Assignment 1

BFF 1811
MACHINING 2

Lecturer : Mr. Shahanzair Bahrom

NAME
Mohamad Radzi B. Mohd Sojak

MATRIX NO.
FB14009

Introduction
What is Milling Machine, Milling machines are tools designed to machine metal,
wood, and other solid materials. Often automated, milling machines can be positioned in
either vertical or horizontal orientation to carve out materials based on a pre-existing
design. These designs are often CAD directed, and many milling machines are CNC-operated
(computer numerical control),

Although manually and traditionally-automated milling devices are also common. Milling
machines are capable of dynamic movement; both of the tool and the work piece, and many
milling machines can perform multi-axis machining. Because of variations in orientation,
operation and application, milling machines have varying functions and different operating
principles.
We will focus about milling machine base on these 6 topics:a) Safety
b) Types of milling machines and its components function
c) Processes perform or operation by milling machines
d) Cutting Tools for milling operation
e) Clamping technique
Work piece clamping
f) Type and method of cutting fluid use in milling processes
g) Relation of the parameter e.g cutting speed, feed rate and depth of cut

SAFETY

List of standard procedure before operate or using the milling machines

PRE-OPERATIONAL SAFETY CHECKS
1. Ensure no slip/trip hazards are present in workspaces and walkways.
2. Locate and ensure you are familiar with the operation of the ON/OFF starter and E-Stop
(if fitted).
3. Do not leave equipment on top of the machine.
4. Check that machine guards are in position.
5. Ensure cutter is in good condition and securely mounted.
6. Check coolant delivery system to allow for sufficient flow of coolant.
7. Faulty equipment must not be used, immediately report suspect machinery.
OPERATIONAL SAFETY CHECKS
1. Keep clear of moving machine parts.
2. Never leave the machine running unattended.
3. Follow correct clamping procedures- keep overhangs as small as possible and check work
piece is secure.
4. Set the correct speed to suit the cutter diameter, the depth of cut and the material.
5. Before making adjustments and measurements or before cleaning swarf accumulations
switch off and bring the machine to a complete standstill.

HOUSEKEEPING
1. Switch off the machine.
2. Remove milling cutters and store them safely.
3. Leave the machine and work area in a safe, clean and tidy state.

POTENTIAL HAZARDS

Sharp cutters
Moving components - hair/clothing entanglement
Eye injury
Skin irritation
Metal splinters and burrs
Flying debris

Before starting, make sure that:

all guards are in place;

work is properly secured in place;

bolts used to hold down work clear the tooling;

tooling and supporting pieces are properly tightened in position;

table stops are secured properly;

handles on all feed screws are in neutral;

table is free of stock, tools or other loose material;

the arbor and arbor support are clear of the work;

the cutter is rotating in the right direction.

Types Of Milling Machines And Its

Components Function
There are several types of milling machines:1.
2.
3.
4.
5.
6.

Knee and Column Type Milling Machines

Universal Horizontal Milling Machines
Vertical Knee and Column Type Milling Machine
Fixed Bed Type Milling Machines
Bridge Type Milling Machines
Special Milling Machines

Knee and Column Type Milling Machines

Column and knee type milling machines are the most common milling machines.
The spindle to which the milling cutter is may be horizontal (slab milling) or vertical (face
and end milling).

Knee-type milling machines 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,
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 require d 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 work piece past the milling cutter. The table may be
manually controlled or power fed.
The universal knee and column milling is very similar to the plain knee and column
milling machine. The largest difference being the swivelling table housing. The swivelling
table housing allows the table to be swivelled at an angle to the axis of the spindle.

Universal Horizontal Milling Machines

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.

Vertical Knee and Column Type Milling Machine

Ram Style Knee and Column Type Vertical Milling Machine.

A vertical type knee and column milling machine has the spindle located vertically,
parallel to the face of the column, and perpendicular to the top of the table.
The ram style knee and column type milling machine is a light duty milling machine.
This type of machine is well suited for a variety of tool room work as well as other light duty
operations. The head is mounted on a ram that can be swivelled or brought forward. This
allows the head to be brought into an operating position over most of the table.

Fixed Bed Type Milling Machines

The most distinguishing aspect of the fixed bed type milling machine is the absence of the
knee.

CNC Vertical Spindle Bed-Type Milling Machine.

The fixed bed construction of this style of milling machine minimizes deflection and allows
very heavy cuts to be taken. Fixed bed style milling machines can be used for general
purpose work although many people look upon them as high production machines. The
table can move in a longitudinal and a transverse direction. The vertical position of the
spindle, with respect to the work table, is obtained by moving the head up and down along
the column of the machine.

Bridge Type Milling Machines

The construction of the Bridge Type milling machine resembles that of a bridge.
The table is mounted on the bed. On either side of the bed are two vertical columns
connected at the top by a brace. A cross rail is mounted on the brace. The cross rail houses

the spindle head. Bridge type

milling machines are typically
used to machine large pieces such
as castings, machine tables and
housings.

CNC Vertical Bridge-Type Milling Machine.

Special Milling Machines

Extrusion Screw milling Machine

There are a number of types of special milling machines. Special milling machines are
designed specifically for one particular part or family of similar parts. Specialty milling
machines are used extensively in the automotive and aeronautics industry. The specialty
milling machine in Figure 9 is used to mill screws used in large extruding machines.

Processes Perform Or Operation

By Milling Machines
The three principal machining processes are classified as turning, drilling and milling. Other
operations falling into miscellaneous categories include shaping, planning, boring, broaching
and sawing.

Turning operations are operations that rotate the work piece as the primary method
of moving metal against the cutting tool. Lathes are the principal machine tool used
in turning.
Milling operations are operations in which the cutting tool rotates to bring cutting
edges to bear against the work piece. Milling machines are the principal machine
tool used in milling.
Drilling operations are operations in which holes are produced or refined by bringing
a rotating cutter with cutting edges at the lower extremity into contact with the
work piece. Drilling operations are done primarily in drill presses but sometimes on
lathes or mills.
Miscellaneous operations are operations that strictly speaking may not be
machining operations in that they may not be swarf producing operations but these
operations are performed at a typical machine tool. Burnishing is an example of a
miscellaneous operation. Burnishing produces no swarf but can be performed at a
lathe, mill, or drill press.

An unfinished work piece requiring machining will need to have some material cut away to
create a finished product. A finished product would be a work piece that meets the
specifications set out for that work piece by engineering drawings or blueprints. For
example, a work piece may be required to have a specific outside diameter. A lathe is a
machine tool that can be used to create that diameter by rotating a metal work piece, so
that a cutting tool can cut metal away, creating a smooth, round surface matching the
required diameter and surface finish. A drill can be used to remove metal in the shape of a
cylindrical hole. Other tools that may be used for various types of metal removal are milling
machines, saws, and grinding machines. Many of these same techniques are used in
woodworking.

Cutting Tools For Milling Operation

The variety of milling cutters available helps make milling a
versatile machining process. Cutters are made in a large
range of sizes. Milling cutters are made from High Speed
Steel (HSS), others are carbide tipped and many are
replaceable or indexable inserts.

High-speed steel (HSS) shell end

milling cutter.

Periphery milling cutters Periphery milling cutters are usually arbor-mounted to

perform various operations. Common high-speed steel milling cutters include the
staggered tooth cutter, side-milling cutter, plain-milling cutter, single-angle milling
cutter, double-angle milling cutter, convex milling cutter, concave milling cutter, and
corner-rounded milling cutter.
Light-duty plain mill A general-purpose
cutter for peripheral milling operations. Narrow
cutters have straight teeth, while wide ones have
helical teeth.
Heavy-duty plain mill Similar to the light
duty mill except that it is used for higher rates of
metal removal. To aid it in this function, the teeth
are more widely spaced and the helix angle is
increased to about 45 degrees.
A face-milling cutter with
wedge-clamped indexable inserts

Side milling cutter Has a cutting edge on the

sides as well as on the periphery. This allows the
cutter to mill slots.
Half-side milling cutter Same as the one
previously described except that cutting edges
are provided on a single side. It is used for
milling shoulders. Two cutters of this type are
often mounted on a single arbor for straddle
milling.

Face-milling cutters with

indexable inserts and wedgeclamped milling carriages.

 Stagger-tooth side mill Same as the sidemilling cutter except that the teeth are staggered
so that every other tooth cuts on a given side of
the slot. This allows deep, heavy-duty cuts to be
taken.

Angle cutters The peripheral cutting

edges lie on a cone rather than on a cylinder. A
single or double angle may be provided.

Shell endmill Has peripheral cutting

edges plus face cutting edges on one end. It has a
hole through it for a bolt to secure it to the
spindle.

Indexable-insert ball-nosed
milling cutters using the screw
clamping method
Form mill A peripheral cutter whose edge is shaped to produce a special
configuration on the surface. One example is the gear tooth cutter. The exact
contour of the cutting edge of a form mill is reproduced on the surface of the
workpiece.
End-milling cutters End mills can be used on vertical and horizontal milling
machines for a variety of facing, slotting and profiling operations. Solid end mills are
made from high-speed steel or sintered carbide. Other types, such as shell end mills
and fly cutters, consist of cutting tools that are bolted or otherwise fastened to
adapters.
Solid end mills Solid end mills have two, three, four, or more flutes and cutting
edges on the end and the periphery. Two flute end mills can be fed directly along
their longitudinal axis into solid material because the cutting faces on the end meet.
Three and four fluted cutters with one end cutting edge that extends past the
center of the cutter can also be fed directly into solid material.
Milling cutter nomenclature As far as metal cutting action is concerned, the
pertinent angles on the tooth are those that define the configuration of the cutting
edge, the orientation of the tooth face, and the relief to prevent rubbing on the
land.
o Outside diameter The diameter of a circle passing through the peripheral
cutting edges. It is the dimension used in conjunction with the spindle speed
to find the cutting speed (SFPM).
o Root diameter This diameter is measured on a circle passing through the
bottom of the fillets of the teeth.
o Tooth The tooth is the part of the cutter starting at the body and ending
with the peripheral cutting edge. Replaceable teeth are called inserts.

o
o
o
o
o

Tooth face The tooth face is the surface between the fillet and the cutting
edge, where the chip slides during its formation.
Land The area behind the cutting edge on the tooth that is relieved to
avoid interference is called the land.
Flute The flute is the space provided for chip flow between the teeth.
Gash angle The gash angle is measured between the tooth face and the
back of the tooth immediately ahead.
Fillet The fillet is the radius at the bottom of the flute, provided to allow
chip flow and chip curling.

Clamping Technique
The workpiece should be clamped in the machine vice as shortly as possible above the
clamping jaws to prevent the workpiece from being torn out or from changing its position
during the milling operation.

Clamping the workpiece in the machine vice

1 vice, 2 workpiece. 3 parallel pieces
The following work-holding fixtures are used essentially for milling parallel surfaces:

Machine vice
Magnetic chuck
Direct clamping on table
Clamping fixtures (single and multi-piece clamping)

When clamping the workpieces in the machine vice for milling parallel surfaces it is
absolutely necessary to place the contact surfaces on ground parallel pieces. The following
prerequisites have to be fulfilled:

The grade of parallelism depends on the planeness of the surface worked first.
The workpiece has to be clean (free from chips) and deburred.

The exact workpiece rest can be checked by the tight seat of the parallel pieces.
Same height of parallel pieces is necessary.

The following prerequisites are to be considered when work-pieces are clamped and milled
on a magnetic chuck:

The surface machined first must be clean, deburred and plane. It serves as contact
and reference surface.
To secure the workpiece position, fences having at least 2/3 of the workpiece height
must be available.
The depth of cut must not exceed a maximum of 2.5 mm.
Contact surface width must at least correspond to the height of the workpiece.
Only ferriferous workplaces (steel and cast materials) are permitted to be machined
on the magnetic chuck.

Clamping on magnetic chuck

No.1 magnetic chuck, No. 2 workpieces, No. 3 parallel pieces,No. 4 fence, No.5 operating
elements
Due to the geometrical form or the workpiece size, direct clamping on the milling machine
table is used as well. In this case, clamping fixtures are employed in the form of clamping
bolt, clamping iron and clamping base as well as special auxiliaries (stop rails, work-holding
plates, etc.).

Clamping elements
No. 1 clamp bolt, No. 2 nut, No. 3 washer, No. 4 clamping iron, No.5 step block (workholding base)
Fixtures for milling parallel surfaces are used in those cases where a definite positioning and
securing of the position of the workpiece is not possible with common clamping means.
When a great number of pieces are produced, the employment of multi-piece clamping
fixtures is economically substantiated.

Type and method of cutting fluid use in

milling processes
Cutting fluids can be broken into four main categories: straight cutting oils, water miscible
fluids, gasses, and paste or solid lubricants
Emulsions
Emulsion is a term that describes soluble oils. An emulsion is a suspension of oil droplets in
water. Soluble oils are mineral oils that contain emulsifiers. Emulsifiers are soap-like
materials that allow the oil to mix with water. Emulsions (soluble oils) when mixed with
water produce a milky white coolant. Lean concentrations (more water-less oil) provide
better cooling but less lubrication. Rich concentrations (less water- more oil) have better
lubrication qualities but poorer cooling.
Chemical Fluids
Chemical coolants are also miscible cutting fluids. Chemical cutting fluids are preconcentrated emulsions that contain very little oil. Chemical fluids mix very easily with
water. The chemical components in the fluid are used to enhance the lubrication, bacterial
control, rust, and corrosion characteristics. There are several types of chemical coolants
available, including coolants for extreme cutting conditions.

Inactive chemical cutting fluids are usually clear fluids with high rust inhibition, high cooling,
and low lubrication qualities. Active chemical fluids include wetting agents. They have
excellent rust inhibition and moderate lubrication and cooling properties. Some contain
sulfur or chlorine additives for extreme pressure cutting applications.
Semi-chemical Coolants
Semi-chemical fluids are a combination of a chemical fluid and an emulsion. They have a
lower oil content but more emulsifier. This makes the oil droplets much smaller. They have
moderate lubrication and cooling and high rust inhibition properties. Sulfur, chlorine, and
phosphorous are sometimes added to improve the extreme pressure characteristics.
Straight Cutting Oils
Straight cutting oils are not mixed with water. Cutting oils are generally mixtures of mineral
oil and animal, vegetable, or marine oils to improve the wetting and lubricating properties.
Sulfur, chlorine, and phosphorous compounds are sometimes added to improve the
lubrication qualities of the fluid for extreme pressure applications. There are two main types
of straight oils: active and inactive.
Inactive Straight Cutting Oils
Inactive oils contain sulfur that is very firmly attached to the oil. Very little sulfur is released
in the machining process to react with the work piece. Mineral oils are an example of
straight oils. Mineral oils provides excellent lubrication, but are not very good at heat
dissipation (removing heat from the cutting tool and work piece). Mineral oils are
particularly suited to nonferrous materials, such as aluminum, brass, and magnesium.
Blends of mineral oils are also used in grinding operations to produce high surface finishes
on ferrous and nonferrous materials.
Active Straight Cutting Oils
Active oils contain sulfur that is not firmly attached to the oil. The sulfur is released during
the machining operation to react with the work piece. These oils have good lubrication and
cooling properties. Special blends with higher sulfur content are available for heavy duty
machining operations. They are recommended for tough low carbon and chrome-alloy
steels. They are widely used in thread cutting. They are also good for grinding as they help
prevent the grinding wheel from loading up. This increases the life of the grinding wheel.
Gasses
Cutting oils and water miscible types of cutting fluids are the most widely used. Gasses are
sometimes use. Compressed air and inert gasses are sometimes used. Carbon dioxide,
Freon, and nitrogen are also used sometimes.

Paste and Solid Lubricants

Waxes, pastes, soaps, graphite, and molybdenum disulfide may be used. These are generally
applied directly to the work piece or tool, or in some cases, impregnated directly into a tool,
such as a grinding wheel. One example would be lard. Many experienced journeymen
recommend lard for tapping.
CO2 Coolant
Carbon dioxide (chemical formula CO2) is also used as a coolant. In this application
pressurized liquid CO2 is allowed to expand and this is accompanied by a drop in
temperature, enough to cause a change of phase into a solid. These solid crystals are
redirected into the cut zone by either external nozzles or through-the-spindle delivery, to
provide temperature controlled cooling of the cutting tool and work piece.[4] The ChilAire
system is one of the pioneers in the application of CO2 as a coolant.[citation needed]
Existing CNC machines can be retrofitted with this safe and environmentally friendly coolant
approach. In applications such as turning, milling or drilling tool life and throughput have
been improved substantially; especially in high temperature alloys such as titanium, 4140,
steels and plastics.
The Use of Cutting Fluids in Drill Press Operations
The coolant should be aimed at the
area where the tool contacts the work.
It should be flooded so that as much
fluid as possible reaches the cutting
edges. The operator should withdraw
the tool occasionally to remove the
chips. The best method is the use of
tools that have integral oil holes. This

means that various tools are available

that feed the coolant through the tool and directly to the cutting edge. This also helps wash
the chips out of the hole.

Relation Of The Parameter e.g Cutting Speed, Feed

Rate And Depth Of Cut
Cutting Speed

Important factor that affected milling operation efficiency

In order to work efficiently & economically
Its symbol is V. It is expressed in metre/min (m/min)

Formula:
Cutting speed = diameter of cutter x x spindle speed
V=dxxn
Selection of proper cutting speed:

Type of material to be machined

Type of tool material
Rigidity and condition of the machine
Types of cutting operations
MILLING MACHINE CUTTING SPEEDS
CUTTER MAT.
HIGH SPEED STEEL CUTTER
m/min
RAW MAT.
Machine Steel
20 - 30
Tool Steel
18 - 20
Cast Iron
15 - 25
Bronze
20 - 35
Aluminium
150 - 300

CARBIDE CUTTER
m/min
100 - 125
40 - 60
40 - 60
60 - 120
150 - 300

Spindle Speed

defined as the speed at which the spindle of a milling machine rotates per minute
Its symbol is n. It is expressed in revolution/min (rpm)

Formula:

Selection of proper cutting speed:

a) For longer cutter life, use the lower cutting speeds in the recommended range
b) Know the hardness of the material to be machined
c) When starting a new job, use the lower range of the cutting speed and gradually increase to
the higher range if conditions permit
d) If a fine finish is required, reduce the feed rather than increase the cutter speed
e) The use of coolant, properly applied, will generally produce a better finish and lengthen the
life of the cutter since it absorbs heat, acts as a lubricant and washes chips away

Feed

defined as the distance in millimeters per minute that the work moves into the cutter
Its symbol is f. It is expressed in mm/min

Formula:

Factors on which feed rate depends on

a)
b)
c)
d)
e)
f)
g)

The depth and width of the cut.

The design or type of the cutter.
The sharpness of the cutter.
The workpiece material.
The strength and uniformity of the workpiece.
The type of finish and accuracy required.
The power and rigidity of the machine

Machining Time Calculation

Formula:

I = Workpiece length to be milled

lu = Over travel
la = Advance.
L = Total Milling Length
D = Milling Cutter Diameter
n = r.p.m of the Cutter
Ts = Machining Time (min)
f = Rate of Feed (mm/min)

Formula:
Machining Time = Travelling Distance of the Milling Table (mm)
Rate of Feed (mm/min)

ts = L
f
NOTE: The travelling distance depends on the length of the cut to be milled, the type of
cutter used and the type of milling performed.