POLITEKNIK NILAI, NEGERI SEMBILAN

JABATAN KEJURUTERAAN
MEKANIKAL

DJJ3()082-MECHANICAL WORKSHOP PRACTICE 3

WORKSHOP REPORT

CLO1 Perform machining tasks according to worlcshop Standard Operating Procedure (SOP). (P4, PLO'i)
CLO3 Demonstrate awareness of social responsibility and safety procedure in the workshop according to the workshop safety regulations and create a
secured environment in an organization while doing practical work (A3, PLO6)

TITLE: MILLING MACHINE

NAME REGISTRATION NO CLASS

ADLI SYAHMI BIN AMIRUDDIN 23DKM20F1079 DKM5D

MUHAMMAD AIDIL IDHAM BIN ISMADI 23DKM20F1088 DKM5D

MUHAMMAD HARIS JUHAIR BIN JOHAR 23DKM20F2025 DKM4A

LECTURER NAME
1. SIR SAIFUDIN BIN AHMAD
*

CRITERIA MARK WEIGHT TOTAL

MARKS
INRODUCTION 5 l /5
AIM/OBJECTIVE l /5
WORK MATERIAL/EQUIPMENT 5 l /5
WORK METHOD/PROCEDURE 5 3 /15
DISCUSSION 5 2 /10
CONCLUSION/RECOMMENDATION 5 i /5
REFERENCES 5 I /5
TOTAL /50
TOTAL MARKS %

DATE SUBMISSION 13/10/2022

INTRODUCTION
Milling machine.

Milling is the process of machining using rotary cutters to remove material by

advancing a cutter into a workpiece. This may be done by varying direction on one or several
axes, cutter head speed, and pressure. Milling covers a wide variety of different operations
and machines, on scales from small individual parts to large, heavy-duty gang milling
operations. It is one of the most commonly used processes for machining custom parts to
precise tolerances.
Milling can be done with a wide range of machine tools. The original class of machine
tools for milling was the milling machine (often called a mill). After the advent of computer
numerical control (CNC) in the 1960s, milling machines evolved into machining centers:
milling machines augmented by automatic tool changers, tool magazines or carousels, CNC
capability, coolant systems, and enclosures. Milling centers are generally classified as vertical
machining centers (VMCs) or horizontal machining centers (HMCs).
The integration of milling into turning environments, and vice versa, began with live
tooling for lathes and the occasional use of mills for turning operations. This led to a new
class of machine tools, multitasking machines (MTMs), which are purpose-built to facilitate
milling and turning within the same work envelope.
OBJECTIVES

1) Identify the most important parts of the milling machine and their functions.
2) Understand the milling safety rules.
3) To apply practice workshop safety regulation during working in workshop.
4) To describe the usage of conventional milling machine, various type of hand and
cutting tools used for measurement, marking and metal removed.
5) Know how to perform machining works according to Standard Operational
Procedure.
6) To follow all safety procedures in the machine workshop.

WORK MATERIAL/EQUIPMENT

1) Milling machine
2) Workpiece
3) Safety goggle
4) Vernier caliper
5) Chuck key

SAFETY PRECAUTION
1) Always stop the machine before taking measurements.
2) Always refer to speed and feed tables.
3) Always use cutting tools that are sharp and in good condition.
4) Make sure there is enough clearance for all moving parts before starting a cut.
5) Before a drill bit breaks through the backside of the material, ease up on the
drilling pressure.
6) Do not attempt to clean the machine or part when the spindle is in motion.
7) Stop the machine before attempting to make adjustment or measurements.
8) Remove drill bits from the spindle before cleaning to prevent injury.
9) Make sure the machine is turned off and clean before leaving the workspace.
NO PROCESS APPARATUS DIAGRAM PROCEDURES
1 Calculate the 6 sides
1th side to mill

2 Setting the Milling Setting the

indexing plate machine head of index
90 degress

3 Place the Chuck key Tighten the

workpiece to workpiece
the chuck Milling using chuck key
machine
4 Setting the Milling Set it to 0.00 m
starting point machine and move it
to mill forward and
behind the drill
bit

5 Start the Milling Cutter until

milling machine 1.5m and stop
process

6 Rotate the Milling Remove the

indexing plate t machine lever and
the next loosen the
surface to mill driving plate.
Turn the lever
to move the
indexing plate
by counting 6
holes. finally
tighten the
driving plate.
7 Finishing Finishing
processes alter
the surfaces of
a workpiece to
remove
machining
marks, scaling
or pitting.
Finishing can
also enhance
the appearance
or function of
the part and
prepare it for
subsequent
coating
processes such
as bonding,
plating or
painting.
DISCUSSION

1. List out the workshop safety regulation, safety procedure and equipment in milling
machine.

Workshop safety regulation:

1) Always wear protective eye protection.
2) Make sure the machine is in perfect condition before starting operation.
3) Never run the machine faster than the recommended speed for the specific material.

Safety procedure:
1) Always refer to speed and feed tables.
2) Always use cutting tools that are sharp and in good condition.
3) Seat the workpiece against parallel bars or the bottom of the vice using a soft
hammer or mallet. Check that the work is firmly held and mounted squarely.
4) Before a drill bit breaks through the backside of the material, ease up on the
drilling pressure.

Equipment:
1) Vernier calipers.
2) Tailstock.
3) Drill Bit.

2. What is the purpose of milling machining?

A milling machine removes material from a work piece by rotating a cutting tool
(cutter) and moving it into the work piece. Milling machines, either vertical or
hori- zontal, are usually used to machine flat and irregularly shaped surfaces and can
be used to drill, bore, and cut gears, threads, and slots.

3. Explain the principles of milling machining.

The working principle of milling machine is applied in the metal removing operation.
Cutting action is carried out by feeding the workpiece against the rotating cutter. The
workpiece is rigidly clamped on the table while the revolving mouth teeth cutter is
mounted either on a spindle or an abor. The cutter revolves at a specified speed and
the workpiece feed slowly and steadily pass the cutter. The workpiece can be fed in
vertical, longitudinal and cross direction depending on the desired and type of final
product that need to be produced. After the workpiece is fed, the cutter teeth remove
the metal from the surface to produce the manufactured product. The cutter tool has
specific diameter for the required measurement needed during machining operation.
4. Name the components that make up the schematic representation of the milling
machine.

The components of milling machine include: Column and Base, Knee, Saddle and
Swivel Table, Power Feed Mechanism, Table, Spindle, Over Arm/ Overhanging Arm,
Arbor Support, and Ram.

5. What are some things to consider before proceeding any process in milling
machines?

 Have someone assist you when placing a heavy machine attachment like a rotary table,
dividing head, or vise.
 Withdraw drill bits frequently when drilling a deep hole. This helps to clear out the
chips that may become trapped within the hole.
 Do not reach near, over, or around a rotating cutter.

6. What is the factor to be considered to get a good quality in milling machining

process?

Never run the machine faster than the correct cutting speed. Make sure that the
machine is fully stopped before taking any measurements. Always use cutters which
are sharp and in good condition. Don't place anything on the milling machine table
such as wrenches, hammers, or tools.

7. Based on your observation, what are the defects? Discuss ways to avoid it. Insert
pictures of your experiment.

If the cutting parameters such as the feed rate, spindle speed, or depth of cut are too
high, the surface of the workpiece will be rougher than desired and may contain
scratch marks or even burn marks. Also, a large depth of cut may result in vibration of
the tool and cause inaccuracies in the cut.
LEARNING OUTCOME.

1. Named and draw the types of machining process can be done by milling machine.

1) Bore
While drilling creates a new hole where there wasn’t one before, “boring” enlarges an
existing hole to exact dimensions needed. The piece being created on a milling
machine remains in place. So, the boring tool must be manually adjusted to the
desired size.

2) Cut Gears
The importance of a uniform production of gears that are sized and smoothed to
perfection can’t be understated. CNC milling parts can achieve a quality, reliable gear
cut to ensure its teeth will operate to full efficiency. Gear cutting is typically done
with a hobbing machine. However, a milling machine can be equipped with a cutting
tool matching the gear’s grooves to handle the cut.
 3) Face Milling
Face milling is the process on a milling machine of cutting a flat surface to obtain
maximum smoothness. Accuracy is ensured because the part is clamped down into
place, while the CNC milling parts are exacting in its ability to machine a flat surface.

4) Finishing Coat
After the custom CNC milling has accomplished all its other tasks of drilling, boring,
flattening or cutting, CNC milling can then provide the finishing coat. Even if
machined elsewhere, CNC milling will define its features and provide that professional
smoothness to the materials one sees sold in stores. Every contour, hole or slot will
appear finished. It’ll be ready to go to its intended destination, such as a tool or engine.

2. List the advantages and disadvantages of lathe machining

`Advantages
 The size and durable construction of the milling machine give
tremendous support to handle large and heavier machines without
damaging itself.
 It provides flexible computer control options for cutting purposes.
 It reduces the chances of human errors.
 It assures accurate cuts.
 Availability of customization.
 Use of multiple cutters.
 It can do multiple cuts simultaneously.
 Milling is perfect for producing individual pieces in small or large
batches.
 It has the capability of producing complicated shapes, using multi-
tooth and single point cutting tools.
 The operation costs can be controlled to a great extent if general-
purpose cutters and equipment are used.
 Greater precision in the finishing of the work compared to other
machines
 Disadvantages
 Material Wastage is More in Milling
 There are not Enough Qualified Technicians
 The CNC milling machine and setup are more expensive than manual
instruments
 It takes a period of time for design and programming, not so cost-
effective for small amounts of products.

3. Give examples where milling machining quality is important.

The purpose of milling and pressing is to make the starch or sugar more available for
enzyme action. Crushing and pressing (grapes and other fruits), milling (cereal
grains), or a combination of milling and pressing (sugarcane) are used.

4. What are the environmental impacts when metal manufacturing products? Give
justification and recommendation for improvements.

Metals production and processing businesses can have a number of impacts on the
environment. For examples:

 Air emissions from scrap metal processing, furnace fumes, oil mists, dust, mould
production and casting and cooling processes
 Energy consumption by furnaces, air-handling units, motors and drives
 Noise pollution from materials handling, rolling mills, billet casting, air extraction
equipment and vehicles on your site
 Waste disposal, such as off-cuts, refractories, slags, sludges, fluxes, lubricating fluids
and baghouse and electrostatic precipitator waste
 Water discharges, for example contaminated water from material decontamination,
cooling and wet scrubbing processes, cleaning and testing.
 Land contamination from accidental spills of oil and chemicals and, potentially, the
past use of the site
CONCLUSION
We have learned how to organize the milling machine and understand the operation involved.
Besides that, we also know the purpose of the main parts of this machine. From the
laboratory practice also we realize that the cutter diameter should be chosen in such a manner
that it will not interfere with fixtures and other components in the setup. Before begin the
operation, we must make sure that the milling cutter that would be used was not dull. The
laboratory activities also provide us the information about the various type of milling
machines and cutters available for different milling process in the manufacturing world
process. In addition, we had gained the knowledge of understanding their usage and function
where it can produce different shapes of work piece with different types of surfaces, smooth
or rough. The purpose behind this is to improve their skills and give more confidences once
they do that. Besides that, students also should be neat, tidy, and safely dressed, develop a
responsibility for personal safety and the safety of other students. We should never think that
because we are wearing safety goggles our eyes are safe. If the lenses are not made of
approved safety shatterproof glass, serious eye injury can occur. All safety precautions are
also taken seriously with the clear explanation from the instructor.

REFERENCE
 Introduction to Manufacturing Process-3 rd Edition: John A. Schey.
 Processes and Design for Manufacturing-2 nd Edition: Sherif D. El Wakil.
 Principle of Engineering Manufacture-3 rd Edition: S C Black, V Chiles, A J
Lissaman, S J Martin.
 Practical treatise on milling and milling machines. Brown & Sharpe Manufacturing
Company. 1914. Retrieved 2013-01-28.
 A treatise on milling and milling machines. Cincinnati, Ohio: Cincinnati Milling
Machine Company. 1922. Retrieved 2013-01-28.
 Woodbury, Robert S. (1972) [1960], History of the Milling Machine. In Studies in the
History of Machine Tools, Cambridge, Massachusetts, USA, and London, England:
MIT Press, ISBN 978-0-262-73033-4, LCCN 72006354. First published alone as a
monograph in 1960.