University of Zakho

Department of Mechanical Engineering

Manufacturing process/Workshop

(Milling machine)

Student’s Name: Mohammad Faris

Date of experiment: 14/9/2022

A date lab report is submitted: 12/10/2022

 Table of Contents
Introduction: ..................................................................................................................................................3
Purpose: .........................................................................................................................................................3
Types of milling machines: ...........................................................................................................................3
Vertical milling machines: .........................................................................................................................3
Horizontal milling machines: .....................................................................................................................5
What are the Main Parts of a Horizontal Milling Machine? - Construction of Horizontal Milling
Machine. .....................................................................................................................................................5
Difference Between Horizontal and Vertical Milling MachA figure6
Figure of Vertical Milling MaA figure7
Figure of Horizontal Milling Machine.......................................................................................................7
Procedure: ......................................................................................................................................................8
Exercise No.1(surface cutting):..................................................................................................................8
Objective: ...................................................................................................................................................8
To cut the surface of our workpiece using either a vertical or horizontal milling machine with diffirent
equipment. ..................................................................................................................................................8
Equipment: .................................................................................................................................................8
1. Roughing end mill. .............................................................................................................................8
Woodruff cutter Procedure: .......................................................................................................................8
1. Lunch the milling machine at normal speed. .........................................................................................8
2. Cutting the surface of the workpiece using a vertical milling machine and with a wood ruff cutter tool.
....................................................................................................................................................................8
3. Using the horizontal milling machine with roughing end mill to reduce the diameter of the circular
shape of the workpiece. ..............................................................................................................................8
....................................................................................................................................................................8
Calculations: ................................................................................................................................................11
Discussion: ...................................................................................................................................................11
Safety in the workshop: ...............................................................................................................................12
References: ..................................................................................................................................................12

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Introduction:

Milling is one of the most commonly used processes in the metal manufacturing industry
today. It is used to produce some of the most common and important products we use every
day. Milling is the use of rotating cutting tools to remove material from a fixed workpiece.
During milling, the workpiece remains stationary while the cutting tool rotates. When the
rotating cutting tool is pressed against the workpiece, it will remove material.

Purpose:

To make iron pieces like a gear by using a vertical and horizontal milling machine.

Types of milling machines:

1- vertical milling machines.

2- horizontal milling machines.

Vertical milling machines:

A spindle of a vertical milling machine is positioned at right angles to the table. The cutter
is moved vertically or at an angle by swiveling the vertical head of the machine. The
machine is adapted for machining slots and flat surfaces by moving the table. By mounting
end mills and face milling cutters on the spindle, vertical milling and internal milling are
performed.

 Main Parts of Column and knee-type milling machine base:

It is made of cast iron and supports all the other parts of the machine tool. A vertical column
is mounted upon the base. In some machines, the base serves as a reservoir for cutting fluid.

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Column: It is mounted upon the base and is box-shaped. It houses the mechanism for
providing drive for the spindle. The front vertical face of the column is machined accurately
to form dovetail guideways for the knee to move up and down. The top of the column holds
an overhanging arm.

Knee: It slides up and down on the guideways of the column. An elevating screw mounted
on the base obtains this movement. The saddle is mounted upon the knee and moves in a
cross direction.

Saddle: It is mounted on the guideways of the knee and moves towards or away from the
face of the column. This movement can be obtained either by power or by hand. The top of
the saddle has guide ways for the table movement.

Table: The table is moved longitudinally either by power or manually on the guideways of
the saddle. The trip dogs placed on it control the movement of the table. The table of a
universal milling machine can be swiveled horizontally to perform helical works. The top
surface of the table has got ‘T’ – slots on which the workpieces or other work-holding
devices are mounted.

Spindle: It is located in the upper part of the column. It receives power from the motor
through belts, gears, and clutches. The front end of the spindle has got a tapered hole into
which the cutters are held with different cutter-holding devices.

Overhanging arm: It supports the arbor from the top of the column. The arbor is supported
by the bearing fitted within the arbor support. It is also useful while using some special
attachments.

Front brace: It is extra support fitted between the knee and the overhanging arm. It is slotted
to allow the knee to be adjusted vertically.

Arbor: It supports the different types of cutters used in the machine. It is drawn into the
taper hole of the spindle by a draw bolt. One or more cutters are mounted on the arbor by
placing spacing collars between them. The arbor is supported by arbor support. The arbor is
provided with a Morse taper or self-releasing taper.

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Horizontal milling machines:
The horizontal milling machine is a type of machine tool with a spindle parallel to the
worktable, used to process various planes, inclined planes, and grooves with
cylindrical milling cutters, disc cutters, angle cutters, forming cutters, end mills, and
more tools.

 What are the Main Parts of a Horizontal Milling Machine? - Construction of Horizontal
Milling Machine.
A horizontal milling machine consists of the following basic components. More parts like
vertical knee traverse crank, cross feed hand wheel, table traverse hand wheel, vertical
positioning screw, machine vice, cutting tool, and more are situated on it. With the
development of machine tool manufacturing techniques and CNC machines, the
construction of horizontal milling machines will differ from previous types to suit modern
applications.
1) Base: the main part of various types of milling machines, along with columns, used to
support the table and align, and hold the machine.
2) Table: used to hold and secure the workpiece to be machined.
3) Column: along with the base, to hold, align and support the machine.
4) Knee: can move up and down to position the pie and ice, supports the saddle and table.
5) Saddle: attached to the knee, provides in and out, or Y-axis table travel.
6) Spindle: mounted with the cutting tool, holds the tool, and provides rotation.
7) Overhanging arm: align and support the arbor support.
8) Arbor support (bracket): attached to the overhanging arm, supports the end of the arbor
that is opposite the spindle.
9) Arbor

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Difference Between Horizontal and Vertical Milling Machines:

No Vertical Milling Machine Horizontal Milling Machine

1. In a vertical milling machine, a spindle Here, a spindle axis is placed in a horizontal
axis is aligned vertically. direction.
2. It is cheaper in price. A horizontal milling machine is a little bit
costly.
3. We get a poorer surface finish. By using a horizontal milling machine, you
will get the best surface finishing.
4. Vertical milling machine reduces the Horizontal Milling Machines help to
tool life. increase the tool life.
5. This machine requires a smaller area. A horizontal milling machine requires a bit
larger area.
6. In the vertical milling machine, we In a horizontal milling
don’t get proper removal of chips. machine, chips are removed and thrown
away from the machine properly and
easily.
7. Its working capacity is low. It can do the work of 3 or 4 vertical milling
machines easily.
8. This type of machine is less powerful It is heavier in weight and more powerful
and is lighter in weight. than vertical milling machines.

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Figure of Vertical Milling
Machine

Figure of Horizontal Milling

Machine

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Procedure:
Exercise No.1(surface cutting):

Objective:

To cut the surface of our workpiece using either a vertical or horizontal milling machine
with diffirent equipment.

Equipment:

1. Roughing end mill.

Woodruff cutter Procedure:

1. Lunch the milling machine at normal speed.

2. Cutting the surface of the workpiece using a vertical milling machine and with a wood
ruff cutter tool.

3. Using the horizontal milling machine with roughing end mill to reduce the diameter of
the circular shape of the workpiece.

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Exercise No.2(nut):

Objective:

To cut the diameter of the workpiece in a circular shape and calculate the depth of the
workpiece and also to find the theta of it given side of the workpiece and the height of the
workpiece’s given radius and(X).

Equipment:

1. Involute gear cutter:

2. Fly cutter Procedure:

1. Lunch the milling machine also with the normal speed.

2. Using the horizontal milling machine with an involute gear cutter to cut the sides of the
workpiece and give it the shape that the tool represents.

3. Using a vertical milling machine with a fly cutter tool to cut the diameter of the workpiece.

4. Then find its height of it using theoretical properties.

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Exercise No.3(spur gear):
Objective:
Cut the sides of the workpiece using the tools and rotate the workpiece reto rotate operation
three times to give the correct dimensions.

Equipment:
1. Involute gear cutter
Procedure:
1. As always we launched the milling machine with the medium speed

2. We used only a horizontal milling machine

3. We Cut the sides of the workpiece and give it the shape that the tool represents.

4. We Repeated the process three times to give the correct dimensions.

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Calculations:
Diameter=35.6mm = radius=17.8mm
x
cos36 = 𝑥 = 𝑐𝑜𝑠36 ∗ 𝑟 = 0.8 ∗ 17.8 = 14.40𝑚𝑚
r

ℎ = 𝑟 − 𝑥 = 17.8 − 14.40 = 3.40𝑚𝑚

M=2.25

T=14 The teeth of the gear that is required while exercising.

D(i)=M*T

D(o)=M(T+2)

𝑑(𝑖) = 2.25 ∗ 14 = 31.5𝑚𝑚

𝑑(𝑜) = 2.25 ∗ (14 + 2) = 36𝑚𝑚
12 24
40/14 = 2( )= 2
14 28

Discussion:

We learned a lot about the milling machine device throughout the week we used it, as well
as a lot about its operations. We also completed a lot of activities to help us understand it
better and learn about the various cutters and how they function. We discovered a distinct
process that was applied to workpieces to create the desired shape and size.

We are aware of the two different uses for vertical and horizontal milling machines. One
type of job requires a vertical element, like a key, while another type, like gear and son,
needs a horizontal element. Some tasks, such as drilling and cutting, need that the device
speed is increased while others, on the other hand, require that it be slowed down.

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Safety in the workshop:

All users of workshops and stores should maintain them clean, use the proper attire and
footwear, and only use them for their authorized purposes. A neat workspace does not
obstruct regular business operations and makes it simpler to identify and avoid problems.

References:
https://www.engineeringenotes.com/industrial-engineering/milling-cutter/8-main-types-of-
milling-cutters-milling-machines-industrial-engineering/22640

https://madhavuniversity.edu.in/types-of-milling-cutters.html

https://www.theengineerspost.com/15-different-types-of-milling-machines/

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