

Explain generally the parameters involved in milling process.

Geometrical parameters in high speed cutting . Tool geometrical parameters had great influence on the cutting. The orthogonal finite element model was established. The model was used to simulate the influence of the geometrical parameters (rake angle, clearance angle, radius of tool tip) on the high speed cutting of aluminum alloy 7050T7451, and to investigate the influence of these parameters on the chip formation. In the same cutting condition, the cutting force experiment was carried out. A good agreement between cutting force of simulation and experiment was achieved. The results of simulation were proved to be correct. The study of geometrical parameters provided the base for the selection and optimization of tool in cutting of aluminum alloy 7050T7451 .

4. Describe the typical milling operations.

First, end milling is an end mill makes either peripheral or slot cuts, determined by the step-over distance, across the workpiece in order to machine a specified feature, such as a profile, slot, pocket, or even a complex surface contour. The depth of the feature may be machined in a single pass or may be reached by machining at a smaller axial depth of cut and making multiple passes. .

Second, face milling is a face mill machines a flat surface of the workpiece in order to provide a smooth finish. The depth of the face, typically very small, may be machined in single pass or may be reached by machining at a smaller axial depth of cut and making multiple passes.

Third, drilling is a drill enters the workpiece axially and cuts a hole with a diameter equal

to that of the tool. A drilling operation can produce a blind hole, which extends to some depth inside the workpiece, or a through hole, which extends completely through the workpiece.

5.

Describe the correct procedure to set the workpiece onto milling machine.

The vice jaws and the workpiece must be free from burrs, chips, and cutting fluid. Smaller workpiece should be supported by parallel bars to provide the supporting

datum.

Round bar must be placed between the workpiece and the movable jaw to ensure that the workpiece in perfect contact with the supporting base.

To machine the second and the third faces, the workpiece should be clamped with its preceeding machined surface facing against the fix jaw of the vice.

Similar clamping method can be applied in the machining of the fourth face.

Both ends of the workpiece can be machined with the periphery flutes of the cutter using up cut milling . 6.When cutting the block, an accident happened due to the block is not clamped tightly. Some scatch formed on the block. 7.The operation is processed successfully, and the block is similar to the designed shape and size.The difference between the block and the designed size is less than 0.3mm.

CONCLUSION :

In the end of milling project practical I have learn about type of milling machine that have their own functions and I also know the typical milling machines process. Each part of milling machine that I know can produce the exact product. Milling machine can make us more easier to expel the unwanted part. The skills that Ive learned from the technicians can I bring off for my careers as a mechanical engineering.

REFERENCES :

http://en.wikipedia.org/wiki/Milling_machine Penerbit UTHM, Milling machines . http://en.wikipedia.org/wiki/Milling_machine www.mfg.mtu.edu/marc/primers/milling/index.html

ENGINEERING WORKSHOP PRACTISE REPORT MILLING PROJECT REPORT

NAME : TAN CHEE CHEN

AA 110721

TG MOHD IMRAN BIN TG MUNAWIR AA 110754

SUBJECT CODE : DAM 10202 GROUP : 4 A